Burnham HF SERIES Boiler User Manual
Contents
1. Lti f a Ld 4 TOP VIEW T r A a oe B 1 313 i N 1 AF R N m 20 AFG BURNER NS RETURN _ CONNECTION FRONT VIEW SIDE VIEW SEE TABLE BELOW gt Figure 1 HF Packaged Boiler HF 98 HF 173 Table 1 WATER RATINGS AND SPECIFICATIONS DOE Heating Capacity MBH 132 154 184 IBR Net Water rating MBH 90 115 134 160 Firing Rate gal hr 85 1 10 1 25 1 50 Nozzle Specification 75 x 45 B 90 x 45 B 1 00 x 45 B 1 25 x 45 B Stack Diameter inch 6 6 7 7 Number of Tubes 12 12 18 18 Boiler Water Cap gal 20 20 Supply Size FPT 1 1 Return Size FPT 1 1 Tankless Heater Size gal min 4 5 Optional 4 5 Optional Chimney Size min 8 x 8 x 15 8 x 8 x 15 8 x 8 x 15 8 x 8 x 15 Approx Shipping Wt Ib 450 450 720 720 DIMENSIONS Max Working Pressure 30 PSI Water Only Overall Width in Overall Length Boiler in Jacket Height in Jacket Length in Jacket Width in Smoke Outlet Height in Overall Length w Burner in Notes 1 Firing rates based on 140 000 BTU per gallon of oil 2 IBR net water ratings based on a pick up allowance of 1 15 3 Manufacturer should be consulted before selecting a boiler for installations having unusual piping and pick up requirements 4 Firebox draft setting 02 inches water column 5 Ratings based on 13 0 CO 5 A INSPECT SHIPMENT carefully for any signs of damage 2 FORB2. II Installation Instructions 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 clearance from hot water piping to combustible prevent oxygen contamination of boiler water and materials frequent water additions a If this boiler is used in connection with refrig 1 There are many possible causes of oxygen contami nation such as a Addition of excessive make up water as a result of system leaks Absorption through open tanks and fittings 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 Eliminating open tanks from the system Eliminating and or repairing fittings which allow oxygen absorption Use of non permeable materials in the distribu tion system Isolating the boiler from the system water by installing a heat exchanger WARNING System supply and return
3. Attach a hose to bib cock located just below isolation valve in boiler supply piping Note Terminate hose at a suitable floor drain or outdoor area 4 Starting with one circuit at a time open zone valve or valve 5 Open bib cock 6 Open fill 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 flow 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 9 Close bib cock continue filling the system until the pressure gauge reads 12 psig Close fill valve Note If make up water line is equipped with pressure reducing valve system will automatically fill to 12 psig 10 Open isolation valve in boiler supply piping 11 Remove hose from bib cock 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 filled 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 residenti
4. o e lalalo N tQ R N NNNJ S 2 100 L Two PipeOilLines 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 O N co IN Q to Figure 13 OUTSIDE TANK FUEL PUMP ABOVE BOTTOM OF TANK F FUEL PUM AIR j PIPE NTA TI Mm Es FILTER i AJ A INLET I EMC T a i 7 L m pip p i 28 J l Het LL RETURN TE INE Figure 13 Two Pipe Installation 17 lll 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 Confirm all electrical water and oil supplies are turned off at the source and that the vent is clear from obstructions 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
5. 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 unatttended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative 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 or gaseous fuel i e natural gas LP propane All flammable debris 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 joists is considered combustible flooring Do not operate on masonry floors which may contain moisture Tables of Contents I General Information cee eeeeeeee 5 IV Service and Cleaning J 23 Il Installation Instructions 00008 8 Vi Repair Parts Lai ko ssii akiai sis Eni oi 4 M System Start Up I General Information AN VENT TINE CTION i SEE TABLE BELOW _ SAFETY RELIEF VALVI CONNECTION SEE ABLE BELOW SUPPLY CONNECTION SEE TABLE BELOW L8 148C LIMIT CONTROL
6. failure The maintenance of system integrity is the best method to achieve this IV 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 mainte nance B Firetubes and Combustion Chamber 1 CLEAN THEFIRETUBES a For access to fireside of boiler remove fasteners holding flue box panel closed b Usinga 1 1 2 diameter wire brush 30 handle clean firetubes c Remove fasteners holding burner door Carefully remove door with burner still attached 2 CLEAN THECOMBUSTION CHAMBER Using wire or fiber bristle brush clean inside of combustion chamber 3 AFTERCLEANING a Vacuum debris inside combustion chamber and vacuum remaining fireside of boiler as necessary 23 V Repair Parts 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 15 HF Series Bare Boiler 24 Jacket Right Side Panel 70437031 D16850 70437042 8103702 4 1 2 3 70437040 5 61137010 61137010 D16800 Flue Box Door w Insula
