Burnham BOILERS manual

1 Price - $3.00 INST ALLA TION, OPERA TING AND SER VICE INSTRUCTIONS FOR RSA BOILERS[...]

2 The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DA NG ER Indicates an imm in ently h a zard o us si tuation w hi ch , if n o t a v o id e d , w il l r e su lt in d e a th , se ri ous i nj u ry or subs tant i al propert y [...]

3 DA NG ER DO N OT sto r e or use g aso li ne o r o ther fl am m able vapo r s o r l iq u ids in the v ic inity o f th is or any othe r app li anc e. WA R N I N G Imp ro p er install ati o n , adjustm en t, al teration , servic e o r m ainte n a nce can cause p r op er ty damage , persona l i nj ury or los s of li fe . Fai lur e t o fol l ow al l i[...]

4 WA R N I N G A ppli an ce mate r i al s o f c onstr uct i o n, pro duct s of co m bust i on and t h e f uel conta i n al u m i na, si l i ca , he av y me ta l s, ca rb on m on oxi de, ni t rog e n oxides , a l de h yd es a nd/ or ot h er tox ic or harm ful sub stan ces wh ich can cause d eat h o r seriou s inju ry and which ar e kn o wn to th e s[...]

5 T ables 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 Figure 1: RSA Packaged Boiler (RSA85 / RSA135) VI. Oil Piping[...]

6 Figure 1A: RSA Packaged Boiler (RSA170 / RSA285) Bo il e r Mo d e l Nu m b e r B a r e B o ile r A sse m b l y Mi n i mu m C h i m n e y S i z e s Wa te r Capac i t y G a llo n s Ap p ro x. Sh ip p i ng We ig h t In . x In . x F t. (h ei gh t) In . ( d i a. ) x F t. (h ei gh t) RS A 1 70 WV -29- 10 8 x 8 x 20 7" x 2 0' 4 2. 6 6 00 l b. [...]

7 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 varianc[...]

8 C . PROVIDE AIR SUPPLY AND VENTILATION to accommodate proper combustion. If natural ventila- tion 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 consum- ing appliances are near the boiler, the[...]

9 II. Knock-Down Boiler Assembly 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 exten- sion. Refer to Figure 4. A . REMOVAL OF[...]

10 Figure 5: Burner Mounting[...]

11 Figure 6: RSA Jacket Assembly[...]

12 III. W ater Piping and T rim 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 contami- nation such as: a . Addition of excessive make-up water as a result of system leaks. b. Absorption through open tanks and fittings. c.[...]

13 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. E . After th[...]

14 Figure 8: Recommended Boiler Piping for Circulator Zoned Heating Systems[...]

15 Figure 9: Boiler Piping for Zone Valve Zoned Heating Systems[...]

16 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 possibil- ity 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 seeki[...]

17 Figure 11: Schematic Tankless Heater Piping Table 1: Tankless Heater Ratings B oil e r Model S T D. #7524 OP T . #753 0 G PM PS I D G PM PS I D R SA 1 70 3 ¾ 25 ½ 4 26 ½ R SA 1 9 5, 2 4 0, & 2 85 4 29 4 ¼ 31 B oil er M odel S 350 S375 G PM P SID GPM P SID R S A( H ) 85 & 1 1 0 3 1 2 3½ 1 5 R SA1 1 0 ( H ) 1 25 & 1 3 5 3 ¼ 1 6 3[...]

18 IV . V enting 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 fire officials about restrictions and installation inspec- tion in your area. 2. The RSA Series is designed to be vented into a fireclay tile-lined masonry ch[...]

19 Figure 12: Recommended Smokepipe Arrangement and Chimney Requirements Figure 13: Draft Regulator Locations[...]

20 A . General 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such require- ments the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electric Code. 2. A separate electrical circuit should be run from the main electrical service with a fused discon[...]

21 Figure 14: “RSAL” Wiring Less Tankless, Single Circulator Figure 15: “RSAT” or “RSAR” Wiring with Tankless, Single Circulator[...]

22 Figure 16: Circulator Zoned Wiring for Honeywell R8888[...]

23 Figure 17: Zone Valve Zoned Wiring for R8889[...]

24 Figure 18: Different Manufacturer’s Zone Valve Connections to Honeywell R8889[...]

25 NO T IC E The B urnham EC5 0 00 C ontrol i ncl udes a w a te r t emperat u re se nsor . Mount t hi s s ens or t o t he sy s t e m s upp l y pi pi ng. 8. Burnham EC5000 Circulator 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[...]

