Burnham LEDV User Manual

Price - $3.00

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

LEDV SERIES DIRECT VENT

OIL FIRED BOILER

As an ENERGY STAR Partner, Burnham Corporation has determined that the LEDV-1, fired at the 0.60 GPH rate, meets the ENERGY STAR guidelines for Energy efficiency established by the United States Environmental Protection Agency (EPA).

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

Boiler Model Number

L EDV__ - __ ____ _

Heating Contractor Phone Number

Address

81433101R3-3/00

Boiler Serial Number

6 _ _ _ _ _ _ _

Installation Date

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULL Y

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.

DA NGER

DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell g as vapors, DO NOT try to op erate any ap pliance - 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 sup p lier's instru ctions o r if th e supplier is unavailab le, cont act th e fire department.

WARN ING

Improper installation, adjustment, alteration, service or maintena nce can cause property damage, personal injury or loss of li fe. Failure to fo llow all instructions in the proper order can cause personal injury or death. Read and und erstand all instruction s, including all those contained in component manufac turers manuals which are provided w ith the appliance before installing, starting-u p , op erating, maintaining or servicing this ap pliance. Keep this manual and liter ature in legib le conditio n and posted near appliance fo r reference by owner and service technician. This boiler req uires regular maintenance and service to operate safely. Follow the instructions contained in this manu al. Installatio n, maintenance, and service must be p erform ed on ly by an ex perienced, skilled installer or servi ce agency. A ll he ating systems should be designed by co mpetent contractor s and on ly person s kn o wled geable in the layout and installat ion of hydronic heating sy stems s ho uld attemp t installa tion of any bo iler. It is the resp on sibility of the in stalling contractor to see that all controls are correctly installed and are operating properly when the inst allation i s comp leted . Inst allation is not comp lete u nles s a p res sure re lief va lve is in stalled into the tapp ing loca ted on top of applian ce - S ee Se ction III o f t his m anua l for details.

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 inj ury and which are kno wn to th e state of California to cause cancer, birth def ects and o ther repro ductive h arm . Always use proper safety clothing, respirators and equipment when servicing or working near by th e boiler. This boiler contains very hot water under high pressures. Do not unscrew any pipe fittin gs nor attempt to disconnect any components of this boiler witho ut positively assur ing the water is cool and has no pressure. Always wear p ro tective cloth ing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely o n t h e pressure and temperatur e gauges to determ ine the temp erature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. D o not touch any components unless they are cool. This boiler must be properly vented and connected to an approved vent system in goo d condition. Serious p roperty dam age could result if the boiler is connected to an unapproved ven t system This boiler needs fresh air for safe op eration and m ust be installed so there are provisio ns for adequate combustion and ventilation air. The interior of the venting an d 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 an d air intake systems ar e 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. This boiler is supplied with controls which may cau se the boiler to shut down and not re-start withou t service - If d amage due to fro zen pipes i s a pos sibility, t he heating system should not be left unatttended in cold weather; or appropriate safegu ards and alarms should be installed on the h eating system to prevent damage if th e boiler is inoperative. This boiler is desig ned to bur n No. 2 fu el oil only. D o not use gasoline, crankcase drainings, or any oil containing gasoline. Never bu rn garb age or paper in thi s boiler. Do not convert to any solid fuel (i. e. wood, coal) or gaseous fuel (i. e. natural gas, LP/propane). All flammable debr is, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. K eep the boiler area clean an d f ree of fire hazards. All boilers equipped w ith Burner Swing Door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. B efore opening swing door, turn off service switch to boiler and disconnect two halves o f Burner Swing Doo r Interlock wiring harness to prevent accidental firing of b u rner ou tside the co mbustio n chamber. Be sure to tigh ten swing door fastener completely and reconnect two halves of Burner Swing Door Interlock when service is co mpleted.

NOTICE

Th is boiler has a limited warranty, a copy of which is printed o n the back of th is ma nua l. It is the respons ibility of the in stalling cont ractor to see th at all controls are correctly in stalled and are operat ing prop e rly when the installatio n is c omplete. T he warran ty for this boile r is valid only if the boiler has been installed, maintain ed and operated in accor d ance with th ese instr u ctions.

