Burnham RSA User Manual

INSTALLATION, OPERATING AND  
SERVICE INSTRUCTIONS FOR  
RSA™ SERIES  
OIL - FIRED BOILER  
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  
RSA  
Heating Contractor  
Phone Number  
Address  
Price - $3.00  
8ꢀ43508R2ꢀ-ꢀ/ꢀ0  
DANGER  
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other  
appliance.  
WARNING  
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,personal  
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or  
death. Read and understand all instructions, including all those contained in component manufacturers  
manuals which are provided with the appliance before installing, starting-up, operating, maintaining or  
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance  
for reference by owner and service technician.  
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained  
in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled  
and knowledgeable installer or service agency. All heating systems should be designed by competent  
contractors and only persons knowledgeable in the layout and installation of hydronic heating systems  
should attempt installation of any boiler. It is the responsibility of the installing contractor to see that all  
controls are correctly installed and are operating properly when the installation is completed. Installation  
is not complete unless a pressure relief valve is installed into the tapping located on top of appliance  
- See Section III of this manual for details.  
This boiler is not suitable for installation on combustible flooring, unless installed with a combustible  
floor shield (available at extra cost).  
Do not install boiler on carpeting.  
When boiler is installed on concrete which is over a material that is subject to melting (PVC, PEX radiant  
tubing, etc.) the combustible floor shield must be used.  
A concrete pad is not sufficient to protect combustible flooring.  
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to  
assure that the unit is properly adjusted and maintained.  
Have Firetubes cleaned at least once a year - preferably at the start of the heating season to remove soot  
and scale. The inside of combustion chamber should also be cleaned and inspected at the same time.  
Have Oil Burner and Controls checked at least once a year or as may be necessitated.  
Do not operate unit with jumpered or absent controls or safety devices.  
Do not operate unit if any control, switch, component, or device has been subject to water.  
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy  
metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which  
can cause death or serious injury and which are known to the state of California to cause cancer, birth  
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when  
servicing or working nearby the boiler.  
This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil  
containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.  
wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All 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.  
3
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. This boiler contains components which become very hot when  
the boiler is operating. Do not touch any components unless they are cool.  
This appliance must be properly vented and connected to an approved vent system in good condition.  
Serious property damage could result if the boiler is connected to an approved vent system.  
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate  
combustion and ventilation air.  
The interior of the venting and air intake systems must be inspected and cleaned before the start of the  
heating season and should be inspected periodically throughout the heating season for any obstructions.  
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could  
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency.  
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without  
service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in  
cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent  
damage if the boiler is inoperative.  
Donotoperateboileroncombustibleoorwithoutafactorysuppliedoorshield. Concreteoverwoodjoists  
is considered combustible flooring. Do not operate on masonry floors, which may contain moisture.  
4
Table of Contents  
I.  
Pre-Installation.......................................7  
VI. Oil Piping .............................................  
28  
VII. System Start-Up ...................................30  
VIII. Service and Cleaning  
II. Knockdown Boiler Assembly ................9  
III. Water Piping and Trim .........................12  
IV. Venting .................................................18  
V. Electrical and Sequence of Operation..20  
............................38  
IX. Repair Parts..........................................  
40  
X. Appendix  
Low Water Cut Off...............................50  
Minimum Recommended Chimney Sizes  
Water  
Capacity  
(gallons)  
Approx.  
Shipping  
Weight (lb.)  
Boiler Model Number  
Dim. ‘A’  
In. x In. x Ft. (ht.)  
In. (dia.) x Ft. (ht.)  
RSA85  
RSA110  
RSA125  
RSA135  
9.1  
8.5  
34¾  
41¼  
300  
6 x 15  
7 x 15  
8 x 8 x 20  
13.9  
13.0  
340  
355  
Figure 1: RSA Packaged Boiler (RSA85 / RSA135)  
5
Figure 1A: RSA Packaged Boiler (RSA170 / RSA285)  
Minimum Recommended Chimney Sizes  
Boiler  
Model  
Number  
Water  
Capacity  
(gallons)  
Approx.  
Shipping  
Weight (lb.)  
Bare Boiler  
Assembly  
In. x In. x Ft. (height)  
8 x 8 x 20  
In. (dia.) x Ft. (height)  
7 x 20  
RSA170  
RSA195  
RSA240  
RSA285  
WV-29-10  
WV-29-13A  
WV-29-16A  
WV-29-19A  
42.6  
39.9  
37.3  
34.6  
600  
630  
660  
690  
8 x 20  
9 x 20  
8 x 12 x 20  
I. Pre-Installation  
install on carpeting. See Figure 26 for floor shield  
part number and installation instructions.  
A. INSPECT SHIPMENT carefully for any signs of  
damage.  
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.  
1. ALL EQUIPMENT is carefully manufactured,  
inspected and packed. Our responsibility ceases  
upon delivery of the crated boiler to the carrier in  
good condition.  
3. PROVIDE SERVICE CLEARANCE of at least 48”  
from the front of the jacket for servicing of burner  
and removal of tankless heater.  
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.  
For minimum clearances to combustible materials. See  
Figure 2.  
B. LOCATE BOILER in front of final position before  
WARNING  
removing crate.  
Do not support boiler by placing blocks at the  
four (4) corners of the boiler.  
Boiler base must be evenly supported under  
entire base.  
CAUTION  
Do not drop boiler. Do not bump boiler jacket  
against floor.  
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.  
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  
Figure 2: Minimum Clearances to Combustible Materials  
NOTE:  
1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.  
2. RSA™ boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances can not  
be reduced for alcove or closet installations.  
3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31  
standard.  
7
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:  
C. PROVIDE COMBUSTION AND VENTILATION  
AIR. Local code provisions may apply and should be  
referenced.  
WARNING  
a. Direct communication with outdoors.  
Minimum free area of 1 square inch per 4,000  
BTU per hour input of all equipment in space.  
Adequate combustion and ventilation air must  
be provided to assure proper combustion and  
to maintain safe ambient air temperatures.  
b. 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.  
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.  
c. Horizontal ducts. Minimum free area of 1  
square inch per 2,000 BTU per hour input of all  
equipment in space. Duct cross-sectional area  
shall be same as opening free area.  
1. Determine volume of space (boiler room). Rooms  
communicating directly with the space in which  
the appliances are installed, through openings not  
furnished with doors, are considered a part of the  
space.  
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.  
Volume(ft3) = Length(ft) x Width(ft) x Height(ft)  
2. Determine total input of all appliances in the space.  
Add inputs of all appliances in the space and round  
the result to the nearest 1000 BTU per hour.  
3. Determine type of space. Divide Volume by total  
input of all appliances in space. If the result is  
greater than or equal to 50 ft3/1000 BTU per hour,  
then it is considered an unconfined space. If the  
result is less than 50 ft3/1000 BTU per hour then the  
space is considered a confined space.  
