Burnham RSA BOILERS Instruction Manual
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
RSA BOILERS
Price - $3.00
1
IMPORTANT INFORMATION - READ CAREFULLY
All boilers mu st be ins ta lled in accordance with Nationa l, State and Local Plum bing,
Heating and Electrical Co des and the r egulations of the serving utilities. These Co des and
Regulations may differ from this instruction manual. Authorities hav ing jurisdiction should
be consulted before installations are made.
In a ll cases , reference should be made to the following Standards:
A ll wiring on bo ilers in stal led in th e US A s hall b e ma de in ac corda n ce wit h th e N ation al
Electrical Code and/or Loc al Regulations.
All wiring on boilers installed in Canada shall be made in ac cordance with the Canadian
Electrical Code and/or Local Regulations.
U SA B OI LERS
Current Edition of America n Nation a l Standar d ANSI/NFPA 31, “Installation of O il Burning
A.
Equipment”, for recom mended installation practices.
Current Edition of American N ational Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
B.
Vents, and Solid Fuel Burning Ap pliances”, For Venting requirements.
Current Edition of American Society of Mechanical Engineers ASME CS D-1, "Controls and
C.
Safety Devices for Automatically Fired Boilers", for assembly and operations of controls
and safety devices.
CA NAD IAN B OILERS
A. Current Edition of Canadian Standards Association CSA B139, "Installation C ode for Oil
Burning Equipment", for recommen ded 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 ha zard o u s situation
w hic h, if n ot av oid ed, w ill re su lt in d eath ,
serious injury or substantial property
damage.
WA R N I NG
Indic ates a potentially hazardous situation
which, if not avoided, could re sult in death,
serious injury or substantial property
damage.
Indic ates a potentially hazardous situation
which, if no t avo ided, may result in
modera te or minor injury or property
damage.
Indicates special instructions on
installation, operation, or m aintenance
which are importa nt but not related to
personal injury hazards.
CAU TION
NOTICE
NOTICE
Th is boiler has a limited warranty, a copy of which is p rint e d on th e back of this manual.
It is the respons ibility of the in stalling cont ractor to see th at all controls are correctly in stalled
and are operat ing prop e rly when the installatio n is c omplete. The warran t y for th is boiler is valid
only if the boiler has been installed, maintained and operated in accordance with these
instructions.
2
DA NGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.
WARNI N G
Impro per installation, ad justment, alteration, servic e or mainte na nce can cause p roperty
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, inc luding all
those con tained in compone nt manufac turers manuals w hich are p rovided with th e
appliance before installing, starting-up, opera ting, maintaining or servicing this appliance.
Keep this manual and lite rature in legible conditio n and posted near appliance for reference
by owner an d service technic ian.
This boiler requires regular maintenance and service to operate safely. Follow the instruction s
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 app liance - See Section III of
this ma nual for details.
This boiler is not su itable for installation o n c ombusti ble flooring, unless install ed with a
comb ustible floor shield (avai lable at extra cost). Do n ot install boiler on carpeting .
Do not tam per with or alter the boiler or controls. Re tain your contractor or a compet ent
se rv icem an to assure that the un it is p rop erly ad justed an d main taine d.
Have Firetu be s cleane d at l eas t once a ye ar - prefe rab ly at th e star t o f the he ating sea son
to remove soot and scale. The inside of combustion cha mber should also be cle aned and
ins pecte d at the same time .
Have Oil B urn er and Contro ls ch ecke d at l eas t once a ye ar or as may be n ecess itate d.
Do not operate unit with jumpered or abs ent controls or safety devices.
Do no t operate unit if any control, switch, c omponent, or device has been subject to
water.
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WARNING
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,
respirato r s and equipment when servicing or working nearby the appliance.
This boiler co ntains very hot water u nder high pressures. Do not unscrew any pipe fitting s nor
attempt to disconnect any comp onents of this boil er without positively assuring the water is cool
and has no pressure. A lways w ear 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 o f the boiler. This boiler contains components
w hich become very hot w hen 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. Do not ope rate boiler with the absence of an unapproved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for
adeq uate combustion and ventilation air.
The interior of the venting and air intake systems m u st b e inspected and cleaned before the start
of the heating season and should be inspected periodically throughout the heating season for
any obstructions. Clean and unobstructed venting and air intake systems are necessary to allow
noxious fum es that could cause injury or loss of life to vent safely and will con tribute toward
maintaining th e boiler's efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start
withou t service. If dam age du e to frozen pipe s is a pos sibility, the hea ting system s hould
not be left u n atttended in cold weather; or appropriate safeguards and alarms should be installed
on the heating system to prevent dam age if the boiler is inoperative.
This boiler is designed to bu rn No. 2 fuel oil only. D o not use gasoline, crankcase drainings, or
any oil containing gasoline. Never burn garbage o r paper in this boiler. Do not convert to any
solid fuel (i. e. wo o d, co al) or gaseous fuel (i. e. natural g as, LP/propane). All flammable d ebris,
rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area
clean and free of fire hazards.
Do not operate boiler on combustible floor without a factory supplied floor shield. Concrete over
wood joi sts is considered com bustible flooring. Do not operate on masonry floors, which may
contain moisture.
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T ables of Contents
I. Pre-Installation ..................................... 7
II. Knockdown Boiler Assembly ............... 9
III. Water Piping and Trim ...................... 12
IV. Venting............................................... 1 8
V. Electrical and Sequence of Operation 20
VI. Oil Piping ........................................... 28
VII. System Start-Up.................................. 30
VIII. Service and Cleaning .......................... 36
IX. Repair Parts ........................................ 38
Figure 1: RSA Packaged Boiler (RSA85 / RSA135)
5
Figure 1A: RSA Packaged Boiler (RSA170 / RSA285)
Boiler
Mode l
Number
RSA170 WV-29-10
RSA195 WV-29-13A
RSA240 WV-29-16A 8 x 12 x 20 8" x 20' 37.3 660 lb.
