Burnham RSA User Manual

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IMPORTANT INFORMATION - READ CAREFULLY

All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards: All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or Local Regulations.

USA BOILERS

A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices.

B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements. 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.

CANADIAN BOILERS

A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment”, for recommended 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 imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in accordance with these instructions.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow 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 appliance

- See Section III of this manual for details.

This boiler is not suitable for installation on combustible ooring, unless installed with a combustible oor shield (available at extra cost).

Do not install boiler on carpeting.

When boiler is installed on concrete which is over a material that is subject to melting (PVC, PEX radiant tubing, etc.) the combustible oor shield must be used.

A concrete pad is not sufcient to protect combustible ooring.

Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to assure that the unit is properly adjusted and maintained.

Have Firetubes cleaned at least once a year - preferably at the start of the heating season to remove soot and scale. The inside of combustion chamber should also be cleaned and inspected at the same time.

Have Oil Burner and Controls checked at least once a year or as may be necessitated. Do not operate unit with jumpered or absent controls or safety devices. Do not operate unit if any control, switch, component, or device has been subject to water.

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

defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when

servicing or working nearby the boiler. This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil

containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e. wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,

wood scraps, etc., should be kept clear of the boiler at all times.

Keep the boiler area clean and free of re hazards.

WARNING

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler 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 temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

This appliance must be properly vented and connected to an approved vent system in good condition. Serious property damage could result if the boiler is connected to an approved vent 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 be 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 contribute toward maintaining the boiler’s efciency.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

Do not operate boiler on combustible oor without a factory supplied oor shield. Concrete over wood joists is considered combustible ooring. Do not operate on masonry oors, which may contain moisture.

Table of Contents

I. Pre-Installation ....................................... 7

II. Knockdown Boiler Assembly ................ 9

III. Water Piping and Trim ......................... 12

IV. Venting .................................................18

V. Electrical and Sequence of Operation ..20

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

VII. System Start-Up ................................... 30

VIII. Service and Cleaning............................ 38

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

X. Appendix

Low Water Cut Off ............................... 50

Boiler Model Number Dim. ‘A’

RSA85

RSA110 8.5

RSA125

RSA135 7 x 15 13.0 355

34¾

41¼

Figure 1: RSA Packaged Boiler (RSA85 / RSA135)

Minimum Recommended Chimney Sizes

In. x In. x Ft. (ht.) In. (dia.) x Ft. (ht.)

8 x 8 x 20

6 x 15

Water Capacity (gallons)

9.1

13.9 340

Weight (lb.)

Approx.

Shipping

300

Figure 1A: RSA Packaged Boiler (RSA170 / RSA285)

Boiler

Model

Number

RSA170 WV-29-10

RSA195 WV-29-13A

RSA240 WV-29-16A

RSA285 WV-29-19A 9 x 20 34.6 690

Bare Boiler

Assembly

Minimum Recommended Chimney Sizes

In. x In. x Ft. (height) In. (dia.) x Ft. (height)

8 x 8 x 20

8 x 12 x 20

7 x 20 42.6 600

8 x 20

Water Capacity (gallons)

39.9 630

37.3 660

Approx.

Shipping

Weight (lb.)

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 the crated boiler to the carrier in good condition.

2. ANY CLAIMS for damage or shortage of shipment

must 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.

B. LOCATE BOILER in front of nal position before

removing crate.

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

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 oor

shield, supplied by Burnham, is used. DO NOT

install on carpeting. See Figure 26 for oor shield

part number and installation instructions.

2. 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.

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.

WARNING

Do not support boiler by placing blocks at the

four (4) corners of the boiler.

Boiler base must be evenly supported under entire base.

Do not operate boiler on combustible oor

without a factory supplie d floor shield. Concrete over wood joists is considered combust i b le floo r ing. D o not op erate on ma s onry floors, which may contain moisture.

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. RSA™ 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.

C. 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 and to maintain safe ambient air temperatures.

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored.

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 unconned space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a conned space.

4. For boiler located in an unconned space of a

conventionally constructed building, the fresh

air inltration through cracks around windows

and doors normally provides adequate air for combustion and ventilation.

5. For boiler located in a conned space or an

unconned 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.

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

conned space. Use indoor air if two permanent

openings communicate directly with additional

space(s) of sufcient volume such that combined volume of all spaces meet criteria for unconned

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 xed in the open

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

II. Knock-Down Boiler Assembly

A. REMOVAL OF BOILER.

1. Remove, all boiler to skid, hold down fasteners.

Refer to Figure 3.

2. Carefully walk boiler to the edge of skid. Tilt the

boiler back, allowing an edge to rest on the oor,

and remove the skid.

Figure 3: Base on Skid

B. TEST HEAT EXCHANGER FOR LEAKS before

proceeding with jacket assembly. Heat exchanger, canopy, and base are preassembled.

1. Install pressure gauge supplied, a hose to the city

water and a valve in the supply tapping. Plug remainder of tappings.

2. Fill boiler with water and apply a pressure of at least

10 psig but no more than 30 psig.

WARNING

Do not apply more than 30 psig to boiler.

WARNING

Any combustion chamber which was damaged must be replaced immediately.

CAUTION

If heat exchanger is not square on base DO NOT

twist. Carefully lift and reposition.

WARNING

Do not assemble boiler without cerafelt gaskets between heat exchanger and combustion chamber. Gaskets must also be between canopy and heat exchanger.

C. INSTALLING THE JACKET

1. Before jacket can be secured to boiler assembly tankless heater coil or blank plate must be attached. Using rubber gasket and bolts provided secure heater coil or blank plate to boiler extension by inserting the bolts from the backside of the extension. Refer to Figure 4.

Figure 4: Coil Plate Attachment

2. Bend jacket according to Figure 28. Starting from the front, wrap the jacket around the boiler. Make sure that return pipe, observation port and

shell extension t proper into there corresponding

clearance holes. Continue bending jacket around until front panels meet.

3. Attach jacket to boiler assembly with provided screws at appropriate locations. Make sure that the

jacket is at least ½” to ¾” off of the oor before

attaching.