NOTICE

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 manu a l. Authorities having jurisdic t ion should be con s ulted before installatio ns are made. In all cases, r eferen ce sho uld b e made to th e following Standards:

USA BOILERS

C urr ent Edition of American Na t iona l Standard AN SI/NFPA 31, “Inst a llation of Oil Burning

Equipment”, for recommen ded installation practices.

Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Ven ts, a nd Solid Fuel Bu rning App lian ces”, F or Venting r equirem ents.

Cu rrent Edition of American Society of Mechanical Engineers ASME CSD-1, "Contro ls and Safety Devices for Automatically Fired Boilers", for assembly and operations of con trols and safety devices.

CA NADIAN B OIL ERS

A. Current Edition of C anadian Standards Association CSA B139, "Installation Code for Oil

Burning Equipment", for recommended Installation Practices.

This boiler is suitable for installation on combustible flooring. Boiler cannot be installed on carpeting.

For optimum performance and servi ceability from this unit adhere to the following recommendations:

Do not tamper w ith or alter the unit or controls. Retain your contractor or a competent serviceman to assur e th at th e unit is properly adjusted and maintained.

Clean firetub es at least once a year - p referably at the start of the heating season to remove soot and scale. Inside of Combustion Chamber should also be cleaned at the same time.

Have Oil Bu rner and Con tro ls checked at least once a year or as may b e necessitated.

Do not operate unit with jumpered o r absen t con trols or devices.

Do not op erate unit if any control, switch , com p onent, or device has been subject to w ater.

T able of Contents

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

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

III. Water Piping and Trim ............................ 9

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

V. Electrical and Sequence of Operations .. 18

VI. Oil Piping ............................................... 20

VII. System Start-up ...................................... 22

VIII. Service and Cleaning .............................. 26

IX. Repair Parts ............................................ 29

Figure 1: LEDV Packaged Boiler

I. Pre-Installation

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.

2. ANY CLAIMS for damage or shortage in shipment must be 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. 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 floor is not level, or if water may be encountered on floor around boiler.

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.

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

E. Do not install boiler where gasoline or other

flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.

II. Unpack Boiler

CAUTION

Do not drop boiler. Do not bump boiler jacket against floor.

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 fittings.

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 floor. 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).

1. Pull 2 halves of Burner Swing Door Interlock apart. Swing Door Interlock is connected to R-W terminals on R8184P Control. Lift Honeywell R8184P 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 20.

3. Remove 2 (two) 5/16" - 18 x 3" long hex head cap screws and flat 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 4. 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 flat 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 20.

8. Connect wiring harness to burner Junction Box and install Honeywell R8184P Control, see Wiring Diagram, Figure 15. 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 flexible 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 flashlight to inspect insulation secured to front and rear doors. Inspect ceramic fiber blanket secured to bottom of combustion chamber. Inspect inner and outer door gaskets. Replace any damaged pieces.

TS-98-14-A

Figure 4: Hinge AssemblyFigure 3: Proper Hinge Bracket Installation

Figure 2: Minimum Clearances to Combustible Materials

III. Water Piping and Trim

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 fittings.

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 fittings 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.

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.

3 . 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.

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.).

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 flow 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 bypass valve will raise the boiler return temperature. Opening the boiler return valve while closing the bypass 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.

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.

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

WARNING

Safety (relief) valve dischar ge p iping must be piped near floor to elim inate potential of severe bur ns. D o not pipe in any ar ea where freezing co uld occur. Do not install any shutoff valves, plugs or caps.

Figure 5: Recommended Boiler Piping for Zoning with Valves

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 flushed. A qualified 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

flushed, and before refilling 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.

isolation valve in boiler supply piping. (Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area).

4. Starting with one circuit, open zone valve.

5. Open bib cock.

6. Open fill valve (Make-up water line should be located directly above isolation valve in boiler supply piping).

7 . Allow water to overflow from bucket until dis charge

from hose is bubble free for 30 seconds.