RSA285 WV-29-19A
B are B oile r
Assembly
In. x In . x Ft.
Minimum Chimney Sizes
In. (dia.) x Ft.
(height)
8 x 8 x 20 7" x 20' 42.6 600 lb.
8 x 8 x 20 8" x 20' 39.9 630 lb.
8 x 12 x 20 9" x 20' 34.6 690 lb.
(height)
Water
Capacity
Gallons
Approx.
Shipping
We igh t
6
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 filed immediately against the carrier by the
consignee. No claims for variances from, or
shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after
receipt of goods.
B. LOCATE BOILER in front of final position before
removing crate.
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 floor shield,
supplied by Burnham, is used. DO NOT install on
carpeting.
2. FOR BASEMENT INSTALLATION, provide a
solid base, such as concrete, if floor is not level, or
if water may be encountered on floor around boiler.
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.
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.
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C. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate proper combustion. If natural ventilation is inadequate, provide a screened opening or duct
from the boiler room to the outside. The opening or
duct must be sized so the boiler input will not exceed
4,000 BTUH/Sq. In. of free area. If other air consuming appliances are near the boiler, the air inlet should
be larger. Consult respective manufacturers.
D. VENTILATION AIR must be provided to maintain
the ambient temperature at safe limits. Local and
national codes may apply and should be referenced.
1. In unconfined spaces (basement) in buildings of
conventional frame, brick, or stone construction,
infiltration normally is adequate to provide air for
ventilation.
2. In confined spaces, two permanent openings, one
near the top of the enclosure and one near the
bottom, shall be provided. Each opening shall have
a free area of not less than 1 sq. inch per 1000
BTUH of the total input of all appliances in the
space.
3. PROVIDE COMBUSTION AND VENTILATION
AIR. Local code provisions may apply and should be
referenced.
than 50 ft3/1000 BTU per hour then the space is
considered a confined space.
D. For boiler located in an unconfined space of a conven-
tionally constructed building, the fresh air infiltration
through cracks around windows and doors normally
provides adequate air for combustion and ventilation.
E. For boiler located in a confined space or an unconfined
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:
1. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 BTU per hour
input of all equipment in space.
2. Vertical ducts. Minimum free area of 1 square
inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be
same as opening free area.
3. Horizontal ducts. Minimum free area of 1 square
inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be
same as opening free area.
Alternate method for boiler located within confined
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufficient volume such that combined volume of all
spaces meet criteria for unconfined 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.
A. Determine volume of space (boiler room). Rooms
communicating directly with the space in which the
appliances are installed, through openings not furnished with doors, are considered a part of the space.
Volume(ft3) = Length(ft) x Width(ft) x Height(ft)
B. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round the
result to the nearest 1000 BTU per hour.
C. Determine type of space. Divide Volume by total input
of all appliances in space. If the result is greater than
or equal to 50 ft3/1000 BTU per hour, then it is
considered an unconfined space. If the result is less
F. Louvers and Grilles of Ventilation Ducts
1. All outside openings should be screened and
louvered. Screens used should not be smaller than
1/4 inch mesh. Louvers will prevent the entrance of
rain and snow.
2. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of the
louver or grille is not known, assume wood louvers
have 20-25 percent free area and metal louvers and
grilles have 60-75 percent free area.
3. Louvers and grilles must be fixed in the open
position, or interlocked with the equipment to open
automatically during equipment operation.
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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 floor,
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.
H. 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.
9
Figure 5: Burner Mounting
10
11
Figure 6: RSA Jacket Assembly
III. Water Piping and Trim
WAR N I NG
Failure to properly pipe boiler may result in improper ope ration and dam age to boiler or
structur e .
Oxyg en contam ination of boi le r wa t e r will c a use c orrosion of iron a nd steel bo iler
c ompone nts, and can lead to boiler failure. Burnh am's Standard Warranty does no t cover
problems caused by oxygen contamination of boiler water or scale (lime) build-up c aused
by freque nt a ddition 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 fittings.
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 fittings which
allow oxygen absorption.
d. Use of non-permeable materials in the distribu-
tion system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
WARN ING
System supply and return piping must
be conn ected to corr ect boiler pipe.
Burnham recommends sizing the
s ystem circulator to su pply sufficient
flow (GPM) to allow a 20°F temper ature
diff eren tial i n the s ys tem . When s izing
the system circu lator, the pressur e
drop of all radiators, baseboard and
radiant tubing and a ll 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 refrig-
eration 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.
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 flow 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 Figure 10 in
order to regulate water flow 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.
12
Figure 7: Recommended Piping for Combination Heating and Cooling (Refrigeration) System
B. Install Pressure Relief Valve. See Figures 8 and 9.
Pressure 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.
C. Install Drain Valve in return piping. See Figures 8
and 9.
D. Oil, grease, and other foreign materials which accumu-
late in new hot water and a new or reworked system
should be boiled out, and then thoroughly flushed. A
qualified water treatment chemical specialist should be
consulted for recommendations regarding appropriate
chemical compounds and concentrations which are
compatible with local environmental regulations.
E. After the boiler and system have been cleaned and
flushed, and before refilling the entire system add
appropriate water treatment chemicals, if necessary, to
bring the pH between 7 and 11.
13
14
Figure 8: Recommended Boiler Piping for Circulator Zoned Heating Systems
15
Figure 9: Boiler Piping for Zone Valve Zoned Heating Systems
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