4. Attach top panel with provided screws.

D. INSTALLATION OF BOILER CONTROLS

1. Install provided pressure/temperature gauge and immersion well into appropriate holes on tankless heater coil plate. Tighten so not to have any water leaks.

2. Mount the aquastat control onto the immersion well. Wire the control according to Figure 13 or 14, in the Electrical and Sequence of Operation Section.

3. Mount burner on Base front panel and wire according to instructions provided with the burner. Refer to Figure 5.

Figure 5: Burner Mounting

THIS PAGE IS LEFT INTENTIONALLY BLANK

III. Water Piping and Trim

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham’s Standard Warranty does not cover problems caused by oxygen

contamination of boiler water or scale (lime) build-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 ttings.

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 ttings which allow

oxygen absorption.

d. Use of non-permeable materials in the

distribution system.

e. Isolating the boiler from the system water by

installing a heat exchanger.

WARNING

System supply and return piping must be connected to correct boiler pipe.

Burnham recommends sizing the system

circulator to supply sufcient ow (GPM) to

allow a 20°F temperature differential in the system. When sizing the system circulator, the pressure 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

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

Figure 7: Recommended Piping for Combination

Heating and Cooling (Refrigeration) System

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 ow 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 Figures 8 and 9

in order to regulate water ow 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.

If a low water cut-off is required, it must be

mounted 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.

B. Install Safety Relief Valve. See Figures 8 and 9.

Safety Relief Valve must be installed with spindle in the vertical position. Installation of the relief valve

must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

WARNING

Safety (relief) valve discharge piping must be piped near oor to eliminate potential of severe

burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps.

C. Install Drain Valve in return piping. See Figures 8 and

D. Oil, grease, and other foreign materials which

accumulate in new hot water and a new or reworked system should be boiled out, and then thoroughly

ushed. A qualied water treatment chemical specialist

should be consulted for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations.

E. After the boiler and system have been cleaned and

ushed, and before relling the entire system add

appropriate water treatment chemicals, if necessary, to bring the pH between 7 and 11.

WARNING

Installation is not complete unless a safety relief valve is installed as shown in Figure 1 or 1A.

Figure 8: Recommended Water Piping for Circulator Zoned Heating Systems

Figure 9: Recommended Water Piping for Zone Valve Zoned Heating Systems

F. CONNECT TANKLESS HEATER PIPING AS

SHOWN IN FIGURE 10. See Table 1 for Tankless Heater Rating.

WARNING

Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to

excessively hot water at xtures. Adjust and

maintain the mixing valve in accordance with the manufacturer's instructions. Do not operate tankless heater without mixing valve.

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

1. FLOW REGULATION — If ow 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 ow regulator matching the heater

rating should be installed in the cold water line to

the heater. The ow 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

ow regulator also limits the ow 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 xtures. 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 10.

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 benecial to the tankless heater but to piping and xtures plus the many other benets derived from soft water.

Figure 10: Schematic Tankless Heater Piping

Table 1: Tankless Heater Ratings

Boiler Model

RSA85 & 110 3 12 3½ 15

RSA110, 125 & 135 3¼ 16

RSA125 & 135 3½ 19

Boiler Model

RSA170 3¾ 25½ 4 26½

RSA195, 240 & 285 4 29 4¼ 31

GPM PSID GPM PSID

S350 S375

3¾ 25

STD. #7524 OPT. #7530

IV. Venting

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 re ofcials about restrictions and installation inspection

in your area.

2. The RSA Series is designed to be vented into a

reclay 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 or vent pipe

shall have a sufcient draft at all times, to assure

safe proper operation of the boiler. See Figure 11 for recommended installation.

a. Install a draft regulator (supplied by installer)

following the instructions furnished with the regulator. See Figure 12 for alternate regulator locations.

b. With any new or replacement installation the

chimney has to be considered. Chimneys that have a high heat loss become less suitable as the heat loss of the home goes down and the

efciency of the boiler 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 inefcient oil red

boiler built into 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 efciency

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, 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 red 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 ring at 13.0% CO2.

Outside wall chimneys take longer to heat up and can have .00” W.C. draft at burner start-up. You may have to consider a special alloy chimney

ue liner with insulation around it and stabilizing

draft cap or even a draft inducing fan in severe cases.

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

extractors mounted into the breeching are not recommended.

3. For minimum clearances to combustible materials refer to Figure 2.

Figure 11: Recommended Smoke Pipe Arrangement and Chimney Requirements

Figure 12: Draft Regulator Locations

V. Electrical

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of

electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock

once power is turned off.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more 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 instructions supplied with the controls.

A. General

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 must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions.

3. Wiring should conform to Figure 13 and/or 14.

B. 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 – Refer to Figure 13 or 14 of this manual for the electrical diagram for this type of system. Connect the system circulator wire leads to the proper locations on the Aquastat control, L7224C/L7248C.

Connect the thermostat to the ‘T-T’ terminals on

the L7224C/L7248C control. Set thermostat heat anticipator settings to 0.60 amps.

6. Conventional Circulator Zoned System – Refer to Figure 15 for the electrical diagram for this type of system.

Read, understand and follow all of the instructions

provided with the Honeywell R8888 control.

7. Conventional Zone Valve Zoned System – Refer to Figure 16. Wiring to the most popular models of zone valves are given in Figure 17.

Locate C1 and C2 inside the L7224C 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 L7224C Honeywell Control. Refer to Figure 16.

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.

Figure 13: “RSAL” Wiring Less Tankless, Single Circulator

Sequence of Operation

A call for heat by the thermostat energizes the L7224C/L7248C control which in turn energizes the Honeywell R4184D primary control to turn

on the burner. If burner ignites within approximately 45 seconds and the cad cell sees ame, the burner will continue to operate until the call for heat is satised or the setting of the high limit is reached. The circulator will operate as long as the thermostat is calling for heat. If the thermostat is not satised and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high limit is closed by a

drop in water temperature.

Figure 14: “RSAT” or “RSAR” Wiring with Tankless, Single Circulator

Sequence of Operation

A call for heat by the thermostat energizes the L7224C/L7248C control which in turn energizes the Honeywell R4184D primary control to turn

on the burner. If burner ignites within approximately 45 seconds and the cad cell sees ame the burner will continue to operate until the call for heat is satised. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low

limit in the L8124C control. If boiler water temperature is below the low limit setting the burner will operate but the circulator will not, giving preference to the domestic hot water demand.