7. inefficient oil fired boiler built into a home without insulation or storm windows With increas ing fuel prices that home probably has been insu lated and fitted 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 efficiency 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 firing rate reduced firing 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 condensed water may be visible on the outside of the breeching or chimney In those 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 fired 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 ade
8. this reason a flow regulator matching the heater rating should be installed in the cold water line to the heater The flow 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 flow regulator also limits the flow of supply water regardless of inlet pressure variations in the range of 20 to 125 psi 2 TEMPERING OF HOT WATER Installation ofan 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 fixtures 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 5 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 c
9. 2BKA 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 5780 5780 5780 5780 Spider Spacer Assembly 5503 5503 5503 5503 Escutcheon Plate 3493 3493 3493 3493 Flange and Air Tube Assembly 3146806 3146806 3146806 3146806 Gasket 31498 31498 31498 31498 Head 5912 5912 5913 5913 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 ne EE NL50MB NL50MB NL50MD NL50MD Pump 2460 2460 2460 2460 Static Plate 3384 3384 3383P 3383P Ignitor 7440 7440 7440 7440 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 Baffle N A N A N A N A 27 28
10. ASEMENT INSTALLATION providea I ALLEQUIPMENTiscarefully manufactured concrete base if floor is not perfectly level or if me water may be encountered on floor around boiler inspected and packed Our responsibility ceases upon delivery of the crated boiler to the carrier in 3 PROVIDE SERVICE CLEARANCE of at least 48 good condition from the front of the jacket for servicing of burner 2 ANY CLAIMS for damage or shortage of shipment and removal of tankless heater must filed immediately against the carrier by the consignee No claims for variances from or shortage in orders will be allowed by the manufac turer unless presented within sixty 60 days after receipt of goods B LOCATEBOILER infront of final position before removing crate For minimum clearances to combustible materials See Figure 2 1 LOCATE so that smoke pipe connection to chim ney will be short and direct BOILER IS NOT SUITABLE FOR INSTALLATION ON COMBUS TIBLE FLOOR unless combustible floor shield supplied by Burnham is used DO NOT install on carpeting TTT R 14 L EAN A o FRONT VIEW FLOOR LINE RIGHT SIDE VIEW 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 HF boilers can be installed in rooms with clearan
11. IP 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 HINTS ON COMBUSTION a NOZZLES Although the nozzle is a relatively inexpensive device its function is critical to the successful operation of the oil burner The selection of the nozzle supplied with the HF boiler is the result of extensive testing to obtain the best flame shape and efficient combustion Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO and smoke Nozzles are See Manila folder in file titled HF Figure 14 Electrode Head Setting delicate and should 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 service man to carry FLAME SHAPE Looking into the combus tion chamber through the flame plug hole the flame should appear straight with no sparklers rolling up toward the top of the chamber If the flame drags to the right or left sends sparklers upward or makes wet spots on the 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 20 FUEL LEAKS Any fuel leak between the pump and the nozzle wil
12. NE EEE CTR DSS OCOuHOL Conventional Zone Valve Zoned System Locate C1 and C2 inside the L8124C 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 L8124C Honeywell 2 Use anti short bushings on all wiring passing Control through boiler jacket junction boxes and or control boxes Connect the thermostat of each zone and the circulator for that zone to R8889 panel If an 3 Use armored cable BX over all exposed line Alliance indirect water heater is used connect voltage wiring the Alliance thermostat and circulator to the Zone 1 4 If an Alliance indirect water heater is used use EO tne BBB poten os tar au ater priority zoning Do not use priority zoning for Hydro Air Systems 14 settings to 0 12 amps T T ful Le al he cl ce Be Bl B WH H BK IRE TYPE TW WITH 27 MI V 18 AWG WIRE TYPE TEW AWM 31 MIL THICK INSULATION 24V 18 THICK INSU E TYPE SPT W HONEYWELL R4184D PRIMARY CONTRO K WIRE CODE Figure 10 Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls without Tankless Heater Figure 11 Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls with Tankless Heater 15 J Oil Piping 1 Use flexible oil line s so that burner can be remo
13. Price 3 00 INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR HF SERIES OIL FIRED BOILER BEFORE INSTALLATION READ THIS MANUAL SAVE THESE INSTRUCTIONS Installing contractor and homeowner should read and be informed as to the proper installation and operation of this unit The manufacturer will not be responsible for improper installation or operation This manual and all associated instruction material should be conspicuously posted near the e eguipment For service or repairs to boiler call your heating contractor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number Boiler Serial Number Installation Date HF_ Heating Contractor Phone Number CBurnham AMERICA S BOILER COMPANY Burnham Corporation Lancaster PA 17604 3079 8143709R3 12 99 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 USA BOILERS A Current Edition of American National St
