IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR R S A™ S E R I E S OI L - F I R E D BOI L E R F o r s e rvi c e o r r e p a i rs to b o i le r, c a ll yo ur he a ti ng c o ntra c to r. W he n s e e k i ng i nfo rma ti o n o n b o i le r, p ro vi d e B o i le r M o d e l Numb e r a nd S e ri a l Numb e r a s s ho wn o n Ra ti ng L a b e l.
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.
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.
WARNING This boiler contains very hot water under high pressure. 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.
Table of Contents I. Pre-Installation........................................7 VI. Oil Piping.............................................. 28 II. Knockdown Boiler Assembly.................9 VII. System Start-Up....................................30 III. Water Piping and Trim..........................12 VIII. Service and Cleaning............................38 IV. Venting..................................................18 IX. Repair Parts...........................................40 V.
Figure 1A: RSA Packaged Boiler (RSA170 / RSA285) Boiler Model Number Bare Boiler Assembly RSA170 WV-29-10 RSA195 WV-29-13A RSA240 WV-29-16A RSA285 WV-29-19A Minimum Recommended Chimney Sizes In. x In. x Ft. (height) 8 x 8 x 20 In. (dia.) x Ft. (height) Water Capacity (gallons) Approx. Shipping Weight (lb.) 7 x 20 42.6 600 39.9 630 37.3 660 34.
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.
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 flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored. 1. Determine volume of space (boiler room).
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. 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 Figure 3: Base on Skid B.
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 fit 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 floor before attaching. 4. Attach top panel with provided screws. D.
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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.
and return line as illustrated in Figures 8 and 9 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.
Figure 8: Recommended Water Piping for Circulator Zoned Heating Systems
Figure 9: Recommended Water Piping for Zone Valve Zoned Heating Systems
F. CONNECT TANKLESS HEATER PIPING AS SHOWN IN FIGURE 10. See Table 1 for Tankless Heater Rating. WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. 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.
Figure 10: Schematic Tankless Heater Piping Table 1: Tankless Heater Ratings Boiler Model S350 S375 GPM PSID GPM PSID 3½ 15 3¾ 25 RSA85 & 110 3 12 RSA110, 125 & 135 3¼ 16 RSA125 & 135 3½ 19 Boiler Model STD. #7524 OPT.
IV. Venting A. General Guidelines. 1. Vent system installation must be in accordance with these instructions and applicable provisions of local building codes. Contact local building or fire officials about restrictions and installation inspection in your area. 2. The RSA Series is designed to 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.
Figure 11: Recommended Smoke Pipe Arrangement and Chimney Requirements Figure 12: Draft Regulator Locations 19
V. Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.
Figure 13: “RSAL” Wiring Less Tankless, Single Circulator Sequence of Operation A call for heat by the thermostat energizes the L7224C/L7248C control which in turn energizes the Honeywell R4184D primary control to turn on the burner. If burner ignites within approximately 45 seconds and the cad cell sees flame, the burner will continue to operate until the call for heat is satisfied or the setting of the high limit is reached. The circulator will operate as long as the thermostat is calling for heat.
Figure 15: Circulator Zoned Wiring for Honeywell R8888
Figure 16: Zone Valve Zoned Wiring for R8889
NOTICE The Honeywell R8889 Control is available in two three (3) zone models and two four (4) zone models. Burnham recommends using Model R8889A for three (3) zone systems and Model R8889B for four (4) zone systems. Models R8889C and R8889D have less load capacity and may not operate with certain types of zone valves. Up to four (4) R8889’s may be used together to provide up to sixteen (16) individual zones.
NOTICE The Burnham EC5000 Control includes a water temperature sensor. Mount this sensor to the system supply piping. 8. Burnham EC5000 Circulator Zoned System – Refer to Figure 18 of this manual for the electrical diagram for this type of system. Wire the system as indicated in that diagram. Refer to the manual provided with the Burnham EC5000 Control for control operation and setup details. 9.
Figure 18: Circulator Zoning with EC5000 Wiring Schematic
Figure 19: Zone Valve Zoned with EC5000 Wiring Schematic
VI. Oil Piping A. General. B. Single-pipe Oil Lines. 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. 1. Standard burners are provided with single-stage 3450 rpm fuel units with the bypass plug removed for single-pipe installations. 2.
Table 3: Two-Stage Units (3450 RPM) Two Pipe Systems Table 2: Single-Stage Units (3450 RPM) Two Pipe Systems Lift "H" (See Figure 21) Maximum Length of Tubing "H" + "R" (See Figure 21) Lift "H" (See Figure 21) Maximum Length of Tubing "H" + "R" (See Figure 21) 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 93' 100' 3/8" OD Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 0' 84' 100' 1' 78' 100' 2' 85' 100' 2' 73' 100' 4' 77' 100' 3' 68' 100' 6' 69' 100' 4' 63' 100' 8' 60' 100' 5' 5
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. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. C. Fill entire heating system with water and vent air from system.
Figure 22: L7248/L7224 Circuit Board Layout Horizontal Mount Then, press the UP and/or DOWN buttons to move the set point to the desired value. After 60 seconds without any button inputs, the control will automatically return to the RUN mode. 7. OPERATION The L7224 model can be in any of four operational states - Normal, High Limit, Low Limit and Error. The controller moves back and forth from High Limit to Normal to Low Limit state as part of normal operation.
9. Table 5: L7224 / L7248 Controller Operating Sequence Action System Response Thermostat calls for heat. Circulator starts when water temperature is above Low Limit setting (if applicable). Boiler temperature is checked. Burner starts when water temperature is below High Limit setting. Boiler exceeds the High Limit. Burner is turned off. Burner restarts when the water temperature drops below the High Limit setting minus the Differential. Thermostat is satisfied. Circulator and burner turn off.