On call for heat by the thermostat the burner will continue to operate until the thermostat is satised or the setting of the high limit is reached. If the thermostat is not satised when the high limit is reached the burner will stop but the circulator will continue to operate until the thermostat is satised. Any time the boiler water temperature drops below the setting of the low limit the burner will be energized in order to maintain domes-

tic water temperature.

Figure 15: Circulator Zoned Wiring for Honeywell R8888

Figure 16: Zone Valve Zoned Wiring for R8889

NOTICE

The Honeywell R8889 Control is available in two three (3) zone models and two four (4) zone models. Burnham recommends using Model R8889A for three (3) zone systems and Model R8889B for four (4) zone systems.

Models R8889C and R8889D have less load capacity and may not operate with certain types of zone valves.

Up to four (4) R8889’s may be used together to provide up to sixteen (16) individual zones. Only one (1) zone, the rst zone of the main control will provide priority zoning for the Alliance indirect water heater. If more than four (4) zones are required, connect additional R8889’s by wiring the A, B and C terminals of each control together. Each R8889 requires a 120 volt power supply. If more than one (1) R8889 is used, set the panel type switch to “main” on the rst R8889 and set the panel type switch to “expansion” on the second, third or

fourth R8889.

Figure 17: Different Manufacturer’s Zone Valve Connections to Honeywell R8889

NOTICE

The Burnham EC5000 Control includes a water temperature sensor. Mount this sensor to the system supply piping.

8. Burnham EC5000 Circulator Zoned System – Refer to Figure 18 of this manual for the electrical diagram for this type of system. Wire the system as indicated in that diagram. Refer to the manual provided with the Burnham EC5000 Control for control operation and setup details.

9. Burnham EC5000 Zone Valve Zoned System – Refer to Figure 19 of this manual for the electrical diagram for this type of system. Wire the system as indicated in that diagram. Refer to the manual provided with the Burnham EC5000 for control operation and setup details.

Figure 18: Circulator Zoning with EC5000 Wiring Schematic

Figure 19: Zone Valve Zoned with EC5000 Wiring Schematic

VI. Oil Piping

A. General.

1. Use exible oil line(s) so that burner can be

removed without disconnecting the oil supply.

2. 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 ring rate

application to prevent nozzle fouling.

3. Use Flared ttings only. Do not use compression ttings.

4. Use of a high efciency micron lter (Garber or equivalent) in addition to conventional lter 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 20.

NOTICE

Oil piping must be absolutely airtight or leaks or loss of prime may result. Bleed line and fuel unit completely.

Figure 20: Single-Pipe Installation

Table 2: Single-Stage Units (3450 RPM) -

Two Pipe Systems

Table 3: Two-Stage Units (3450 RPM) -

Two Pipe Systems

Maximum Length of Tubing

Lift "H"

(See Figure 21)

"H" + "R" (See Figure 21)

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)

Maximum Length of Tubing

Lift "H"

(See Figure 21)

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'

"H" + "R" (See Figure 21)

3/8" OD Tubing

1/2" OD Tubing

(3 GPH)

C. 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 21.

Figure 21: Two-Pipe Installation

VII. 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. Conrm all electrical, water and oil supplies are

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

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

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 hose bib located just below isolation valve in boiler supply piping. (Note

- Terminate hose at a suitable oor drain or outdoor

area).

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

5. Open hose bib.

6. Open ll 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 ow 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.

WARNING

The maximum operating pressure of this boiler is 30 psig. Never exceed this pressure. Do not plug or change pressure relief valve.

9. Close hose bib, continue lling the system until the pressure gauge reads 12 psig. Close ll valve.

(Note - If make-up water line is equipped with

pressure reducing valve, system will automatically

ll to 12 psig.

10. Open isolation valve in boiler supply piping.

11. Remove hose from hose bib.

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 lled 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 eld lubrication. Water lubricated circulators do not need eld lubrication.

G. ADJUST CONTROL SETTINGS with burner service

switch turned “ON”.

1. SET ROOM THERMOSTAT about 10°F below room temperature.

2. PRESS RED RESET BUTTON on R7184B Oil Primary Control and release.

3. On BOILERS WITHOUT TANKLESS HEATERS equipped with L7248 electronic aquastat controller, set High Limit (HL) at 180°F. This temperature can be varied to suit installation requirements. L7248 controller has the High Limit adjustment range from 180°F to 240°F (82°C to 116°C). High Limit

Differential is xed at 15°F (8°C).

4. On BOILERS WITH TANKLESS HEATERS equipped with L7224 electronic aquastat controller, set operating control (low limit [LL]) at 190°F and high limit (HL) at 210°F. Operating control (low limit) setting must be a minimum of 20°F below high limit setting.

L7224 controller has the High Limit adjustment

range from 130°F to 240°F (55°C to 116°C), and the Low Limit adjustment range from 110°F to 220°F (43°C to 104°C). High Limit Differential is

xed at 10°F (6°C), and Low Limit Differential has

adjustment range from 10°F (6°C) to 25°F (14°C).

5. ADJUSTING AQUASTAT CONTROLLER SETTINGS. To discourage unauthorized changing of Aquastat settings, a procedure to enter the

ADJUSTMENT mode is required. To enter the ADJUSTMENT mode, press the UP, DOWN, and I buttons (refer to Figure 22) simultaneously for

three seconds. Press the I button until the feature requiring adjustment is displayed:

• HL_  High Limit.

• LL_  Low Limit.

• Ldf  Low Limit Differential.

• °F  °C.

Figure 22: L7248/L7224 Circuit Board Layout -

Horizontal Mount

Then, press the UP and/or DOWN buttons to

move the set point to the desired value. After 60 seconds without any button inputs, the control will automatically return to the RUN mode.

Note that L7224 Aquastat Controller will display all

four (4) above-listed adjustment features, but L7248 Aquastat Controller will not display Low Limit and Low Limit Differential adjustment features.

6. DISPLAY READOUT

In the RUN mode, the Aquastat will ash "bt"

(boiler temp) followed by the temperature (i.e.,

220), followed by °F or °C.