8. Open zone valve to the second zone to be purged, then close the first. Repeat this step until all zones have been purged, but always have one zone open. At completion, open all zone valves.

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

10. Open isolation valve in boiler supply piping.

3. Attach a hose to bib cock located just below

11. Remove hose from bib cock.

Figure 6: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems

Figure 7: Recommended Boiler Piping for Zoning with Circulators

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 fire officials about restrictions and installation inspection in your area.

2 . The LEDV Series is designed as a Direct Vent boiler.

In this configuration, all air for combustion is supplied directly to the burner from outdoors and flue 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 configuration may be used in installations where infiltration 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.

5 . Vent Terminal Location (see Figure 8). Locate vent

terminal so vent pipe is short and direct. The vent terminal must be located:

a. Not less than 12 inches above grade plus snow

accumulation.

b. Not less than 4 feet below, 4 feet horizontally, or

1 foot above any door, window, or gravity air inlet.

c. Not less than 3 feet above any forced air inlet

located within 10 feet. d. Not less than 2 feet from an adjacent building. e. Not less than 7 feet above a public walkway.

Figure 8: Vent Terminal Location

6 . Intake Terminal Location (Direct Vent only) - Locate

Air Intake Terminal not less than 12 inches to the left, right, or bottom of the vent terminal. Do not locate air intake terminal above vent terminal. Intake terminal must be at least 12 inches above grade plus snow accumulation. See Figure 9.

7. The LEDV must be vented with 4" Z-Flex Direct Oil™ Vent. 20 feet is the maximum vent length allowed. The vent pipe is available in 5, 10, 15, and 20 foot lengths. Table 1 lists vent part numbers.

Components of this kit are listed in the Repair Parts Section of this manual.

B. Vent Installation (Direct Vent and Side-Wall Vent)

1. Install Vent Terminal. See Figure 10.

Table 1: Vent Pipe Part Numbers

4" Direct Oi l™ Vent Pipe

Pipe Length Burnham Part No.

5 Ft. 8113302 10 F t. 8113303 15 F t. 8113304 20 F t. 8113305

8 . The vent system must be completed with the Direct

Oil™ Vent Kit, which is shipped with the boiler.

a. After determining the location from previous

Section, cut an opening in the wall for the vent terminal.

• Combustible wall: 8 inches diameter hole is

required to maintain a 1 inch clearance to combustible materials.

• Non-combustible wall: 6½ inches diameter

hole is required. b. Secure trim plate to outside wall. c. Insert the vent terminal through the opening

until the stop bead rest against the trim plate.

d. Slide the inside trim plate assembly (fitted with

gear clamp) onto the terminal pipe.

Figure 9: Intake Terminal Location

Figure 10: Vent Installation

Figure 11: Vent Connector, Un-Assembled

Figure 12: Vent Connector, Assembled

Figure 13: Air Intake Installation

e. Secure the inside trim plate to inside wall. f. Tighten the gear clamp to the terminal pipe. g. Seal all external joints with a weatherproof caulk.

2 . Cut vent pipe to length with a hack saw.

3. Install Vent Connector/Appliance Adaptor. See Figures 11 and 12.

a. Apply a continuous bead of high temperature

adhesive/sealant (supplied with boiler) around outside of corrugated pipe of vent connector.

b. Twist vent connector into end of vent pipe.

Turn the connector counter-clockwise until it is engaged approximately 4 inches into the inner vent pipe and the outer collar of the connector overlaps the outside of the vent pipe.

a. All horizontal runs must rise at least ¼ inch per

foot toward vent terminal.

b. Avoid any sags or dips in vent pipe.

C. Air Intake Installation (Direct Vent only)

See Figure 13.

1. General

c. Tighten the gear clamp on the outer collar of the

connector.

d. Repeat steps a. through c. with the appliance

adapter.

4. Connect vent pipe to boiler. a. Apply a continuous bead of high temperature

adhesive/sealant (supplied with boiler) to inside of appliance adapter (approximately ½ inch from end).

b. Slip appliance adapter over boiler flue collar and

tighten gear clamp.