6. Louvers and Grilles of Ventilation Ducts  
a. All outside openings should be screened and  
louvered. Screens used should not be smaller  
than 1/4 inch mesh. Louvers will prevent the  
entrance of rain and snow.  
4. 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  
combustion and ventilation.  
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.  
5. 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  
c. Louvers and grilles must be fixed in the open  
position, or interlocked with the equipment to  
open automatically during equipment operation.  
8
II. Knock-Down Boiler Assembly  
A. REMOVAL OF BOILER.  
WARNING  
1. Remove, all boiler to skid, hold down fasteners.  
Refer to Figure 3.  
Do not apply more than 30 psig to boiler.  
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  
Any combustion chamber which was damaged  
must be replaced immediately.  
CAUTION  
If heat exchanger is not square on base DO NOT  
twist. Carefully lift and reposition.  
WARNING  
Do not assemble boiler without cerafelt gaskets  
between heat exchanger and combustion  
chamber. Gaskets must also be between canopy  
and heat exchanger.  
Figure 3: Base on Skid  
B. TEST HEAT EXCHANGER FOR LEAKS before  
proceeding with jacket assembly. Heat exchanger,  
canopy, and base are preassembled.  
C. INSTALLING THE JACKET  
1. Before jacket can be secured to boiler assembly  
tankless heater coil or blank plate must be attached.  
Using rubber gasket and bolts provided secure  
heater coil or blank plate to boiler extension  
by inserting the bolts from the backside of the  
extension. Refer to Figure 4.  
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.  
Figure 4: Coil Plate Attachment  
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.  
D. INSTALLATION OF BOILER CONTROLS  
1. Install provided pressure/temperature gauge and  
immersion well into appropriate holes on tankless  
heater coil plate. Tighten so not to have any water  
leaks.  
2. Mount the aquastat control onto the immersion well.  
Wire the control according to Figure 13 or 14, in the  
Electrical and Sequence of Operation Section.  
3. 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.  
3. Mount burner on Base front panel and wire  
according to instructions provided with the burner.  
Refer to Figure 5.  
4. Attach top panel with provided screws.  
Figure 5: Burner Mounting  
ꢀ0  
THIS PAGE IS LEFT INTENTIONALLY BLANK  
11  
III. Water Piping and Trim  
WARNING  
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.  
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and  
can lead to boiler failure. Burnham’s Standard Warranty does not cover problems caused by oxygen  
contamination of boiler water or scale (lime) build-up caused by frequent addition of water.  
a. If this boiler is used in connection with  
refrigeration systems, the boiler must be installed  
so that the chilled medium is piped in parallel  
with the heating boiler using appropriate valves  
to prevent the chilled medium from entering  
the boiler. See Figure 7. Also, consult I=B=R  
Installation and Piping Guides.  
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  
distribution system.  
Figure 7: Recommended Piping for Combination  
Heating and Cooling (Refrigeration) System  
e. Isolating the boiler from the system water by  
installing a heat exchanger.  
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.  
WARNING  
System supply and return 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.  
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  
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.  
ꢀ2  
must be consistent with ANSI/ASME Boiler and  
Pressure Vessel Code, Section IV.  
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. 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.  
WARNING  
Safety (relief) valve discharge piping must be  
piped near floor to eliminate potential of severe  
burns. Do not pipe in any area where freezing  
could occur. Do not install any shut-off valves,  
plugs or caps.  
C. Install Drain Valve in return piping. See Figures 8 and  
9.  
D. Oil, grease, and other foreign materials which  
accumulate in new hot water and a new or reworked  
system should be boiled out, and then thoroughly  
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. A water boiler installed above radiation level  
must be provided with a low water cutoff device  
as part of the installation.  
If a low water cut-off is required, it must be  
mounted in the system piping above the boiler.  
The minimum safe water level of a hot water  
boiler is just above the highest water containing  
cavity of the boiler; that is, a hot water boiler  
must be full of water to operate safely.  
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.  
B. Install Safety Relief Valve. See Figures 8 and 9.  
Safety Relief Valve must be installed with spindle in  
the vertical position. Installation of the relief valve  
WARNING  
Installation is not complete unless a safety relief valve is installed as shown in Figure ꢀ or ꢀA.  
ꢀ3  
ꢀ4  
ꢀ5  
2. TEMPERING OF HOT WATER — Installation of  
an automatic mixing valve will lengthen the delivery  
of the available hot water by mixing some cold  
water with the hot. This prevents the possibility  
of scalding hot water at the 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 10.  
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:  
3. FLUSHING OF HEATER — All water contains  
some sediment which settles on the inside of the  
coil. Consequently, the heater should be periodically  
backwashed. This is accomplished by installing  
hose bibs as illustrated and allowing water at city  
pressure to run into hose bib A, through the heater,  
and out hose bib B until the discharge is clear. The  
tees in which the hose bibs are located should be  
the same size as heater connections to minimize  
pressure drop.  
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 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.  
4. HARD WATER — A water analysis is necessary to  
determine the hardness of your potable water. This  
is applicable to some city water and particularly to  
well water. An appropriate water softener should  
be installed based on the analysis and dealer’s  
recommendation. This is not only beneficial to the  
tankless heater but to piping and fixtures plus the  
many other benefits derived from soft water.  
ꢀꢁ  
Figure ꢀ0: Schematic Tankless Heater Piping  
Table ꢀ: Tankless Heater Ratings  
S350  
S375  
Boiler Model  
GPM  
3
PSID  
12  
GPM  
3½  
PSID  
15  
RSA85 & 110  
RSA110, 125 & 135  
RSA125 & 135  
3¼  
3½  
16  
3¾  
25  
19  
STD. #7524  
OPT. #7530  
Boiler Model  
GPM  
PSID  
25½  
29  
GPM  
PSID  
26½  
31  
RSA170  
3¾  
4
4
RSA195, 240 & 285  
4¼  
17  
IV. Venting  
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, 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  
adequate sizing produced only -.035” W.C. after  
30 minutes of continuous firing at 13.0% CO2.  
Outside wall chimneys take longer to heat up and  
can have .00” W.C. draft at burner start-up. You  
may have to consider a special alloy chimney  
flue liner with insulation around it and stabilizing  
draft cap or even a draft inducing fan in severe  
cases.  
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. The chimney or vent pipe  
shall have a sufficient draft at all times, to assure  
safe proper operation of the boiler. See Figure 11 for  
recommended installation.  
a. Install a draft regulator (supplied by installer)  
following the instructions furnished with the  
regulator. See Figure 12 for alternate regulator  
locations.  
b. With any new or replacement installation the  
chimney has to be considered. Chimneys that  
have a high heat loss become less suitable as  
the heat loss of the home goes down and the  
efficiency of the boiler 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 inefficient oil fired  
boiler built into a home without insulation or  
storm windows. With increasing fuel prices that  
home probably has been insulated 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  
c. For the same reasons as in (2.) above, heat  
extractors mounted into the breeching are not  
recommended.  