To read boiler settings, press the I key to read the

parameter of interest. For example, press I High Limit (HL) is displayed, followed by a three-digit number, i.e., 220, followed by °F or °C. Pressing the I button again (on L7224 models) will display the Low Limit (LL) followed by a three-digit number and the corresponding degree designator. See Display Readout, Figure 23.

After approximately 60 seconds without any key

presses, the display will enter a dim display mode. To return to the bright display mode, simply press any key.

7. OPERATION

The L7224 model can be in any of four operational

states - Normal, High Limit, Low Limit and Error. The controller moves back and forth from High Limit to Normal to Low Limit state as part of normal operation.

The L7248 model is restricted to three operational

states - Normal, High Limit and Error. The controller moves back and forth from High Limit to Normal state as part of normal operation.

For both models, the controller will enter the Error

state when there is an abnormal condition. The operating states are:

a. Normal: Boiler temperature went below the

High Limit setting (minus the Differential) and has not exceeded the High Limit setting; or the boiler temperature went above the Low Limit setting and has not gone below the Low Limit setting (minus the Differential).

b. High Limit: Boiler temperature went above the

High Limit setting and has not dropped below the High Limit setting (minus the Differential).

c. Low Limit: Boiler temperature went below

the Low Limit setting (minus the Low Limit Differential) and has not gone above the Low Limit setting.

d. Error: The controller has detected an error

condition (e.g., open sensor) and has shut down the burner output. The ZC output is energized. The controller continues to monitor the system and automatically restarts if the error condition clears. Refer to Table 4.

Table 4: LED Error Codes

Error Code

Err1 Sensor fault; check sensor.

Err2 ECOM fault; check EnviraCOM™ wiring.

Err3 Hardware fault; replace control.

Err4 B1 fault; check B1 wiring/voltage.

Err5 Low Line; check L1-L2, 110 Vac.

Err6 Fuse; check ECOM wires, replace fuse.

Err7

Err8

EEPROM, HL, LL, Hdf, Ldf; reset to default values. Restore desired settings.

Repeated B1 fault (voltage present at B1 when output is turned off); check B1 wiring/voltage.

Cause / Action

Figure 23: Display Readout Denitions

The operating sequence for the L7224/L7248 is

shown in Table 5. See Table 6 for Trouble Shooting Guide.

8. HIGH LIMIT CONTROLLER

The High Limit opens and turns off the burner

when the water temperature reaches the setpoint. The High Limit automatically resets after the water temperature drops past the setpoint and through the

Table 5: L7224 / L7248 Controller Operating Sequence

Action System Response

Thermostat calls for heat.

Boiler exceeds the High Limit.

Thermostat is

satised.

Error condition 1-5.

Error condition 6.

Error condition 7.

Error condition 8.

Circulator starts when water temperature is above Low Limit setting (if applicable). Boiler temperature is checked. Burner starts when water temperature is below High Limit setting.

Burner is turned off. Burner restarts when the water temperature drops below the High Limit setting minus the Differential.

Circulator and burner turn off.

If an error condition is detected, all outputs except ZC are shut down. Burner is off. Control continues to function and restarts when error is corrected. During the error check sequence, the system checks for drift in the sensor and corrosion in the connections.

EnviraCOM communication is not available.

The control has reset the High Limit, Low Limit and Differential setting to a default setting and will continue to run at those settings. Performance of the system will be degraded.

If the error condition is detected, all outputs except ZC are shut down. Burner is off. Control continues to function and restarts when all three user keys have been pressed longer than 60 seconds.

9. LOW LIMIT AND CIRCULATOR CONTROLLER

On a temperature rise, with the adjustable

Differential at the default setting of 10°F (6°C), the burner circuit breaks and the circulator circuit makes (assuming no call for heat is present) at the Low Limit setpoint. On a temperature drop of 10°F (6°C) below the Low Limit setpoint, the burner circuit makes and the circulator circuit breaks. See Figure 24.

Differential. The L7248 models have High Limit Differential presets of 15°F (8°C). The L7224

Figure 24: Setpoints and Differentials

models have High Limit Differential presets of 10°F (6°C).

Table 6: Trouble Shooting Guide

System Condition Diagnostic Condition Check Action

Boiler is cold, house is cold.

Boiler is hot, house is cold.

Display is OFF. 120 Vac System power. Turn system power on.

Display is ON. 24 Vac T-T No 24 V; replace control.

24 V present; disconnect thermostat, short T-T.

120 Vac at B1-B2 • If no, replace control.

Refer to Err on display. -----

Display is ON. 120 Vac at C1-C2 • 120 Vac at C1-C2, check wiring

Boiler below the Low Limit temperature, wait for boiler to go above Low Limit temperature.

Boiler above LL? If yes, check for 120 Vac between ZC and L2.

Boiler starts, check wiring and thermostat.

• If yes, check burner and wiring.

to pump.

• Wiring OK, is pump running?

• If not, replace the pump.

• If pump is running, check for trapped air or closed zone valves

-----

• If no 120 Vac , replace control.

• If yes, check zone relays, circulators and wiring.

Table 7: Beckett AFG, AF, & SF Burners

Boiler Model

RSA85* .85 .75 x 80B 10

RSA110 1.10 .90 x 80B 8

RSA125 1.25 1.0 x 80B 7

RSA135 1.35 1.10 x 80B 9

RSA170 1.70 1.65 x 80A 7

RSA195 1.95 2.00 x 80B 7

RSA240 2.40 2.50 x 80B 7

RSA285 2.85 3.00 x 80B 7

* Equipped with low ring rate bafe

Firing Rate

(GPH)

Hago Nozzle

Table 7A: Becket AFG Burner

Boiler Model

RSAH85 .75 .65 x 80B 6

RSAH110 1.0 .85 x 80B 7

RSAH125 1.1 .90 x 80B 7

RSAH135 1.25 1.0 x 80B 9

Firing Rate

(GPH)

Hago Nozzle

Air Settings

Shutter Band Head (stop screw) Pump Pressure

140

0 N/A

100

Air Settings

Shutter Band

0 N/A 140

Head

(stop screw)

Pump Pressure

Table 7B: Carlin EZ-2HP Burner

Boiler Model Firing Rate Manufacturer GPH Angle Type Head Bar Air Band Setting

RSA85 .85

RSAH85 .75 .65

RSA110 1.10 .90

RSAH110 1.00 .85 .60

RSA125 1.25 1.10

RSAH125 1.10 .90 .85/1.00 .65

RSA135 1.35 1.20 W

RSAH135 1.25 1.10 A .85

Delavan

.75

60°

A .75 .60

.60/.65 .50

.85/1.00

1.10/1.25 .90

1.10/1.25

.75

.85

Figure 25: Electrode / Head Setting for

Beckett Burner

Figure 25A: Electrode / Head Setting for

Carlin EZ-1HP Burner

H. REMOVE GUN ASSEMBLY

1. Check nozzle size, head size, gun setting, and positioning of electrodes. This information is shown in Figure 25 and Tables 7 and 7A for Beckett burner, Figure 25A and Table 7B for Carlin EZ-1HP burner.