14. al type burners employ permanently lubricated bearings and thus do not require any field lubrication Water lubricated circulators do not need field lubrication G SET CONTROLS with burner service switch turned OFF 1 SET ROOM THERMOSTAT about 10 above room temperature 2 PRESS RED RESET BUTTON on R4184D Oil Primary Control and release 3 SET HIGH LIMIT dial on L8124C L8148A at temperature to suit requirements of installation H REMOVE GUN ASSEMBLY 1 Check nozzle size head size gun setting and Table 4 Beckett AFG Boiler Firing si Rate SOLID stream without air bubbles for approxi mately 10 seconds 3 Close vent fitting and burner flame should start immediately 4 If the burner does not start immediately check the manual overload switch on the motor if so equipped and the safety switch on the burner primary control K ADJUST OIL PRESSURE 1 Locate oil pressure adjusting screw and turn screw until Pressure Gauge reads the correct pump pressure required for the specific boiler Refer to Table 4 2 DO NOT REMOVE PRESSURE GAUGE until later L OTHER ADJUSTMENTS 1 ADJUST THE AIR BAND AND OR AIR SHUT TER Beckett Burners a Adjust air supply by loosening lock screws and moving the air shutter and if necessary the air band Refer to Table 4 preliminary settings 2 ADJUST DRAFT REGULATOR for a draft of 02 water gauge over the fire after chimney has reached operating temper
15. andard 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 of 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 CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage damage NOTICE Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards NOTICE This boiler has a limited warranty a copy of wh
16. ature and while burner is running 3 READJUST AIR BANDS on burner for a light orange colored flame while draft over the fire is 02 w c Use a smoke test and adjust air for minimum smoke not to exceed 1 with a mini mum of excess air Make final check using suitable instrumentation to obtain a CO of 11 5 to 12 5 with draft of 02 w c in fire box These settings will assure a safe and efficient operating condition If the flame appears stringy instead of a solid flame 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 fire 19 4 TURN OFF BURNER and remove pressure gauge Install gauge port plug and tighten Start burner again M FLAME FAILURE The HF boiler controls operate the burner automati cally If for unknown reasons the burner ceases to fire and the rest button on the primary control has tripped the burner has experienced ignition failure Before pressing the rest button call your serviceman immedi ately 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 IF NOZZLE CONTINUES TO DR
17. ause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance This boiler contains very hot water under high pressures Do not unscrew any pipe fittings 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 Do not operate 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 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 efficiency This
18. ces 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 6 C E 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 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 s inch per 1000 BTUH of the total input of all appliances in the space PROVIDECOMBUSTION 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 1 Determine volu
19. ich 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 flammable 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 sho
20. ity 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 recom mendation This is not only beneficial to the tankless 10 heater but to piping and fixtures plus the many other benefits derived from soft water G INSTALL SMOKEPIPE The HF should be vented into a fireclay 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 and vent pipe shall have a sufficient draft at all times to assure safe proper operation of the boiler See Figure 6 for recommended installation 1 Install a draft regulator following the instructions furnished with the regulator See Figure 7 for alternate draft regulator locations 2 Consider the chimney overall Chimneys that have a high heat loss may become less suitable as the heat loss of the home goes down and the efficiency of the boiler installed 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 fired or an
21. l 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 fire hazard AIR LEAKS Any such leaks should be repaired as they may cause erratic burning of the fuel and in extreme cases may become a fire hazard There may be many possible causes of leaks in oil lines such as i Fitting leaks due to misflared tubing or damaged fitting ii Fuel line leak due to crushed or bent tubing iii Filter connection leaks iv Tank connection leaks The following actions can eliminate air leaks i Bleed pump as detailed in System Start Up Section of this manual i Replace flare fittings ii Replace oil supply line iv Repairoilfilterleaks v Replace or repair tank fittings GASKET LEAKS If 11 5 to 12 5 CO with a 1 smoke cannot be obtained in stack look for air leaks around the canopy seal Such air leaks will cause a lower CO reading in the stack The smaller the firing rate the greater effect an air leak can have on CO readings DIRT A fuel filter 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 WATER Water in the fuel in large amounts will stall the fuel pump Water in the fuel pump in smaller amounts will ca
