Burnham RSA85, RSA110, RSA125, RSA135, RSA170 Installation & Service Instructions Manual
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1
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
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.
2
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 sufcient 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.
3
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 efciency.
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.
4
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 .............................................
28
VII. System Start-Up ................................... 30
VIII. Service and Cleaning............................ 38
IX. Repair Parts ..........................................
40
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
5
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
6
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.
7
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 unconned space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a conned space.
4. For boiler located in an unconned space of a
conventionally constructed building, the fresh
air inltration through cracks around windows
and doors normally provides adequate air for
combustion and ventilation.
5. For boiler located in a conned space or an
unconned 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
b.
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
conned space. Use indoor air if two permanent
openings communicate directly with additional
space(s) of sufcient volume such that combined
volume of all spaces meet criteria for unconned
space. Size each opening for minimum free area
of 1 square inch per 1,000 BTU per hour input
of all equipment in spaces, but not less than 100
square inches.
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.
8
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
9
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.
10
Figure 5: Burner Mounting
THIS PAGE IS LEFT INTENTIONALLY BLANK
11
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 sufcient 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
12
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
9.
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 qualied 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 relling 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.
13
14
Figure 8: Recommended Water Piping for Circulator Zoned Heating Systems
Figure 9: Recommended Water Piping for Zone Valve Zoned Heating Systems
15
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 benecial to the
tankless heater but to piping and xtures plus the
many other benets derived from soft water.
16
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