2. Reinstall gun assembly.

I. VERIFY OIL BURNER SETTINGS BEFORE

STARTING

BURNER AIR BAND AND AIR SHUTTER

1. SETTINGS, see Tables 7 and 7A for Beckett burner, Table 7B for Carlin EZ-1HP burner.

2. OPEN ALL OIL LINE VALVES.

3. Attach a plastic hose to fuel pump vent tting and

provide a container to catch the oil.

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

J. START OIL BURNER

1. Open vent tting on fuel pump.

2. TURN ‘ON’ BURNER service switch and allow

burner to run until oil ows from vent tting

in a SOLID stream without air bubbles for approximately 10 seconds.

3. Close vent tting and burner ame should start

immediately after pre-purge is complete. Pre-purge

prevents burner ame until 10 seconds has elapsed

after initial power is applied to burner. During pre-purge, the motor and ignitor will operate but the oil valve will remain closed. Refer to Oil Primary Control Instructions for more details.

4. For Carlin burner, refer to “Installation and

Operating Instructions for Packaged Heating/ Burner Units, Carlin Elite Oil Burner” (Form CCT-569A) for instructions for Bleeding the Pump

and Starting the Burner.

K. ADJUST OIL PRESSURE

1. Locate oil pressure adjusting screw and turn screw until Pressure Gauge reads the correct pump

pressure required for the specic boiler. Refer to

Tables 7 & 7A for Beckett burners or Table 7B for Carlin burner (set pump pressure to 150 for Carlin EZ-1HP Burner).

2. DO NOT REMOVE PRESSURE GAUGE until later.

2. ADJUST DRAFT REGULATOR for a draft of -

.02” (water gauge) over the re after chimney has

reached operating temperature and while burner is running.

3. READJUST AIR BANDS on burner for a light

orange colored ame while draft over the re 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 nal check using suitable

instrumentation to obtain a CO2 of 11.5 to 12.5%

with draft of -.02” w.c. in re box. These settings will assure a safe and efcient operating condition. If the ame appears stringy instead of a solid ame,

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

re.

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

Carlin Burner

1-4. Refer to “Installation and Operating Instructions

for Packaged Heating/Burner Units, Carlin Elite Oil Burner” (Form CCT-569A) for instructions for

Bleeding the Pump and Starting the Burner.

5. Turn “off” Burner and remove pressure gauge. Install gauge port plug and tighten. Start burner again.

6. CAD Cell Location and Service. The burner is

supplied with a cadmium sulde ame detector

mounted at the factory, mounted on the bottom of the transformer. See “Installation and Operating

Instructions for Packaged Heating/Burner Units, Carlin Elite Oil Burner” (Form CCT-569A). To

service cad cell or to replace the plug in portion, swing open the transformer. After service is complete, be sure to fasten down the transformer.

M. FLAME FAILURE

The RSA boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to re and the reset button on the primary control

has tripped, the burner has experienced ignition failure. Before pressing the reset button, call your serviceman immediately.

L. OTHER ADJUSTMENTS

Beckett Burner

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

a. Adjust air supply by loosening lock screws and

moving the air shutter and if necessary the air band. Refer to Tables 7 and 7A preliminary settings.

WARNING

Do not attempt to start the burner when excess oil has accumulated, when the unit is full of vapor, or when the combustion chamber is very hot.

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

1. 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 RSA boiler is the

result of extensive testing to obtain the best ame shape and efcient 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 carry.

2. FLAME SHAPE — Looking into the combustion

chamber through the ame plug hole, the ame

should appear straight with no sparklers rolling up

toward the top of the chamber. If the ame 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.

3. 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 re hazard.

4. AIR LEAKS— Any such leaks should be repaired, as they may cause erratic burning of the fuel and in

extreme cases may become a re hazard.

There may be many possible causes of leaks in oil

lines such as:

a. Fitting leaks due to misared tubing or damaged

tting.

b. Fuel line leak due to crushed or bent tubing. c. Filter connection leaks. d. Tank connection leaks.

The following actions can eliminate air leaks:

a. Bleed pump as detailed in System Start-Up

Section of this manual.

b. Replace are ttings.

c. Replace oil supply line.

d. Repair oil lter leaks e. Replace or repair tank ttings.

5. GASKET LEAKS— If 11.5% to 12.5% CO2 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 ring rate the greater effect an air leak can have

on CO2 readings.

6. DIRT— A fuel lter 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.

7. 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 ame, causes smoke, and allows un-

burned fuel to pass through the combustion chamber

and clog the ueways of the boiler.

NOTICE

CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the

fuel system and with a 24" length of tubing, re out of an auxiliary ve gallon pail of clean, fresh,

warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite.

8. 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 ame 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.

9. 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.

10. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode

settings, ame shape, air or water in the fuel lines.

11. SHUT DOWN NOISE — If the ame 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 ring

cycles for that air to be fully vented through the

nozzle. Water in the fuel or poor ame shape can

also cause shut down noises.

P. TEST CONTROLS

WARNING

Before installation of the boiler is considered complete, the operation of all boiler controls must 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:

WARNING

Service of this boiler should be undertaken only

by trained and skilled personnel from a qualied

service agency.

Simulate ame failure:

• Follow the starting procedure to turn on the

burner.

• Close the hand valve in the oil supply line.