5. Connect vent pipe to terminal. a. Carefully slide insulation sleeve over vent

connector and vent pipe until gear clamp on small end of connector can be accessed.

a. Use 4 inch diameter single wall metal pipe and

fittings available at most heating distributors. Maximum allowable air intake length is 40 equivalent feet. Each elbow is equal to 6

equivalent feet. b. Start at Burner. Work toward air intake terminal. c. Maintain minimum of ¼ inch per foot slope in

horizontal run to air intake terminal. Slope

down toward air intake terminal. d. Seal all joints gas-tight, using silicone caulk or

self-adhesive aluminum tape.

2. After determining location, cut a hole in the wall to accept 4 inch air intake pipe.

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

4. Mount the vacuum relief valve tee assembly or 90° elbow into the burner inlet ring. See Figure 13.

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

evenly spaced around the burner inlet ring.

b. Apply a continuous bead of high temperature

adhesive/sealant (supplied with boiler) on inside of cent connector (approximately ½ inch from end).

c. Clip connector over vent terminal until it is fully

engaged. Then tighten gear clamp.

d. Slide insulation sleeve over terminal connection

so that connector is completely covered.

e. Secure each end of insulation sleeve with the

gear clamps provided.

6. Secure vent pipe in position with pipe straps.

b. Assemble the vacuum relief valve balance

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

c. Mount the vacuum relief valve into the tee and

fasten with a screw and nut in collar tabs. To ensure proper operation, the gate must be level across the pivot point and plumb. Refer to vacuum relief valve manufacturer's instructions.

5 . Install remainder of air intake, securing each joint

with at least three (3) sheet metal screws evenly spaced.

6. Install air intake terminal. See Figure 13.

7. Seal all external joints with weatherproof caulk.

D. Air Intake Installation (Indoor Air for Combustion)

1 . Remove the black plastic inlet cover from the right

side of the Beckett AFII burner.

2 . Attach the Air Intake Terminal directly to the burner

intake collar.

3 . Discard the Vacuum Relief Valve. Alternate to 1., 2. and 3.:

Keep the black plastic inlet cover in place and discard the Air Intake Terminal and the Vacuum Relief Valve.

V. Electrical and Sequence of Operations

A. ELECTRICAL

1. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electric Code.

2. A separate electrical circuit should be run from the main electrical service with a fused disconnect switch in the circuit.

3. Wiring should conform to Figure 15.

B. SEQUENCE OF OPERATIONS

1. General. A call for heat by the thermostat energizes the L8148A limit control which in turn energizes the R8184P primary control to turn on the burner. The circulator will operate as long as there is a call for heat. If the call for heat is not satisfied and the high limit setting is reached, the circulator will continue to operate, and the burner will stop until the high limit circuit is closed by a drop in boiler water temperature.

2. L8148A Combination Limit control. The switching action within the L8148A control has one setting, the high limit. The switching relay is controlled by the low voltage room thermostat. On a call for heat, the relay contacts close to complete the line voltage circulator circuit and also the burner circuit if the boiler water temperature is below the high limit setting. The high limit switch shuts off the burner if boiler water temperature exceeds the high limit setting. See Figure 14.

and ignition transformer.

b. After a 15 second pre-purge period, in which

time a draft is established in the flueways, the oil valve is opened.

c. If the burner ignites within 15 seconds from the

time the oil valve opens and the CAD cell senses a flame, the burner will operate until the call for heat is satisfied or the setting of the high limit is reached.

d. A manual reset button is provided to reset the

safety switch after lockout.

e. When the call for heat ends, or the CAD cell

fails to sense a flame, the oil valve will close. The combustion blower will continue to operate for a postpurge period of approximately two (2) minutes.

4. CAD Cell. The Beckett AFII burners used on the LEDV Series are supplied with a C554A Cadmium Sulfide (cad cell) Flame Detector to monitor the burner flame and shut down the burner on ignition failure or on flame failure during the run cycle. On either failure, the manual reset button on the R8184P will be tripped.