22. me 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 ft 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 ft 1000 BTU per hour then it is considered an unconfined space If the result is less than 50 ft 1000 BTU per hour then the space is considered a confined space For boiler located in an unconfined space of a conventionally constructed building the fresh air infiltration through cracks around windows and doors normally provides adequate air for combus tion and ventilation For boiler located in a confined space or an uncon fined space in a building of unusually tight con struction 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 a
23. piping must be connected to correct boiler pipe Burnham recommends sizing the system circulator to supply sufficient flow 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 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 3 Also consult I B R Installation and Piping Guides 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 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 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 illus
24. quate sizing produced only 035 W C after 30 minutes of continuous firing at 13 0 CO Outside wall chimneys take longer to heat up and can have 00 W C draft at burner startup You may have to consider a special alloy chimney flue liner with insulation around it and a stabilizing draft cap or even a draft inducing fan in severe cases 3 For the same reasons as in 2 above heat extractors mounted into the breeching are not recommended Figure 6 Recommended Smokepipe Arrangement and Chimney Requirements Figure 7 Proper and Improper Locations of Draft Regulator 11 FROM ALLIANCE WATER HEATER A sg EXPANSION ANK Figure 8 Recommended Boiler Piping for Circulator Zoned Heating Systems ZONES ZONE 2 I ALLIANCE WATER HEATER AIR VENT OFF AIR SCOOP IS USED Sane OPTIONAL 30 R 4 SRR r SCOOP we CHECK VALVE ADDITIONAL REDUCING VALV IF REQUIRED SYSTEM 2 COLD DRAIN COCK X RETURN VALV PIPE WITHIN 6 OF FLOOR Figure 9 Boiler Piping for Zone Valve Zoned Heating Systems 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 ma
25. rea of 1 square inch per 4 000 BTU per hour input of all equipment in space b Vertical ducts Minimum free area of 1 square inch per 4 000 BTU per hour input of all equip ment 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 equip ment 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 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 fixed in the open position or interlocked with the equipment to open automatically during equipment operation
26. served temperature Burner should stop c Adjust limit to setting above observed tempera ture Burner should start d Adjust thermostat to lowest setting Adjust limit to desired setting 4 CHECK LOW WATER CUTOFF ifso equipped a Adjust thermostat to highest setting b With boiler operating open drain valve and slowly drain boiler 22 c Burner should stop when water level drops below low water cutoff probe Verify limit thermostat or other controls have not shut off boiler d Adjust thermostat to lowest setting Refill boiler Q FREQUENT WATER ADDITION A leaky system will increase the volume of make up water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up water are dissolved minerals and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas Both can result in reduced boiler life The accumulation of sediment can eventually isolate the water from contacting the steel When this happens the steel in that area gets extremely hot and eventually cracks The presence of free oxygen in the boiler creates a corrosive atmosphere which if the concentration becomes high enough can corrode the steel through from the inside Since neither of these failure types are the result of a manufacturing defect the warranty does not apply Clearly it is in everyone s best interest to prevent this type of
27. ted through the nozzle Water in the fuel or poor flame shape can also cause shut down noises P TESTCONTROLS 1 CHECK THERMOSTAT OPERATION Raise and lower thermostat setting as required to start and stop burner 2 VERIFY PRIMARY CONTROL SAFETY FEA TURES using procedures outlined in Instructions furnished with control See back of Control Cover or Instructions as follows a Simulate flame failure Follow the starting procedure to turn on the burner e Close the hand valve in the oil supply line e Safety switch should lock out in approxi mately 15 seconds Ignition should stop and oil valve should close Blower will stop after postpurge period e Push red reset button to reset safety switch b Simulate ignition failure Follow the starting procedure to turn on the burner but do not open the oil supply hand valve e Safety switch should lock out in approxi mately 15 seconds Ignition and motor should stop and oil valve should close Push red reset button to reset safety switch c 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 e Restore power Burner should start 3 VERIFYHIGHLIMIT OPERATION a Adjust thermostat to highest setting b Observe temperature gauge When temperature is indicated adjust limit to setting below ob