• Control enters recycle mode and tries

to restart burner after approximately 60 seconds.

• Safety switch should lock out in

approximately 15 seconds. Ignition and motor should stop.

• Indicator light will ash ½ second on,

½ second off.

• Push red reset button to reset safety switch.

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.

• Indicator light will ash ½ second on,

½ second off.

• Push red reset button to reset safety switch.

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

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. Rell

boiler.

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

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD WATER MORE FREQUENTLY THAN ONCE A MONTH, CONSULT A QUALIFIED SERVICE TECHN ICIAN TO CHECK YOUR SYSTEM FOR LEAKS.

A leaky system will increase the volume of make-up

water supplied to the boiler which can signicantly

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.

INSTALLATION INSTRUCTIONS FOR SHIELD REQUIRED FOR COMBUSTIBLE FLOOR

This shield for combustible oors is intended for use only with the following Burnham oil-red boilers:

Use Part Number 6183504 for the following models:

RSA85 RSA110 RSA125 RSA135

ADDS 4-3/16” TO BOILER HEIGHT

Use Part Number 6183505 for the following models:

RSA170 RSA195 RSA240 RSA285

ADDS 5-3/8” TO BOILER HEIGHT

1) Place shield on combustible oor with “TOP” surface

upward and “FRONT” surface directly below the expected position of the oil burner.

2) Locate shield such that clearances to combustible walls

are as indicated in Figure 26. These dimensions will assure that the boiler jacket will be at least 18” from the side and rear walls and 48” from the front wall, as required by ANSI/NFPA 31.

3) Fasten shield to combustible oor to keep shield from

shifting position during setting of boiler.

4) Set boiler squarely on top of shield such that base plate

of boiler rests at on top surface of shield and does not over-hang shield on any side. Conrm clearance to

combustible walls. Refer to Figure 2.

5) Do not enclose boiler (including shield) on all four sides. Boiler may be enclosed on any three sides while maintaining minimum clearances shown in Figure 2 for each of those three sides.

Figure 26

VIII. Service and Cleaning

NOTICE

BURNER SHUTDOWN: Open Service Switch to turn off burner.

Manual Oil Supply Valve should be closed and

Electric Service to boiler turned off if boiler will not be operated for an extended 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. (See Figure 27)

1. CLEAN THE FIRETUBES

a. Disconnect electric to burner and remove stack.

b. For access to the retubes, pull top jacket panel

off. Loosen wing nuts, that hold canopy down. Without taking wing nuts off carriage bolts, disengage bolts from slots on tubesheet. Pull canopy off.

c. Remove turbulators.

d. Using a retube brush clean retubes. DO

NOT extend brush past the end of the bottom tubesheet.

e. Assemble the boiler in reverse order.

Units should be cleaned at least once a year, preferably

at the end of each heating season.

It is not necessary to remove burner to clean boiler.

Brush, scrape, or vacuum from top.

Figure 27: Cleaning of RSA Boiler

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

IX. Repair Parts

All RSA™ 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 Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.

For Carlin oil burner replacement parts, contact your wholesaler or Carlin: CCT, Carlin Combustion Technology, Inc.

70 Maple Street

East Longmeadow, MA 01028 Tel: (413) 525-7700 Fax: (413) 525-8306

ITEM DESCRIPTION PART NUMBER

1 Jacket Rear Top Panel 604350864

2 Jacket Front Top Panel 604350863

4 Temperature / Pressure Gauge 100282-03

7 Burner Primary Control, R7184B 80160847

Jacket Wrap-A-Round Panel, RSA85/110 60435087

Jacket Wrap-A-Round Panel, RSA125/135 60435088

Honeywell L7248C1014 Hi-Limit Control 100059-01

Honeywell L7224C1004 Limit Control 100862-01

Observation Port Cover 7026001

Observation Cover Sprint V1 8026015

Flat Washer, SAE, 5/16” 80860647

Hex Nut, 5/16” -18, Heavy 80860402

Fogire 28: Assembled Boiler

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 29: RSA85-135 Bare Boiler Repair Parts

ITEM QTY. DESCRIPTION PART NUMBER

1 2 Wing Nut, 1/4 -20 80860910

2 10 Washer, Flat 1/4 (SAE) 80860633

3 1 Canopy Assembly 6113509

4 2 1/2” Thick x 1” x 12-3/8” Cerafelt Strip 9206005

5 2 1/2” Thick x 1” x 12-3/8” Cerafelt Strip 9206005

6 2 Carriage Bolt, 1/4 -20 x 3” Lg. 80860119

8 1 Heat Exchanger Assembly

9 10 SA307B 3/8 -16 x 1-1/4” Bolt 80861360

10 1 Tankless Heater Gasket 8206036

11 1 Tapped Heater Cover Plate 7036030

12 1

13 10 Washer, Flat (USS), 3/8” 80860645

14 10 Hex Nut, 3/8 -16, Steel, Plain 80860400

15 2 1/2” Thick x 2” x 13-3/4” Cerafelt Strip 9206003

16 2 1/2” Thick x 2” x 18-1/2” Cerafelt Strip 9206003

17 1 Combustion Chamber 8203006

18 1 Cerablanket 8203512

19 1 Base Assembly 6183508

20 4 Machine Screw, Hex Head, 1/4 -20 x 1-1/4” 80860810

21 4 Hex Nut, 1/4 -20 (Heavy Hex) 80860407

‘A’

Turbulator 7116037

‘B’

Tankless Heater Coil, (Standard S350) (Includes Item 10) 6033509

Tankless Heater Coil, (Optional S375) (Includes Item 10) 6033510

BOILER MODEL

RSA85 12 603350112

RSA110 16 603350116

RSA125 12 603350212

RSA135 16 603350216

‘A’ ‘B’

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 30: RSA170-285 Boiler Repair Parts