Table 7: Beckett AFG, AF, & SF Burners Boiler Model Firing Rate (GPH) Hago Nozzle Air Settings Shutter RSA85* .85 .75 x 80B 10 RSA110 1.10 .90 x 80B 8 RSA125 1.25 1.0 x 80B 7 RSA135 1.35 1.10 x 80B 9 RSA170 1.70 1.65 x 80A 7 RSA195 1.95 2.00 x 80B 7 RSA240 2.40 2.50 x 80B 7 RSA285 2.85 3.
H. REMOVE GUN ASSEMBLY 1. Check nozzle size, head size, gun setting, and positioning of electrodes. This information is shown in Figure 25 and Tables 7 and 7A for Beckett burner, Figure 25A and Table 7B for Carlin EZ-1HP burner. 2. Reinstall gun assembly. I. VERIFY OIL BURNER SETTINGS BEFORE STARTING 1. BURNER AIR BAND AND AIR SHUTTER SETTINGS, see Tables 7 and 7A for Beckett burner, Table 7B for Carlin EZ-1HP burner. 2. OPEN ALL OIL LINE VALVES. 3.
nozzle will compress when burner is on and will expand when burner stops, causing oil to squirt from nozzle at low pressure as burner slows down and causing nozzle to drip after burner stops. Usually cycling the burner operation about 5 to 10 times will rid oil line of this air. 2. IF NOZZLE CONTINUES TO DRIP, repeat step N.1. If this does not stop the dripping, remove cut off valve and seat, and wipe both with a clean cloth until clean. Then replace and readjust oil pressure.
trapped in the nozzle line. It may take several firing cycles for that air to be fully vented through the nozzle. Water in the fuel or poor flame shape can also cause shut down noises. P. TEST CONTROLS WARNING Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and high limit control. 1. CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and stop burner. 2.
INSTALLATION 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: RSA85 RSA110 RSA125 RSA135 ADDS 4-3/16” TO BOILER HEIGHT Use Part Number 6183505 for the following models: RSA170 RSA195 RSA240 ADDS 5-3/8” TO BOILER HEIGHT RSA285 3) Fasten shield to combustible floor to keep shield from shifting position during setting of boiler.
VIII. Service and Cleaning 1. CLEAN THE FIRETUBES NOTICE BURNER SHUTDOWN: Open Service Switch to turn off burner. Manual Oil Supply Valve should be closed and Electric Service to boiler turned off if boiler will not be operated for an extended period of time. A. General. Inspection service and cleaning should be conducted annually. Turn off electric power and close oil supply valve while conducting service or maintenance. B. Firetubes and Combustion Chamber. (See Figure 27) a.
Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
IX. Repair Parts All RSA™ Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408. For Carlin oil burner replacement parts, contact your wholesaler or Carlin: CCT, Carlin Combustion Technology, Inc.
ITEM DESCRIPTION PART NUMBER 1 Jacket Rear Top Panel 604350864 2 Jacket Front Top Panel 604350863 Jacket Wrap-A-Round Panel, RSA85/110 60435087 Jacket Wrap-A-Round Panel, RSA125/135 60435088 Temperature / Pressure Gauge 100282-03 Honeywell L7248C1014 Hi-Limit Control 100059-01 Honeywell L7224C1004 Limit Control 100862-01 3 4 5 6 7 Observation Port Cover 7026001 Observation Cover Sprint V1 8026015 Flat Washer, SAE, 5/16” 80860647 Hex Nut, 5/16” -18, Heavy 80860402 Burner Primary
NOTE: When ordering parts always give the serial number and model number shown on the boiler.
ITEM QTY. DESCRIPTION PART NUMBER 1 2 Wing Nut, 1/4 -20 80860910 2 10 Washer, Flat 1/4 (SAE) 80860633 3 1 Canopy Assembly 6113509 4 2 1/2” Thick x 1” x 12-3/8” Cerafelt Strip 9206005 5 2 1/2” Thick x 1” x 12-3/8” Cerafelt Strip 9206005 6 2 Carriage Bolt, 1/4 -20 x 3” Lg.
NOTE: When ordering parts always give the serial number and model number shown on the boiler.
ITEM DESCRIPTION PART NUMBER 1 Jacket Top Panel Assembly 2 Canopy Assembly 6113510 3 1/2” Thick x 1” x 23” Cerafelt Strip 9206005 4 1/2” Thick x 1” x 17” Cerafelt Strip 9206005 5 Turbulator, See ‘A’ for Quantity 6113504 6 Tankless Heater Gasket 8036025 #7524 Tankless Heater Assembly (Includes Item 6) 6033507 #7530 Tankless Heater Assembly (Includes Item 6) 6033508 8 Blank Heater Cover Plate 7033501 9 Heat Exchanger Assembly ‘B’ 10 1/2” Thick x 2” x 25” Cerafelt Strip 9206003
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.
Ordering Information for Quality Replacement Parts Figure 31: BECKETT AFG MODEL BURNER 47
BECKETT BURNER PARTS LIST FOR RSA SERIES STEEL BOILERS FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER MANUFACTURER: Boiler Model RSA170 RSA195 RSA240/285 Burner Model AF AF SF Air Tube Combination AF60XO AF60XP SF60FY Spec. No.
Figure 32: BECKETT AF and SF MODEL BURNERS 49
X. Low Water Cut Off (LWCO) WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same floor level as the boiler).
SERVICE RECORD DATE SERVICE PERFORMED 51
Limited Warranty For Residential Grade Water and Steam Boilers Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied parts and/or accessories manufactured and shipped on or after July 1, 2008: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY U.S.