28. tion 121350 Combustion Chamber Floor Insulation 121325 Jacket Top Left Side Panel 604370361 121400 121400 70437047 D15800 1 1 121375 1 70437041 604370451 Jacket Top Right Side Panel 704370371 1 Burner Spacer Plate 70237001 NOT SHOWN Jacket Upper Front 70437034 704370461 wo 0 4 2 4 704370432 25 9 NOZZLE 7 ADAPTER A S A t i ELECTRODE fo 4 Se Ns ma CLAMP SCREW ITD SPIDER spacer STATIC PLATE L ED NUT ASSEMBLY NOZZLE DETAIL CADJUSTING PLATE ASSEMBLY FOR VARIABLE HEADS NOT DEPICTED Figure 16 Beckett AFG Oil Burner Repair Part For replacement oil burner parts contact your wholesaler or the burner manufacturer R W Beckett Co P O Box 1289 Elyria OH 44036 216 327 1060 or 800 OIL BURN 645 2876 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 HF 96 HF 122 HF 147 HF 173 Burner Model AFG AFG AFG AFG Air Tube Combination AFG50MB AFG50MBI AFG70MDI AFG70MDI Spec No NY1101 NY1101 NY1108 NY1108 Air Band 3492BKA 3492BKA 349
29. trated in Figure 4 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 tempera ture 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 3 Connect System supply and return piping to boiler See Figures 8 and 9 Also consult I B R Installa tion and Piping Guides Maintain minimum inch A water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation a T tk A AND BY SHUT OFF VALVES ARE CLOSED IN WINTER AND OPEN IN SUMMER C AND D SHUT OFF VALVES ARE OPT WATER CHILLER l HEATING j q lt TH BOILER H lt TH KH D B AIR CUSHION CIRCULATOR ANK Figure 3 Recommended Piping for Combination Heating and Cooling Refrigeration System THEFOLLOWING GUIDELINES SHOULD BEFOLLOWED WHEN PIPING THETANKLESS HEATER 1 FLOW REGULATION If flow 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
30. uld 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 flooring unless installed with a combustible floor shield available at extra cost Do not install boiler on carpeting 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 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 c
31. use excessive wear on the pump but more importantly water does not burn It chills the flame causes smoke and allows unburned fuel to pass through the combustion chamber and clog the flueways of the boiler COLD OIL If the oil temperature approaching the fuel pump is 40 F or lower poor combustion or delayed ignition may result Cold oil is harder to atomize at the nozzle Thus the spray droplets get larger and the flame shape gets longer An outside fuel tank that is above grade or has fuel lines 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 i 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 CO j START UP NOISE Late ignition is the cause of start up noises If it occurs recheck for electrode settings flame shape air or water in the fuel lines k SHUT DOWN NOISE If the flame runs out of air before it runs out of fuel an after burn with noise may occur That may be the result of a faulty cut off valve in the fuel pump or it may be air trapped in the nozzle line It may take several firing cycles for that air to be fully ven
32. ved without disconnecting the oil supply A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is recommended for the lowest firing rate application to prevent nozzle fouling K 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 The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet See Figure 12 3 Use Flared fittings only Do not use compression fittings NOTICE Oil piping must be absolutely airtight or 4 Use of a high efficiency micron filter Garber or equivalent in addition to conventional filter is leaks or loss of prime may result Bleed line highly recommended and fuel unit completely 26 AIK 2 7 VENT z 1 MIN FIL AE S Figure 12 Single Pipe Installation 16 TABLE 2 SINGLE STAGE UNITS 3450 RPM TWO PIPE SYSTEMS Maximum Length of Tubing Lift H H R See Figure TABLE 3 TWO STAGE UNITS 3450 RPM TWO PIPE SYSTEMS Maximum Length of Tubing Lift kis tH R See Figure See Figure lt See Figure 3 8 OD 1 2 OD Tubing 3 GPH Tubing 3 GPH o f e f o 1 78 100 100 100 100 100 100 100 100 100 100 3 8 OD 1 2 OD ao N i ND
33. y 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 System Controls and Wiring 1 Refer to National Electric Code or Local Electric Codes for proper size and type of wire required Follow Code H Electrical 1 Install wiring and electrically ground boiler in Single Zone System Connect the system circula accordance with reguirements of the authority tor wire leads to the proper locations on the having jurisdiction or in absence of such reguire Aquastat control L8124C L8148A See Figure 10 or ments the National Electrical Code ANSI NFPA 11 Connect the thermostat to the T T terminals on 70 and or the CSA C22 1 Electric Code the L8124C L8148A control Set thermostat heat 2 A separate electrical circuit should be run from the HANOI a oa anes main electrical service with a fused disconnect Conventional Circulator Zoned System Read switch in the circuit understand and follow all of the instructions 3 Wiring should conform to Figure 10 and or 11 Pee ae
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