3. R8184P Oil Primary Control. The R8184P operates the oil burner motor, solenoid oil valve, and the ignition transformer in response to a call for heat from the L8148A limit control.

a. A call for heat will energize the burner motor

Figure 14: Control Differential

Figure 15: Schematic Wiring Diagram

VI. Oil Piping

A. General

1. Use flexible oil line(s) so that Swing Door can be opened without disconnecting 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 (.6 GPH) firing rate application to prevent nozzle fouling.

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

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

B. Single-pipe Oil Lines.

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

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

TABLE 2: SINGLE-STAGE U NITS (3450 RPM)

TWO-PIPE SYSTEMS

Maximum Le ngth of Tubing

Lift "H"

(See Fig. 16)

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'

"H" + "R" (Se e Figure 16)

3/8" OD

Tubing (3 GPH )

1/2" OD

12' 21' 83' 13' - -- 62' 14' - -- 41'

Figure 16: Single-Pipe Installation

Figure 17: Two-Pipe Installation

C. Two-Pipe Oil Lines.

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

TABLE 3: T WO-STAGE U NITS (3450 RPM)

TWO-PIPE SYTEMS

Maximum Length of Tubing

Lift "H"

(See Fig. )

"H" + "R" (See Figure)

3/8" OD

Tu bin g (3 G P H)

1/2" OD

Tu bin g (3 G P H)

0' 93' 100' 2' 85' 100' 4' 77' 100' 6' 69' 100'

8' 60' 100' 10' 52' 100' 12' 44' 100' 14' 36' 100' 16' 27' 100' 18' --- 76'

VII. System Start-up

WARNING

All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off ser vice switch to boiler to preven t accidental firing of burn er o utside the combustion chamber. Be su re to tigh ten swin g d o o r fastener completely wh en service is completed.

A. ALWAYS INSPECT INSTALLATION BEFORE

STARTING BURNER.

B. FILL HEATING SYSTEM WITH WATER. Refer to

Section III, G.

C. CHECK CONTROLS, WIRING AND BURNER to be

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

D. LUBRICATION — Follow instruction on burner and

circulator label to lubricate, if oil lubricated. Most motors currently used on residential type burners employ permanently lubricated bearings and thus do not require any field lubrication. Water lubricated circulators do not need field lubrication.

Do not over-lubricate. This can cause as much trouble as no lubrication at all.

E. SET CONTROLS with burner service switch turned

“OFF”.

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

2. PRESS RED RESET BUTTON on R8184P Oil Primary Control and release.

F. BURNER START-UP

1 . VERIFY burner settings.

a. Refer to Table 4.

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

3. Attach a plastic hose to fuel pump vent fitting and provide a container to catch the oil.

4. REMOVE GAUGE PORT PLUG from fuel pump and install pressure gauge.

5. REMOVE TEST PLUG IN FLUE COLLAR.

6. Close the service switch to start the burner. If the burner does not start immediately, check the manual overload switch on the motor, if so equipped, and the safety switch of the burner primary control.

3. Set high limit dial on L8148 at temperature to suit requirements of installation.

TABLE 4: BE CKETT AFII BURNER

Boiler Model

LEDV-1 0.60 AFII 85 HLX50HD 0. 50 x 70° B 2.5 #2 140 LEDV-2 1.00 AFII 150 HLX50HE 0.85 x 60° B 3.5 #3 140 LEDV-3 1.25 AFII 150 HLX50HE 1.00 x 60° B 4.0 #5 140

Firing Rate

(GPH)

Burner

Air Tube

Combination

Delavan No zzle

Air Head

(stop screw)

Setti ngs

Pump Pr essu re

(P SIG )

Figure 18: Electrode / Head Setting

7. Bleed the fuel unit when the burner motor starts rotating. To bleed, loosen the vent fitting (with plastic hose attached) and catch the oil in an empty container. Continue to bleed for 15 seconds after oil is free of air bubbles. Tighten the vent fitting when all the air is purged. NOTE: Bleeding might not be necessary with a two pipe system. When vent fitting is closed, burner flame should start immediately.