ITEM DESCRIPTION PART NUMBER

1 Jacket Top Panel Assembly 60435022

2 Canopy Assembly 6113510

3 1/2” Thick x 1” x 23” Cerafelt Strip 9206005

4 1/2” Thick x 1” x 17” Cerafelt Strip 9206005

6 Tankless Heater Gasket 8036025

8 Blank Heater Cover Plate 7033501

9 Heat Exchanger Assembly

10 1/2” Thick x 2” x 25” Cerafelt Strip 9206003

11 1/2” Thick x 2” x 21” Cerafelt Strip 9206003

12 Combustion Chamber 8203003

13 Block Insulation Assembly Supplied with Item #12

14 Jacket Left Side Panel Assembly 60435061

15 Jacket Upper Front Panel Assembly 60435033

16 Jacket Lower Front Panel Assembly 60435042

17 Base Assembly with Insulation 6186031

18 Jacket Rear Panel Assembly 60435071

19 Jacket Right Side Panel Assembly 60435051

21 Hex Nut, 1/4 -20 (Heavy Hex) 80860407

Turbulator, See ‘A’ for Quantity

#7524 Tankless Heater Assembly (Includes Item 6) 6033507

#7530 Tankless Heater Assembly (Includes Item 6) 6033508

6113504

‘B’

BOILER MODEL

RSA85 12 603350112

RSA110 16 603350116

RSA125 12 603350212

RSA135 16 603350216

‘A’ ‘B’

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 ELYRIA, 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 RSA85 RSA110 RSA125 RSA135

Burner Model AFG AFG AFG AFG

Air Tube Combination AF60BN AF60XN AF60J2 AF60JZSS

Spec. No. BCB6211 BCB6212 BCB6213 BCB6214

Air Band 3492BKA 3492BKA 3492BKA 3492BKA

Air Band Nut 4150 4150 4150 4150

Air Band Screw 4198 4198 4198 4198

Air Shutter 3709BK 3709BK 3709BK 3709BK

Air Shutter Screw 4198 4198 4198 4198

Blower 2999 2999 2999 2999

Bulkhead Fitting 3488 3488 3488 3488

Bulkhead Fitting Locknut 3666 3666 3666 3666

Connector Tube Assembly 5636 5636 5636 5636

Coupling 2454 2454 2454 2454

Electrode Clamp 149 149 149 149

Electrode Clamp Screw 4219 4219 4219 4219

Electrode Insulator Assembly EA21502 EA21502 EA21502 EA21502

Spider Spacer Assembly 5653 5653 5653 5653

Escutcheon Plate 3493 3493 3493 3493

Flange and Air Tube Assembly 3146812 3146812 3146812 3146812

Gasket 31498 31498 31498 31498

Head 360003 360003 360006 360006

Head Screws 4221 4221 4221 4221

Hole Plug 2139 2139 2139 2139

Housing Assembly w/Inlet Bell 5624 5624 5624 5624

Motor 2456 2456 2456 2456

Nozzle Adapter 213 213 213 213

Nozzle Line Electrode Assembly NC6058 NC6058 NC6058 NC6048

Pump (Includes Valve) 21844 21844 21844 21844

Static Plate 31646 3383P 31646 31646

Ignitor 51771U 51771U 51771U 51771U

Ignitor Hinge Screw 4217 4217 4217 4217

Ignitor Holding Screw 4198 4198 4198 4198

Ignitor Gasket Kit 51304 51304 51304 51304

Wire Guard 3345 3345 3345 3345

Bafe 3708 N/A N/A N/A

Ordering Information for Quality Replacement Parts

Figure 31: BECKETT AFG MODEL BURNER

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 ELYRIA, OHIO 44036

1-800-645-2876

Boiler Model RSA170 RSA195 RSA240/285

Burner Model AF AF SF

Air Tube Combination AF60XO AF60XP SF60FY

Spec. No. BCB114 BCB116 BCB211

1) Air Band 3492 3492 3492

Air Band Nut 4150 4150 460

Air Band Screw 4198 4198 4219

2) Air Shutter 3494 3494 3215

Air Shutter Screw 4198 4198 493

6) Blower 2459 2459 2288

7) Bulkhead Fitting 3488 3488 3488

8) Bulkhead Fitting Locknut 3666 3666 3666

9) Connector Tube Assembly 5636 5636 5636

10) Coupling 2454 2454 2433

11) Electrode Clamp 149 149 149

Electrode Clamp Screw 4219 4219 4219

12) Electrode Insulator Assembly EA21502 EA21502 EA21502

15) Spider Spacer Assembly 5653 5653 5653

16) Escutcheon Plate 3493 3493 3493

18) Flange and Air Tube Assembly 58115 58115 58115

Gasket 3616 3616 3616

19) Head 360012 360022 5434

Head Screws 4221 4221 4221

Hole Plug 2139 2139 2139

20) Housing Assembly w/Inlet Bell 5624 5624 53485

21) Motor 2456 2456 2364

22) Nozzle Adapter 213 213 213

23) Nozzle Line Electrode Assembly NC6048 NC6058 NC6048

25) Pump (Includes Valve) 21844 21844 21844

27) Static Plate 3383 3383 3383

28) Ignitor 51824U 51824U 51824U

29) Ignitor Hinge Screw 4217 4217 4217

30) Ignitor Holding Screw 4198 4198 4198

31) Ignitor Gasket Kit 51304 51304 51304

21) Wire Guard 3345 3345 3345

Figure 32: BECKETT AF and SF MODEL BURNERS

X. Low Water Cut Off (LWCO)

WARNING

DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.

baseboard on the same oor level as the boiler). In

addition, some jurisdictions require the use of a LWCO with a hot water boiler.

Where

The universal location for a LWCO on both gas and

oil hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

What Kind

Typically, in residential applications, a probe type

LWCO is used instead of a oat type, due to their

relative costs and the simplicity of piping for a probe LWCO.

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration can be

universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown below.

LWCO Location

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch connection must have a minimum diameter to

prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located

above the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas red

boilers where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.

How to Test

Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by lling the system.

The boiler should attempt to operate once the water level is above the LWCO.

SERVICE RECORD

DATE SERVICE PERFORMED

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Waarrrraannttyy

FFoorrRReessiiddeennttiiaallGGrraaddeeWWaatteerraannddSStteeaammBBooiilleerrs

Using Cast Iron, Carbon Steel, Cast Aluminum,

or Stainless Steel Heat Exchangers

aannddPPaarrttss//AAcccceessssoorriiees

Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied parts and/or accessories manufactured and shipped on or after July 1, 2008:

ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY U.S. BOILER COMPANY, INC.