26 Figure 19: Circulator Zoning with EC5000 Wiring Schematic[...]

27 Figure 20: Zone Valve Zoned with EC5000 Wiring Schematic[...]

28 A . General. 1. Use flexible oil line(s) so that burner can be removed without disconnecting the oil supply. 2. 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. 3. Use Flared fittings only. Do not use[...]

29 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 22. Figure 22: Two-Pipe Installation T AB L E 2: S INGLE S T A G[...]

30 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 . 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 wa[...]

31 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 [...]

32 instrumentation to obtain a CO 2 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 [...]

33 extreme case may become a fire hazard. d. 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 [...]

34 a. Simulate flame failure: • Follow the starting procedure to turn on the burner. • Close the hand valve in the oil supply line. • Safety switch should lock out in approxi- mately 15 seconds. Ignition should stop and oil valve should close. Blower will stop after postpurge period. • Push red reset button to reset safety switch. b. Simula[...]

35 INST ALLA TION INSTRUCTIONS FOR SHIELD REQUIRED FOR COMBUSTIBLE FLOOR This shield for combustible floors is intended for use only with the following Burnham oil-fired boilers: Use Part Number 6183504 for the following models: RSA(H)85 RSA(H)110 RSA(H)125 RSA(H)135 ADDS 4-3/16” TO BOILER HEIGHT Use Part Number 6183505 for the following models: [...]

36 VIII. Service and Cleaning 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. (See Figure 25) NO T IC E B U RN E R SH UT DO W N: O pe n Se r v i c e S witc h t o tu rn o ff b u r n er . Man u[...]

37 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 your Burnham Regional Sales Office as listed below . Bur nha m C or[...]

38 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 26: RSA85-135 Bare Boiler Repair Parts REPAIR PARTS[...]

39 BO I LE R M O D EL 'A ' 'B ' R S A 85 12 6033501 12 R S A 1 10 16 6033501 16 R S A 125 12 603350212 R S A 135 16 603350216 IT E M N O. QT Y . DE SC RIP T IO N P A RT N O. 1 2 W ing N ut, 1/4 - 20 80860910 2 10 Wa s her , Flat 1/4 (SAE ) 80860633 3 1 C anopy A s sembl y 61 13509 4 2 1/2" Thic k x 1 " x 12-3/8" C[...]

40 Figure 27: RSA170-285 Boiler 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:[...]

41 B oi ler Model 'A ' 'B' R S A 170 10 6306332 R S A 195 13 6306329 R S A 240 16 6306309 R S A 285 19 6306310 I TEM N O . D ESC R I PTION P AR T N O. 1 J ac k e t T op P a n el A s se m bl y 60435022 2 C an o py A s se m bl y 61 13510 3 ½" T h ic k x 1" x 2 3" C er af el t S tr ip 9206005 4 ½" T h ic k x 1[...]

42 I TE M D ESCR I PT I O N P ART NUM BER 1 Jac ket T op P anel 604 3508 6 2 Jac ket W rap -A- Roun d P anel , R SA 85/ 1 1 0 604 3508 7 J ack et W ra p-A -Ro und P a nel , RS A125/ 13 5 604 3508 8 3 T em per atu re / P r es sur e G aug e 80 5616 9U 4 Ho neywe l l L8 148A 10 90 Hi -Li m i t Co nt rol 801 6044 9U Hon eywel l L812 4C1 1 02 Li mit Co [...]

43 SER VICE SCHEDULE DA TE SER VICE PERFORMED[...]

44 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 EL YRIA, OHIO 44036 1-800-645-2876 NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also, provi[...]

45 Ordering Information for Quality Replacement Parts Figure 29: BECKETT AFG MODEL BURNER[...]

46 BECKETT BURNER PARTS LIST FOR RSA SERIES STEEL BOILERS FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER MANU- FACTURER: R. W . BECKETT CORP . 38251 CENTER RIDGE RD. P . O. BOX 1289 EL YRIA, OHIO 44036 1-800-645-2876 B oil er M odel R S A 170 RSA19 5 RSA2 40/285 Bu rn e r M od el A F A F A F A i r T ube C ombi nati on A F 6[...]

47 Ordering Information for Quality Replacement Parts Figure 30: BECKETT AF and SF MODEL BURNERS[...]

48[...]