8. ADJUST OIL PRESSURE a. Locate oil pressure adjusting screw and turn

screw to obtain 140 PSIG pressure.

b. DO NOT REMOVE PRESSURE GAUGE until

later.

9. ADJUST AIR SETTING on burner for a light orange colored flame. Use a smoke tester 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%. These settings will assure a safe and efficient operating condition. If the flame appears stringy instead of a solid fire, try another nozzle of the same type. Flame should be solid and compact.

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

11. 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 microTEKDV 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 delicate and should be protected from dirt and abuse. Nozzles are mass-produced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have.

b. FLAME SHAPE — Looking into the

combustion chamber through the 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 rear door insulation piece, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described below.

c. FUEL LEAKS — Any fuel leak between the

pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the transformer, and around the air inlet. Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a 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 are many possible causes of air leaks in oil lines such as:

i. Fitting leaks due to mis-flared tubing or

damaged fitting.

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

There are various test kits available to trace air leaks, such as electronic sight glasses. Follow the manufacturers' instructions to find air leaks.

The following actions can eliminate air leaks:

i. Bleed pump as detailed in System Start-Up

Section of this manual.

ii. 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% CO2 with

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

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

i. HIGH ALTITUDE INSTALLATIONS — Air

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

j. START-UP NOISE — Late ignition is the cause

of start-up noises. If it occurs recheck for electrode settings, 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.

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

Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the firing rate, the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt.

g. WATER — Water in the fuel in large amounts

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

h. COLD OIL — If the oil temperature

approaching the fuel pump is 40°F or lower poor combustion or delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get larger and the flame shape gets longer. An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution

G. TEST CONTROLS

WARNING

Before installation of the boiler is considered complete, the operation of the boiler controls should be checked, particularly the primary control and high limit control.

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

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

FOR HEATING SERVICEMAN ONLY

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

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

• 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

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

• Push red reset button to reset safety switch.

c. Simulate power failure:

temperature. Burner should start.

d. Adjust thermostat to lowest setting. Adjust limit

to desired setting.

4. CHECK LOW WATER CUTOFF (if so equipped). a. Adjust thermostat to highest setting.

b. With boiler operating, open drain valve and

slowly drain boiler.

c. Burner should stop when water level drops

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

d. Adjust thermostat to lowest setting. Refill

boiler.

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

• Follow the starting procedure to turn on the

burner.

• With the burner running, turn off the power

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

• Burner should stop.

• Restore power. Burner should start.

d. If system does not operate as described, go to the

TROUBLESHOOTING AND MAINTENANCE section.

3. VERIFY HIGH LIMIT OPERATION. a. Adjust thermostat to highest setting. b. Observe temperature gauge. When temperature

is indicated, adjust limit to setting below observed temperature. Burner should stop.

c. Adjust limit to setting above observed

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.

Section VIII: Service and Cleaning

WARNING

All boiler service and cleaning must b e completed with burner service switch tu rned off. B o ilers equipped with burn er swing door have a potential hazard which can cause severe prop erty dam age, perso nal in jury or loss of life if igno red. Before o pening swing do or, turn off s ervice switch to boiler to p revent accide ntal firing of b urner outside the combustion chamber. Be sure to tighten swing do or fasteners completely when service is com p leted.

piece. Inspect front and rear door insulation pieces, front door gaskets and combustion chamber liner for damage. Replace any damaged pieces.

4. CLOSE BOILER CAUTION: Do not start burner unless burner swing

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

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, pull two halves

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

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

plastic over combustion chamber liner.

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

handle), clean firetubes. Measure 15" from end of brush opposite handle, and mark handle. DO NOT allow this mark to go past front end of firetube during cleaning, or brush will hit rear door insulation piece.

2. CLEAN THE COMBUSTION CHAMBER Using wire or fiber bristle brush, clean inside of

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

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

soot accumulation, proper support, and deterioration of pipe, fittings, and joints.

1. Inspect inside of vent pipe. a. Disconnect appliance adapter from boiler flue

collar.

b. Remove any obstructions and clean with a wire

brush as required.

c. Reconnect appliance adapter to boiler flue collar

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

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

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

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

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

6. All vent joints must be secure and watertight.

3. AFTER CLEANING a. Vacuum debris inside bottom of rear door,

remove protective cloth, and vacuum remaining fireside of boiler as necessary. BE CAREFUL not to damage liner or rear door insulation

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

D. Burner.

1. Replace the oil supply line filter.

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

3. Replace the nozzle with an equivalent nozzle. See Table 4.

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

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

6. Inspect the transformer cables and connectors.

7. Remove and clean the cad cell.

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

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

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

an external float type low water cutoff is on the boiler, the blow off valve should be opened once a month (use greater frequency where conditions warrant), to flush out the sediment chamber so the device will be free to function properly.

b. Annual Service. Float type low water cutoffs

should be dismantled annually by qualified personnel, to the extent necessary to insure freedom from obstructions and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc., and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly. Give special attention to solder joints on bellows and float when this type of control is used. Check float for evidence of collapse and check mercury bulb (where applicable) for mercury separation or discoloration.

E. Controls. Test Controls for proper operation as

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

F. Low water cutoff (if so equipped).

1. Float Type

a. Monthly Blowoff. During the heating season, if

2. Probe Type (Annual Service). Probe type LWCO should be removed once a year, examined and cleaned of any dirt accumulations to assure proper operations. Do not attempt to repair mechanisms in the field. Complete replacement mechanisms, including necessary gaskets and installation instructions, are available from the manufacturer.

Service Notes

IX. Repair Parts

All LEDV Series Repair Parts may be obtained through your local Burnham Wholesale Distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact your Burnham Regional Sales Office as listed below.

Burnham Corporation Regional Offices

A. B urnham Corporation - Centr al & Western Regions

P.O. Box 3079 La ncaster, PA 17604 -3079 Phone: (717) 481-8400 FAX: (717) 481-8408

B. B urnham Sal es Corporation - Northeast Region

19 -27 Mystic Avenue Somerville, MA 02145 Phone: (617) 625-9735 FAX: (617) 625-9736

C. Burnham Corporation - M etropolitan Region

P.O. Box 3079 Lancas ter, PA 17604-3079 Phone: (717) 481-8400 FAX: (717) 481-8409

D. Burnham Corporation - Mid-Atlantic Region

P.O. Box 3079 La ncaster, PA 17604 -3079 Phone: (717) 481-8400 FAX: (717) 481-8409

Figure 19: LEDV Boiler Trim & Controls

Figure 20: LEDV Boiler Jacket & Insulation

Figure 21: LEDV Bare Boiler Assembly

Figure 22: Vent Kit Repair Parts

Figure 23: Beckett AFII 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

(216) 327-1060 or (800) OIL BURN(645-2876)

BECK ETT A FII BU RNER REPLACEMEN T PARTS

Part Description

Com plete Burner (without Primary Control) BCB5406 BCB5407 BCB5408 Air Tube Com bination HLX50HD HLX50HE Air Tube Screws 4352 Blower Wheel 21439 21438 Coupling (Motor to Pump) 21437 Electrodes (Replacement Kit) 51484U Escutcheon Plate 31623 Stop Screw 3166502 3166503 3166505 Fuel Line 5394 Fuel Pump (Si ngle Stage, with Sol enoid

Valve) Fuel Pump (Two Stage, with Solenoid

Valve) Gasket, Flange 31658

LEDV1 LEDV2 LEDV3

Becke tt Part Number

21757

2583

Head A ssembly (AFII 6 Slot) 51671 51672 Ho le Pl ug 2139 Inlet Air Scoop 51485 Splined Nu t 366 6 Main Housing Assembly 51584 51476 Motor 21444 Nozzle Adapter 213 Nozzle Line Heater 51621 Rear Access Door 5142 4GY Transformer 51402 4 x 4 Electrical Box 31613BK

Burnham LEDV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

T able of Contents