U.S. Boiler Company, Inc. warrants to the original owner that its residential grade water and steam boilers and parts/accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a residential grade boiler or any part or accessory provided by U.S. Boiler Company, Inc. is found to be defective in material or workmanship during this one year period, U.S. Boiler Company, Inc. will, at its option, repair or replace the defective part.

HEAT EXCHANGER WARRANTIES

U.S. Boiler Company, Inc. warrants to the original owner that the heat exchanger of its residential grade boilers will remain free from defects in material and workmanship under normal usage for time period specified in the chart below of the original owner at the original place of installation. If a claim is made under this warranty during the “No

Charge” period from the date of original installation, U.S. Boiler Company, Inc. will, at its

option, repair or replace the heat exchanger. If a claim is made under this warranty after the expiration of the “No Charge” period from the date of original installation, U.S. Boiler Company, Inc. will, at its option and upon payment of the pro-rated service charge set forth below, repair or replace the heat exchanger. The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows:

NOTE: If the heat exchanger involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the Burnham

Repair Parts Pricing where the heat exchanger last

appeared or the current retail price of the then nearest equivalent heat exchanger.

*MegaSteam Waterside Corrosion Warranty: U.S. Boiler Company, Inc. warrants the cast iron sections of the MegaSteam boiler to resist Temperature Induced Chloride Activated Graphitic Corrosion for a period of five years from the date of original installation. In the event that any cast iron section of a Mega Steam boiler fails due to this corrosion mechanism during this period, U.S. Boiler Company, Inc. will repair or replace, at its option, the cast iron section assembly.

LIFETIME NIPPLE LEAKAGE WARRANTY

U.S. Boiler Company, Inc. warrants the cast iron and steel nipples that join the cast iron boiler sections to be free of defects in material and workmanship for the lifetime of the original owner at the original place of installation. In the event that such nipples are found to be defective in material and workmanship during this period, U.S. Boiler Company, Inc. will repair or replace at its option, the cast iron section assembly.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These warranties are applicable only to boilers, parts, or accessories designated as residential grade by U.S. Boiler Company, Inc. and installed in a single or two-family residence and do not apply to commercial grade products.

2. Components Manufactured by Others: Upon expiration of the one year limited warranty on residential grade boilers, all boiler components manufactured by others but furnished by U.S. Boiler Company, Inc. (such as oil burner, circulator and controls) will be subject only to the manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by U.S. Boiler Company, Inc. are conditioned upon the installation of the residential grade boiler, parts, and accessories in strict compliance with U.S. Boiler Co., Inc. installation instructions. U.S. Boiler Company, Inc. specifically disclaims liability of any kind caused by or relating to improper installation.

4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Company, Inc. conditioned upon the use of the residential grade boiler, parts, and accessories for its intended purposes and its maintenance accordance with U. S. Boiler Company, Inc. recommendations and hydronics industry standards. For proper installation, use, and maintenance, see all applicable sections of the

Installation and Operating, and Service Instructions Manual furnished with the unit.

5. This warranty does not cover the following: a. Expenses for removal or reinstallation. The homeowner will be responsible

for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith, and transportation to and from U.S. Boiler Company, Inc.

b. Components that are part of the heating system but were not furnished by

U.S. Boiler Company, Inc. as part of the residential boiler.

c. Improper burner adjustment, control settings, care or maintenance.

d. This warranty cannot be considered as a guarantee of workmanship of an

installer connected with the installation of the U.S. Boiler Company, Inc. boiler, or as imposing on U.S. Boiler Company, Inc. liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation, which liability is expressly disclaimed.

e. Boilers, parts, or accessories installed outside the 48 contiguous United

States, the State of Alaska and Canada.

f. Damage to the boiler and/or property due to installation or operation of the

boiler that is not in accordance with the boiler installation and operating instruction manual.

g. Any damage or failure of the boiler resulting from hard water or scale

buildup in the heat exchanger.

h. Any damage caused by improper fuels, fuel additives or contaminated

combustion air that may cause fireside corrosion and/or clogging of the burner or heat exchanger.

i. Any damage resulting from combustion air contaminated with particulate

which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles, dirt, and dust particulate.

j. Any damage, defects or malfunctions resulting from improper operation,

maintenance, misuse, abuse, accident, negligence including but not limited to operation with insufficient water flow, improper water level, improper water chemistry, or damage from freezing.

k. Any damage caused by water side clogging due to dirty systems or

corrosion products from the system. l. Any damage resulting from natural disaster. m. Damage or malfunction due to the lack of required maintenance outlined in

the Installation and Operating Manual furnished with the unit.

6. Exclusive Remedy: U.S. Boiler Company, Inc. obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties.

7. Limitation of Damages: Under no circumstances shall U.S. Boiler Company, Inc. be liable for incidental, indirect, special or consequential damages of any kind whatsoever under these warranties, including, but not limited to, injury or damage to persons or property and damages for loss of use, inconvenience or loss of time. U.S. Boiler Company, Inc. liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade boiler involved. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entire obligation of U.S. Boiler Company, Inc. with respect to any defect in a residential grade boiler, parts, or accessories and U.S. Boiler Company, Inc. shall have no express obligations, responsibilities or liabilities of any kind whatsoever other than those set forth herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to complete and mail the Warranty Card provided with the product or register product online at www.burnham.com within ten days after the installation of the boiler, although

failure to comply with this request will not void the owner’s rights under these

warranties. Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the owner should write to U.S. Boiler Company, Inc.,

C/O Burnham, P.O. Box 3079, Lancaster, PA 17604, giving

full particulars in support of the claim. The owner is required to make available for inspection by U.S. Boiler Company, Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Company, Inc. to ship these parts prepaid to U.S. Boiler Company, Inc. at the above address for inspection or repair. In addition, the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Years in Service 1-5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25+

Cast Iron Water 5 15 20 25 30 40 45 50 55 60 65 70 75

Cast Iron Steam*

Carbon Steel 5 15 20 25 30 40 45 50 55 60 65 70 75

Cast Aluminum 30 40 50 60 70 Stainless Steel 30 40 50 60 70

Service Charge as a % of Retail Price

No Charge 10

No Charge 100

Burnham RSA User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual