Burnham LEDV SERIES, LEDV-1, LEDV-2, LEDV-3 Installation & Service Instructions 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 _ _ _ _ _ _ _
1
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.
2
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.
.
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
3
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
A.
Equipment”, for recommen ded installation practices.
B.
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.
C.
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:
A.
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.
B.
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.
C.
Have Oil Bu rner and Con tro ls checked at least once a year or as may b e necessitated.
D.
Do not operate unit with jumpered o r absen t con trols or devices.
E.
Do not op erate unit if any control, switch , com p onent, or device has been subject to w ater.
4
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
5
I. Pre-Installation
A. INSPECT SHIPMENT carefully for any signs of
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated boiler to the carrier in good
condition.
2. ANY CLAIMS for damage or shortage in shipment
must be 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.
6
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.
7
TS-98-14-A
Figure 4: Hinge AssemblyFigure 3: Proper Hinge Bracket Installation
Figure 2: Minimum Clearances to Combustible Materials
8
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.
9
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.
10
Figure 6: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems
Figure 7: Recommended Boiler Piping for Zoning with Circulators
11
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