3. For minimum clearances to combustible materials  
refer to Figure 2.  
ꢀ8  
Figure 11: Recommended Smoke Pipe Arrangement and Chimney Requirements  
Figure 12: Draft Regulator Locations  
ꢀꢂ  
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.  
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.  
5. Single Zone System – Refer to Figure 13 or 14 of  
this manual for the electrical diagram for this type  
of system. Connect the system circulator wire leads  
to the proper locations on the Aquastat control,  
L7224C/L7248C.  
A. General  
1. Install wiring and electrically ground boiler in  
accordance with requirements of the authority  
having jurisdiction, or in absence of such  
requirements the National Electrical Code, ANSI/  
NFPA 70, and/or the CSA C22.1 Electric Code.  
Connect the thermostat to the ‘T-T’ terminals on  
the L7224C/L7248C control. Set thermostat heat  
anticipator settings to 0.60 amps.  
2. A separate electrical circuit must be run from  
the main electrical service with an over-current  
device/disconnect in the circuit. A service switch is  
recommended and may be required by some local  
jurisdictions.  
6. Conventional Circulator Zoned System – Refer to  
Figure 15 for the electrical diagram for this type of  
system.  
Read, understand and follow all of the instructions  
provided with the Honeywell R8888 control.  
3. Wiring should conform to Figure 13 and/or 14.  
7. Conventional Zone Valve Zoned System – Refer  
to Figure 16. Wiring to the most popular models of  
zone valves are given in Figure 17.  
B. System Controls and Wiring  
1. Refer to National Electric Code or Local Electric  
Codes for proper size and type of wire required.  
Follow Code.  
Locate C1 and C2 inside the L7224C Honeywell  
control. Connect the two (2) terminals to the system  
circulator wire leads, supplied with boiler.  
2. Use anti-short bushings on all wiring passing  
through boiler jacket, junction boxes and/or control  
boxes.  
Connect the H1 and H2 terminals inside the R8889  
to the ‘T-T’ terminals in the L7224C Honeywell  
Control. Refer to Figure 16.  
3. Use armored cable (BX) over all exposed line  
voltage wiring.  
Connect the thermostat of each zone and the  
circulator for that zone to R8889 panel. If an  
Alliance indirect water heater is used, connect the  
Alliance thermostat and circulator to the Zone 1  
terminals of the R8889. Set thermostat anticipator  
settings to 0.12 amps.  
4. If an Alliance indirect water heater is used, use  
priority zoning. Do not use priority zoning for  
Hydro-Air Systems.  
20  
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. If the thermo-  
stat is not satisfied and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high limit is closed by a  
drop in water temperature.  
Figure 14: “RSAT” or “RSAR” Wiring with 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. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low  
limit in the L8124C control. If boiler water temperature is below the low limit setting the burner will operate but the circulator will not, giving  
preference to the domestic hot water demand.  
On call for heat by the thermostat the burner will continue to operate until the thermostat is satisfied or the setting of the high limit is reached. If  
the thermostat is not satisfied when the high limit is reached the burner will stop but the circulator will continue to operate until the thermostat is  
satisfied. Any time the boiler water temperature drops below the setting of the low limit the burner will be energized in order to maintain domes-  
tic water temperature.  
2ꢀ  
22  
23  
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 R888ꢂC and R888ꢂD 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. Only one (1) zone,  
the first zone of the main control will provide priority zoning for the Alliance indirect water heater. If more  
than four (4) zones are required, connect additional R8889’s by wiring the A, B and C terminals of each control  
together. Each R8889 requires a 120 volt power supply. If more than one (1) R8889 is used, set the panel  
type switch to “main” on the first R8889 and set the panel type switch to “expansion” on the second, third or  
fourth R888ꢂ.  
Figure 17: Different Manufacturer’s Zone Valve Connections to Honeywell R8889  
24  
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. Burnham EC5000 Zone Valve 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  
provided with the Burnham EC5000 for control  
operation and setup details.  
25  
2ꢁ  
27  
VI. Oil Piping  
A. General.  
B. Single-pipe Oil Lines.  
1. Use flexible oil line(s) so that burner can be  
1. Standard burners are provided with single-stage  
3450 rpm fuel units with the bypass plug removed  
for single-pipe installations.  
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.  
2. The single-stage fuel unit may be installed single-  
pipe with gravity feed or lift. Maximum allowable  
lift is 8 feet. See Figure 20.  
3. Use Flared fittings only. Do not use compression  
fittings.  
NOTICE  
Oil piping must be absolutely airtight or leaks or  
loss of prime may result. Bleed line and fuel unit  
completely.  
4. Use of a high efficiency micron filter (Garber or  
equivalent) in addition to conventional filter is  
highly recommended.  
Figure 20: Single-Pipe Installation  
28  
Table 3: Two-Stage Units (3450 RPM) -  
Table 2: Single-Stage Units (3450 RPM) -  
Two Pipe Systems  
Two Pipe Systems  
Maximum Length of Tubing  
Maximum Length of Tubing  
"H" + "R" (See Figure 21)  
"H" + "R" (See Figure 21)  
Lift "H"  
Lift "H"  
(See Figure 21)  
(See Figure 21)  
3/8" OD Tubing 1/2" OD Tubing  
3/8" OD Tubing 1/2" OD Tubing  
(3 GPH)  
(3 GPH)  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
83'  
(3 GPH)  
(3 GPH)  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
100'  
76'  
0'  
1'  
84'  
0'  
2'  
93'  
78'  
85'  
2'  
73'  
4'  
77'  
3'  
68'  
6'  
69'  
4'  
63'  
8'  
60'  
5'  
57'  
10'  
12'  
14'  
16'  
18'  
52'  
6'  
52'  
44'  
7'  
47'  
36'  
8'  
42'  
27'  
9'  
36'  
---  
10'  
11'  
12'  
13'  
14'  
31'  
C. Two-Pipe Oil Lines  
26'  
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 21.  
21'  
---  
62'  
---  
41'  
Figure 2ꢀ: Two-Pipe Installation  
2ꢂ  
VII. System Start-Up  
D. CONFIRM that the boiler and system have no water  
A. Verify that the venting, water piping, oil piping, and  
electrical system are installed properly. Refer to  
installation instructions contained in this manual.  
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.  
B. Confirm all electrical, water and oil supplies are  
turned off at the source and that the vent is clear from  
obstructions.  
WARNING  
F. LUBRICATION. Follow instruction on burner and  
circulator label to lubricate, if oil lubricated. Most  
motors currently used on residential type burners  
employ permanently lubricated bearings and thus do  
not require any field lubrication. Water lubricated  
circulators do not need field lubrication.  
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. Use the following procedure on a Series Loop  
or multi-zoned system installed as per Figure 8 or 9.  
G. ADJUST CONTROL SETTINGS with burner service  
switch turned “ON”.  
1. Close isolation valve in boiler supply piping.  
1. SET ROOM THERMOSTAT about 10°F below  
room temperature.  
2. Isolate all circuits by closing zone valves or  
balancing valves.  
2. PRESS RED RESET BUTTON on R7184B Oil  
Primary Control and release.  
3. Attach a hose to hose bib located just below  
isolation valve in boiler supply piping. (Note  
- Terminate hose at a suitable floor drain or outdoor  
area).  
3. On BOILERS WITHOUT TANKLESS HEATERS  
equipped with L7248 electronic aquastat controller,  
set High Limit (HL) at 180°F. This temperature can  
be varied to suit installation requirements. L7248  
controller has the High Limit adjustment range  
from 180°F to 240°F (82°C to 116°C). High Limit  
Differential is fixed at 15°F (8°C).  
4. Starting with one circuit at a time, open zone valve  
or valve.  
5. Open hose bib.  
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).  
4. On BOILERS WITH TANKLESS HEATERS  
equipped with L7224 electronic aquastat controller,  
set operating control (low limit [LL]) at 190°F and  
high limit (HL) at 210°F. Operating control (low  
limit) setting must be a minimum of 20°F below  
high limit setting.  
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.  
L7224 controller has the High Limit adjustment  
range from 130°F to 240°F (55°C to 116°C), and  
the Low Limit adjustment range from 110°F to  
220°F (43°C to 104°C). High Limit Differential is  
fixed at 10°F (6°C), and Low Limit Differential has  
adjustment range from 10°F (6°C) to 25°F (14°C).  
WARNING  
The maximum operating pressure of this boiler is  
30 psig. Never exceed this pressure. Do not plug  
or change pressure relief valve.  
5. ADJUSTING AQUASTAT CONTROLLER  
SETTINGS. To discourage unauthorized changing  
of Aquastat settings, a procedure to enter the  
ADJUSTMENT mode is required. To enter the  
ADJUSTMENT mode, press the UP, DOWN, and  
I buttons (refer to Figure 22) simultaneously for  
three seconds. Press the I button until the feature  
requiring adjustment is displayed:  
9. Close hose bib, 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.  
• HL_ High Limit.  
• LL_ Low Limit.  
• Ldf Low Limit Differential.  
• °F °C.  
10. Open isolation valve in boiler supply piping.  
11. Remove hose from hose bib.  
30  
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.  
The L7248 model is restricted to three operational  
states - Normal, High Limit and Error. The  
controller moves back and forth from High Limit to  
Normal state as part of normal operation.  
For both models, the controller will enter the Error  
state when there is an abnormal condition. The  
operating states are:  
a. Normal: Boiler temperature went below the  
High Limit setting (minus the Differential) and  
has not exceeded the High Limit setting; or the  
boiler temperature went above the Low Limit  
setting and has not gone below the Low Limit  
setting (minus the Differential).  
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.  
b. High Limit: Boiler temperature went above the  
High Limit setting and has not dropped below  
the High Limit setting (minus the Differential).  
Note that L7224 Aquastat Controller will display all  
four (4) above-listed adjustment features, but L7248  
Aquastat Controller will not display Low Limit and  
Low Limit Differential adjustment features.  
c. Low Limit: Boiler temperature went below  
the Low Limit setting (minus the Low Limit  
Differential) and has not gone above the Low  
Limit setting.  
6. DISPLAY READOUT  
d. Error: The controller has detected an error  
condition (e.g., open sensor) and has shut down  
the burner output. The ZC output is energized.  
The controller continues to monitor the system  
and automatically restarts if the error condition  
clears. Refer to Table 4.  
In the RUN mode, the Aquastat will flash "bt"  
(boiler temp) followed by the temperature (i.e.,  
220), followed by °F or °C.  
To read boiler settings, press the I key to read the  
parameter of interest. For example, press I High  
Limit (HL) is displayed, followed by a three-digit  
number, i.e., 220, followed by °F or °C. Pressing  
the I button again (on L7224 models) will display  
the Low Limit (LL) followed by a three-digit  
number and the corresponding degree designator.  
See Display Readout, Figure 23.  
Table 4: LED Error Codes  
Error  
Cause / Action  
Code  
Err1  
Err2  
Err3  
Err4  
Err5  
Err6  
Sensor fault; check sensor.  
ECOM fault; check EnviraCOM™ wiring.  
Hardware fault; replace control.  
B1 fault; check B1 wiring/voltage.  
Low Line; check L1-L2, 110 Vac.  
Fuse; check ECOM wires, replace fuse.  
After approximately 60 seconds without any key  
presses, the display will enter a dim display mode.  
To return to the bright display mode, simply press  
any key.  
EEPROM, HL, LL, Hdf, Ldf; reset to default values.  
Restore desired settings.  
Err7  
Err8  
Repeated B1 fault (voltage present at B1 when out-  
put is turned off); check B1 wiring/voltage.  
The operating sequence for the L7224/L7248 is  
shown in Table 5. See Table 6 for Trouble Shooting  
Guide.  
8. HIGH LIMIT CONTROLLER  
The High Limit opens and turns off the burner  
when the water temperature reaches the setpoint.  
The High Limit automatically resets after the water  
temperature drops past the setpoint and through the  
Figure 23: Display Readout Definitions  
3ꢀ  
9. LOW LIMIT AND CIRCULATOR CONTROLLER  
Table 5: L7224 / L7248 Controller  
Operating Sequence  
On a temperature rise, with the adjustable  
Differential at the default setting of 10°F (6°C),  
the burner circuit breaks and the circulator circuit  
makes (assuming no call for heat is present) at the  
Low Limit setpoint. On a temperature drop of 10°F  
(6°C) below the Low Limit setpoint, the burner  
circuit makes and the circulator circuit breaks. See  
Figure 24.  
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  
Circulator and burner turn off.  
satisfied.  
Error condition  
1-5.  
If an error condition is detected, all outputs ex-  
cept ZC are shut down. Burner is off. Control  
continues to function and restarts when error is  
corrected.  
During the error check sequence, the system  
checks for drift in the sensor and corrosion in  
the connections.  
Error  
EnviraCOM communication is not available.  
condition 6.  
Error  
condition 7.  
The control has reset the High Limit, Low Limit  
and Differential setting to a default setting and  
will continue to run at those settings.  
Performance of the system will be degraded.  
Error  
condition 8.  
If the error condition is detected, all outputs  
except ZC are shut down. Burner is off. Control  
continues to function and restarts when all  
three user keys have been pressed longer than  
60 seconds.  
Differential. The L7248 models have High Limit  
Differential presets of 15°F (8°C). The L7224  
models have High Limit Differential presets of 10°F  
(6°C).  
Figure 24: Setpoints and Differentials  
Table ꢁ: Trouble Shooting Guide  
System Condition  
Diagnostic Condition  
Display is OFF.  
Check  
120 Vac System power.  
24 Vac T-T  
Action  
Turn system power on.  
No 24 V; replace control.  
Boiler is cold, house is  
cold.  
Display is ON.  
24 V present; disconnect thermostat,  
short T-T.  
Boiler starts, check wiring and thermostat.  
120 Vac at B1-B2  
• If no, replace control.  
• If yes, check burner and wiring.  
Refer to Err on display.  
120 Vac at C1-C2  
-----  
Boiler is hot, house is  
cold.  
Display is ON.  
• 120 Vac at C1-C2, check wiring  
to pump.  
• Wiring OK, is pump running?  
• If not, replace the pump.  
• If pump is running, check for  
trapped air or closed zone valves  
Boiler below the Low Limit tempera-  
ture, wait for boiler to go above Low  
Limit temperature.  
-----  
• If no 120 Vac , replace control.  
• If yes, check zone relays, circulators  
and wiring.  
Boiler above LL? If yes, check for  
120 Vac between ZC and L2.  
32  
Table 7: Beckett AFG, AF, & SF Burners  
Air  
Settings  
Head (stop screw)  
Firing Rate  
Boiler Model  
Hago Nozzle  
(GPH)  
Shutter  
Band  
Pump Pressure  
RSA85*  
RSA110  
RSA125  
RSA135  
RSA170  
RSA195  
RSA240  
RSA285  
.85  
.75 x 80B  
.90 x 80B  
1.0 x 80B  
1.10 x 80B  
1.65 x 80A  
2.00 x 80B  
2.50 x 80B  
3.00 x 80B  
10  
8
1.10  
1.25  
1.35  
1.70  
1.95  
2.40  
2.85  
140  
7
9
0
N/A  
7
7
100  
7
7
* Equipped with low firing rate baffle  
Table 7A: Becket AFG Burner  
Air  
Settings  
Firing Rate  
Boiler Model  
Hago Nozzle  
Head  
(stop screw)  
(GPH)  
Shutter  
Band  
Pump Pressure  
RSAH85  
RSAH110  
RSAH125  
RSAH135  
.75  
1.0  
.65 x 80B  
.85 x 80B  
.90 x 80B  
1.0 x 80B  
6
7
7
9
0
N/A  
140  
1.1  
1.25  
Table 7B: Carlin EZ-2HP Burner  
Boiler Model Firing Rate  
Manufacturer  
GPH  
Angle  
Type  
A
Head Bar  
.75  
Air Band Setting  
RSA85  
RSAH85  
RSA110  
RSAH110  
RSA125  
RSAH125  
RSA135  
RSAH135  
.85  
.75  
.65  
.60  
.50  
.75  
.60  
.90  
.65  
.85  
.85  
.75  
.60/.65  
1.10  
1.00  
1.25  
1.10  
1.35  
1.25  
.90  
W
.85/1.00  
.85  
Delavan  
60°  
1.10  
.90  
1.10/1.25  
.85/1.00  
A
1.20  
1.10  
W
A
1.10/1.25  
Figure 25A: Electrode / Head Setting for  
Carlin EZ-ꢀHP Burner  
Figure 25: Electrode / Head Setting for  
Beckett Burner  
33  
H. REMOVE GUN ASSEMBLY  
2. ADJUST DRAFT REGULATOR for a draft of  
.02” (water gauge) over the fire after chimney has  
reached operating temperature and while burner is  
running.  
-
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.  
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  
2. Reinstall gun assembly.  
I. VERIFY OIL BURNER SETTINGS BEFORE  
minimum smoke (not to exceed #1) with a minimum  
of excess air. Make final check using suitable  
instrumentation to obtain a CO2 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.  
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. Attach a plastic hose to fuel pump vent fitting and  
provide a container to catch the oil.  
4. REMOVE GAUGE PORT PLUG from fuel pump  
and install pressure gauge.  
4. TURN “OFF” BURNER and remove pressure  
gauge. Install gauge port plug and tighten. Start  
burner again.  
J. START OIL BURNER  
1. Open vent fitting on fuel pump.  
Carlin Burner  
2. TURN ‘ON’ BURNER service switch and allow  
burner to run until oil flows from vent fitting  
in a SOLID stream without air bubbles for  
approximately 10 seconds.  
1-4. Refer to “Installation and Operating Instructions  
for Packaged Heating/Burner Units, Carlin Elite  
Oil Burner” (Form CCT-569A) for instructions for  
Bleeding the Pump and Starting the Burner.  
3. Close vent fitting and burner flame should start  
immediately after pre-purge is complete. Pre-purge  
prevents burner flame until 10 seconds has elapsed  
after initial power is applied to burner. During  
pre-purge, the motor and ignitor will operate but the  
oil valve will remain closed. Refer to Oil Primary  
Control Instructions for more details.  
5. Turn “off” Burner and remove pressure gauge.  
Install gauge port plug and tighten. Start burner  
again.  
6. CAD Cell Location and Service. The burner is  
supplied with a cadmium sulfide flame detector  
mounted at the factory, mounted on the bottom of  
the transformer. See “Installation and Operating  
Instructions for Packaged Heating/Burner Units,  
Carlin Elite Oil Burner” (Form CCT-569A). To  
service cad cell or to replace the plug in portion,  
swing open the transformer. After service is  
4. For Carlin burner, refer to “Installation and  
Operating Instructions for Packaged Heating/  
Burner Units, Carlin Elite Oil Burner” (Form  
CCT-569A) for instructions for Bleeding the Pump  
and Starting the Burner.  
K. ADJUST OIL PRESSURE  
complete, be sure to fasten down the transformer.  
1. Locate oil pressure adjusting screw and turn screw  
until Pressure Gauge reads the correct pump  
pressure required for the specific boiler. Refer to  
Tables 7 & 7A for Beckett burners or Table 7B for  
Carlin burner (set pump pressure to 150 for Carlin  
EZ-1HP Burner).  
M. FLAME FAILURE  
The RSA boiler controls operate the burner  
automatically. If for unknown reasons the burner  
ceases to fire and the reset button on the primary control  
has tripped, the burner has experienced ignition failure.  
Before pressing the reset button, call your serviceman  
immediately.  
2. DO NOT REMOVE PRESSURE GAUGE until  
later.  
L. OTHER ADJUSTMENTS  
WARNING  
Beckett Burner  
Do not attempt to start the burner when excess oil  
has accumulated, when the unit is full of vapor, or  
when the combustion chamber is very hot.  
1. ADJUST THE AIR BAND AND/OR AIR  
SHUTTER.  
a. Adjust air supply by loosening lock screws and  
moving the air shutter and if necessary the air  
band. Refer to Tables 7 and 7A preliminary  
settings.  
N. CHECK FOR CLEAN CUT OFF OF BURNER  
1. AIR IN THE OIL LINE between fuel unit and  
34  
c. Replace oil supply line.  
d. Repair oil filter leaks  
e. Replace or repair tank fittings.  
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.  
5. GASKET LEAKS— If 11.5% to 12.5% CO2 with a  
#1 smoke cannot be obtained in stack, look for air  
leaks around the canopy seal. Such air leaks will  
cause a lower CO2 reading in the stack. The smaller  
the firing rate the greater effect an air leak can have  
on CO2 readings.  
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.  
If dripping or after burn persist replace fuel pump.  
6. 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.  
O. HINTS ON COMBUSTION  
1. 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 RSA 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  
CO2 and smoke. Nozzles are delicate and should  
be 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 serviceman to carry.  
7. WATER— Water in the fuel, in large amounts, will  
stall the fuel pump. Water in the fuel pump, in  
smaller amounts, will cause excessive wear on the  
pump, but more importantly water does not burn.  
It chills the flame, causes smoke, and allows un-  
burned fuel to pass through the combustion chamber  
and clog the flueways of the boiler.  
NOTICE  
CHECK TEST PROCEDURE. A very good test for  
isolating fuel side problems is to disconnect the  
fuel system and with a 24" length of tubing, fire  
out of an auxiliary five gallon pail of clean, fresh,  
warm #2 oil from another source. If the burner runs  
successfully when drawing out of the auxiliary  
pail then the problem is isolated to the fuel or fuel  
lines being used on the jobsite.  
2. FLAME SHAPE — Looking into the combustion  
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.  
8. 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.  
3. FUEL LEAKS— Any fuel leak between the  
pump and the nozzle will 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.  
4. 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.  
9. 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% CO2.  
There may be many possible causes of leaks in oil  
lines such as:  
a. Fitting leaks due to misflared tubing or damaged  
fitting.  
b. Fuel line leak due to crushed or bent tubing.  
c. Filter connection leaks.  
d. Tank connection leaks.  
10. 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.  
11. 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  
The following actions can eliminate air leaks:  
a. Bleed pump as detailed in System Start-Up  
Section of this manual.  
b. Replace flare fittings.  
35  
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.  
With the burner running, turn off the power  
to the system by tripping the circuit breaker  
or removing the fuse.  
Burner should stop.  
P. TEST CONTROLS  
Restore power. Burner should start.  
3. VERIFY HIGH LIMIT OPERATION.  
WARNING  
a. Adjust thermostat to highest setting.  
b. Observe temperature gauge. When temperature  
is indicated, adjust limit to setting below  
observed temperature. Burner should stop.  
c. Adjust limit to setting above observed  
temperature. Burner should start.  
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.  
d. Adjust thermostat to lowest setting. Adjust limit  
to desired setting.  
4. CHECK LOW WATER CUTOFF (if so equipped).  
2. VERIFY PRIMARY CONTROL SAFETY  
FEATURES using procedures outlined in  
Instructions furnished with control (See back of  
Control Cover) or Instructions as follows:  
a. Adjust thermostat to highest setting.  
b. With boiler operating, open drain valve and  
slowly drain boiler.  
c. Burner should stop when water level drops  
below low water cutoff probe. Verify limit,  
thermostat or other controls have not shut off  
boiler.  
WARNING  
Service of this boiler should be undertaken only  
by trained and skilled personnel from a qualified  
service agency.  
d. Adjust thermostat to lowest setting. Refill  
boiler.  
Q. Boiler is now ready to be put into service.  
a. Simulate flame failure:  
Follow the starting procedure to turn on the  
burner.  
IMPORTANT  
IF, DURING NORMAL OPERATION, IT IS  
NECESSARY TO ADD WATER MORE FREQUENTLY  
THAN ONCE A MONTH, CONSULT A QUALIFIED  
SERVICE TECHNICIAN TO CHECK YOUR  
SYSTEM FOR LEAKS.  
Close the hand valve in the oil supply line.  
Control enters recycle mode and tries  
to restart burner after approximately 60  
seconds.  
Safety switch should lock out in  
approximately 15 seconds. Ignition and  
motor should stop.  
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 failure. The maintenance of system  
integrity is the best method to achieve this.  
Indicator light will flash ½ second on,  
½ second off.  
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.  
Safety switch should lock out in  
approximately 15 seconds. Ignition and  
motor should stop.  
Indicator light will flash ½ second on,  
½ second off.  
Push red reset button to reset safety switch.  
c. Simulate power failure:  
Follow the starting procedure to turn on the  
burner.  
3ꢁ  
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  
RSA285  
ADDS 5-3/8” TO BOILER HEIGHT  
3) Fasten shield to combustible floor to keep shield from  
1) Place shield on combustible floor with “TOP” surface  
upward and “FRONT” surface directly below the  
expected position of the oil burner.  
shifting position during setting of boiler.  
4) Set boiler squarely on top of shield such that base plate  
of boiler rests flat on top surface of shield and does not  
over-hang shield on any side. Confirm clearance to  
combustible walls. Refer to Figure 2.  
2) Locate shield such that clearances to combustible walls  
are as indicated in Figure 26. These dimensions will  
assure that the boiler jacket will be at least 18” from  
the side and rear walls and 48” from the front wall, as  
required by ANSI/NFPA 31.  
5) Do not enclose boiler (including shield) on all four  
sides. Boiler may be enclosed on any three sides while  
maintaining minimum clearances shown in Figure 2 for  
each of those three sides.  
Figure 2ꢁ  
37  
VIII. Service and Cleaning  
1. CLEAN THE FIRETUBES  
NOTICE  
a. Disconnect electric to burner and remove stack.  
BURNER SHUTDOWN: Open Service Switch  
to turn off burner.  
b. For access to the firetubes, pull top jacket panel  
off. Loosen wing nuts, that hold canopy down.  
Without taking wing nuts off carriage bolts,  
disengage bolts from slots on tubesheet. Pull  
canopy off.  
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.  
c. Remove turbulators.  
d. Using a firetube brush clean firetubes. DO  
NOT extend brush past the end of the bottom  
tubesheet.  
A. General. Inspection service and cleaning should be  
conducted annually. Turn off electric power and  
close oil supply valve while conducting service or  
maintenance.  
e. Assemble the boiler in reverse order.  
Units should be cleaned at least once a year, preferably  
at the end of each heating season.  
B. Firetubes and Combustion Chamber. (See Figure 27)  
It is not necessary to remove burner to clean boiler.  
Brush, scrape, or vacuum from top.  
Figure 27: Cleaning of RSA Boiler  
38  
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.  
AVOID Breathing Fiber Particulates and Dust  
Precautionary Measures:  
Do not remove or replace RCF parts or attempt any service or repair work  
involving RCF without wearing the following protective gear:  
1. A National Institute for Occupational Safety and Health (NIOSH)  
approved respirator  
2. Long sleeved, loose fitting clothing  
3. Gloves  
4. Eye Protection  
• Take steps to assure adequate ventilation.  
• Wash all exposed body areas gently with soap and water after contact.  
• Wash work clothes separately from other laundry and rinse washing  
machine after use to avoid contaminating other clothes.  
• Discard used RCF components by sealing in an airtight plastic bag. RCF  
and crystalline silica are not classified as hazardous wastes in the United  
States and Canada.  
First Aid Procedures:  
• If contact with eyes: Flush with water for at least 15 minutes. Seek  
immediate medical attention if irritation persists.  
• If contact with skin: Wash affected area gently with soap and water.  
Seek immediate medical attention if irritation persists.  
• If breathing difficulty develops: Leave the area and move to a location  
with clean fresh air. Seek immediate medical attention if breathing  
difficulties persist.  
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek  
immediate medical attention.  
3ꢂ  
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 ques-  
tions 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.  
70 Maple Street  
East Longmeadow, MA 01028  
Tel: (413) 525-7700  
Fax: (413) 525-8306  
40  
ITEM  
DESCRIPTION  
PART NUMBER  
1
2
Jacket Rear Top Panel  
604350864  
604350863  
60435087  
60435088  
100282-03  
100059-01  
100862-01  
7026001  
Jacket Front Top Panel  
Jacket Wrap-A-Round Panel, RSA85/110  
Jacket Wrap-A-Round Panel, RSA125/135  
Temperature / Pressure Gauge  
Honeywell L7248C1014 Hi-Limit Control  
Honeywell L7224C1004 Limit Control  
Observation Port Cover  
3
4
5
Observation Cover Sprint V1  
8026015  
6
7
Flat Washer, SAE, 5/16”  
80860647  
80860402  
80160847  
Hex Nut, 5/16” -18, Heavy  
Burner Primary Control, R7184B  
Fogire 28: Assembled Boiler  
4ꢀ  
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 2ꢂ: RSA85-ꢀ35 Bare Boiler Repair Parts  
42  
ITEM  
QTY.  
DESCRIPTION  
PART NUMBER  
1
2
2
10  
1
Wing Nut, 1/4 -20  
80860910  
80860633  
6113509  
9206005  
9206005  
80860119  
7116037  
Washer, Flat 1/4 (SAE)  
3
Canopy Assembly  
4
2
1/2” Thick x 1” x 12-3/8” Cerafelt Strip  
1/2” Thick x 1” x 12-3/8” Cerafelt Strip  
Carriage Bolt, 1/4 -20 x 3” Lg.  
Turbulator  
5
2
6
2
7
‘A’  
1
8
Heat Exchanger Assembly  
‘B’  
9
10  
1
SA307B 3/8 -16 x 1-1/4” Bolt  
Tankless Heater Gasket  
80861360  
8206036  
7036030  
6033509  
6033510  
80860645  
80860400  
9206003  
9206003  
8203006  
8203512  
6183508  
80860810  
80860407  
10  
11  
1
Tapped Heater Cover Plate  
Tankless Heater Coil, (Standard S350) (Includes Item 10)  
Tankless Heater Coil, (Optional S375) (Includes Item 10)  
Washer, Flat (USS), 3/8”  
12  
1
13  
14  
15  
16  
17  
18  
19  
20  
21  
10  
10  
2
Hex Nut, 3/8 -16, Steel, Plain  
1/2” Thick x 2” x 13-3/4” Cerafelt Strip  
1/2” Thick x 2” x 18-1/2” Cerafelt Strip  
Combustion Chamber  
2
1
1
Cerablanket  
1
Base Assembly  
4
Machine Screw, Hex Head, 1/4 -20 x 1-1/4”  
Hex Nut, 1/4 -20 (Heavy Hex)  
4
BOILER MODEL  
‘A’  
‘B’  
RSA85  
RSA110  
RSA125  
RSA135  
12  
16  
12  
16  
603350112  
603350116  
603350212  
603350216  
43  
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 30: RSA170-285 Boiler Repair Parts  
44  
ITEM  
DESCRIPTION  
PART NUMBER  
1
2
3
4
5
6
Jacket Top Panel Assembly  
60435022  
6113510  
9206005  
9206005  
6113504  
8036025  
6033507  
6033508  
7033501  
Canopy Assembly  
1/2” Thick x 1” x 23” Cerafelt Strip  
1/2” Thick x 1” x 17” Cerafelt Strip  
Turbulator, See ‘A’ for Quantity  
Tankless Heater Gasket  
#7524 Tankless Heater Assembly (Includes Item 6)  
#7530 Tankless Heater Assembly (Includes Item 6)  
Blank Heater Cover Plate  
7
8
9
Heat Exchanger Assembly  
‘B’  
9206003  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
21  
1/2” Thick x 2” x 25” Cerafelt Strip  
1/2” Thick x 2” x 21” Cerafelt Strip  
Combustion Chamber  
9206003  
8203003  
Block Insulation Assembly  
Supplied with Item #12  
60435061  
60435033  
60435042  
6186031  
Jacket Left Side Panel Assembly  
Jacket Upper Front Panel Assembly  
Jacket Lower Front Panel Assembly  
Base Assembly with Insulation  
Jacket Rear Panel Assembly  
60435071  
60435051  
80860407  
Jacket Right Side Panel Assembly  
Hex Nut, 1/4 -20 (Heavy Hex)  
BOILER MODEL  
‘A’  
‘B’  
RSA85  
RSA110  
RSA125  
RSA135  
12  
16  
12  
16  
603350112  
603350116  
603350212  
603350216  
45  
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  
RSA85  
AFG  
RSA110  
AFG  
RSA125  
AFG  
RSA135  
AFG  
Burner Model  
Air Tube Combination  
Spec. No.  
AF60BN  
BCB6211  
3492BKA  
4150  
AF60XN  
BCB6212  
3492BKA  
4150  
AF60J2  
BCB6213  
3492BKA  
4150  
AF60JZSS  
BCB6214  
3492BKA  
4150  
Air Band  
Air Band Nut  
Air Band Screw  
Air Shutter  
4198  
4198  
4198  
4198  
3709BK  
4198  
3709BK  
4198  
3709BK  
4198  
3709BK  
4198  
Air Shutter Screw  
Blower  
2999  
2999  
2999  
2999  
Bulkhead Fitting  
Bulkhead Fitting Locknut  
Connector Tube Assembly  
Coupling  
3488  
3488  
3488  
3488  
3666  
3666  
3666  
3666  
5636  
5636  
5636  
5636  
2454  
2454  
2454  
2454  
Electrode Clamp  
Electrode Clamp Screw  
Electrode Insulator Assembly  
Spider Spacer Assembly  
Escutcheon Plate  
Flange and Air Tube Assembly  
Gasket  
149  
149  
149  
149  
4219  
4219  
4219  
4219  
EA21502  
5653  
EA21502  
5653  
EA21502  
5653  
EA21502  
5653  
3493  
3493  
3493  
3493  
3146812  
31498  
360003  
4221  
3146812  
31498  
360003  
4221  
3146812  
31498  
360006  
4221  
3146812  
31498  
360006  
4221  
Head  
Head Screws  
Hole Plug  
2139  
2139  
2139  
2139  
Housing Assembly w/Inlet Bell  
Motor  
5624  
5624  
5624  
5624  
2456  
2456  
2456  
2456  
Nozzle Adapter  
Nozzle Line Electrode Assembly  
Pump (Includes Valve)  
Static Plate  
213  
213  
213  
213  
NC6058  
21844  
31646  
51771U  
4217  
NC6058  
21844  
3383P  
51771U  
4217  
NC6058  
21844  
31646  
51771U  
4217  
NC6048  
21844  
31646  
51771U  
4217  
Ignitor  
Ignitor Hinge Screw  
Ignitor Holding Screw  
Ignitor Gasket Kit  
Wire Guard  
4198  
4198  
4198  
4198  
51304  
3345  
51304  
3345  
51304  
3345  
51304  
3345  
Baffle  
3708  
N/A  
N/A  
N/A  
4ꢁ  
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:  
R. W. BECKETT CORP.  
38251 CENTER RIDGE RD.  
P. O. BOX 1289  
ELYRIA, OHIO 44036  
1-800-645-2876  
Boiler Model  
RSA170  
AF  
RSA195  
AF  
RSA240/285  
SF  
Burner Model  
Air Tube Combination  
Spec. No.  
AF60XO  
BCB114  
3492  
AF60XP  
BCB116  
3492  
SF60FY  
BCB211  
3492  
1) Air Band  
Air Band Nut  
4150  
4150  
460  
Air Band Screw  
4198  
4198  
4219  
2) Air Shutter  
Air Shutter Screw  
6) Blower  
3494  
3494  
3215  
4198  
4198  
493  
2459  
2459  
2288  
7) Bulkhead Fitting  
8) Bulkhead Fitting Locknut  
9) Connector Tube Assembly  
10) Coupling  
3488  
3488  
3488  
3666  
3666  
3666  
5636  
5636  
5636  
2454  
2454  
2433  
11) Electrode Clamp  
Electrode Clamp Screw  
12) Electrode Insulator Assembly  
15) Spider Spacer Assembly  
16) Escutcheon Plate  
18) Flange and Air Tube Assembly  
Gasket  
149  
149  
149  
4219  
4219  
4219  
EA21502  
5653  
EA21502  
5653  
EA21502  
5653  
3493  
3493  
3493  
58115  
3616  
58115  
3616  
58115  
3616  
19) Head  
360012  
4221  
360022  
4221  
5434  
Head Screws  
4221  
Hole Plug  
2139  
2139  
2139  
20) Housing Assembly w/Inlet Bell  
21) Motor  
5624  
5624  
53485  
2364  
2456  
2456  
22) Nozzle Adapter  
23) Nozzle Line Electrode Assembly  
25) Pump (Includes Valve)  
27) Static Plate  
213  
213  
213  
NC6048  
21844  
3383  
NC6058  
21844  
3383  
NC6048  
21844  
3383  
28) Ignitor  
51824U  
4217  
51824U  
4217  
51824U  
4217  
29) Ignitor Hinge Screw  
30) Ignitor Holding Screw  
31) Ignitor Gasket Kit  
21) Wire Guard  
4198  
4198  
4198  
51304  
3345  
51304  
3345  
51304  
3345  
48  
Figure 32: BECKETT AF and SF MODEL BURNERS  
4ꢂ  
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  
draining the heating system. Many probe LWCO  
manufacturers recommend an annual inspection of the  
probe.  
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). In  
addition, some jurisdictions require the use of a LWCO  
with a hot water boiler.  
How to Wire  
LWCO’s are available in either 120 VAC or 24 VAC  
configurations. The 120 VAC configuration can be  
universally applied to both gas and oil boilers by wiring  
it in the line voltage service to the boiler (after the  
service switch, if so equipped).  
The presence of water in a properly installed LWCO  
will cause the normally open contact of the LWCO to  
close, thus providing continuity of the 120 VAC service  
to the boiler.  
Where  
The universal location for a LWCO on both gas and  
oil hot water boilers is above the boiler, in either the  
supply or return piping. The minimum safe water level  
of a water boiler is at the uppermost top of the boiler;  
that is, it must be full of water to operate safely.  
It is recommended to supply power to the probe LWCO  
with the same line voltage boiler service as shown  
below.  
What Kind  
Typically, in residential applications, a probe type  
LWCO is used instead of a float type, due to their  
relative costs and the simplicity of piping for a probe  
LWCO.  
How to Pipe  
A “tee” is commonly used to connect the probe LWCO  
to the supply or return piping, as shown below.  
Wiring of Typical LWCO  
A 24 VAC LWCO is used primarily for gas fired  
boilers where a 24 volt control circuit exists within the  
boiler. However, a 24 VAC LWCO can only be used  
if the boiler manufacturer has provided piping and  
wiring connections and instructions to allow for this  
application.  
LWCO Location  
Select the appropriate size tee using the LWCO  
manufacturer’s instructions. Often, the branch  
connection must have a minimum diameter to  
prevent bridging between the probe and the tee. Also,  
the run of the tee must have a minimum diameter to  
prevent the end of the probe from touching or being  
located too close to the inside wall of the run of the tee.  
How to Test  
Shut off fuel supply. Lower water level until water  
level is BELOW the LWCO. Generate a boiler demand  
by turning up thermostat. Boiler should not attempt to  
operate. Increase the water level by filling the system.  
The boiler should attempt to operate once the water  
level is above the LWCO.  
Ideally, manual shutoff valves should be located  
above the LWCO and the boiler to allow for servicing.  
This will allow probe removal for inspection without  
50  
SERVICE RECORD  
DATE  
SERVICE PERFORMED  
5ꢀ  
For Residential Grade Water and Steam Boilers  
Using Cast Iron, Carbon Steel, Cast Aluminum,  
Limited Warranty  
or Stainless Steel Heat Exchangers  
and Parts/Accessories  
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:  
d. This warranty cannot be considered as a guarantee of workmanship of an  
installer connected with the installation of the U.S. Boiler Company, Inc.  
boiler, or as imposing on U.S. Boiler Company, Inc. liability of any nature for  
unsatisfactory performance as a result of faulty workmanship in the  
installation, which liability is expressly disclaimed.  
e. Boilers, parts, or accessories installed outside the 48 contiguous United  
States, the State of Alaska and Canada.  
f. Damage to the boiler and/or property due to installation or operation of the  
boiler that is not in accordance with the boiler installation and operating  
instruction manual.  
g. Any damage or failure of the boiler resulting from hard water or scale  
buildup in the heat exchanger.  
h. Any damage caused by improper fuels, fuel additives or contaminated  
combustion air that may cause fireside corrosion and/or clogging of the  
burner or heat exchanger.  
ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS  
AND PARTS / ACCESSORIES SUPPLIED BY U.S. BOILER COMPANY, INC.  
U.S. Boiler Company, Inc. warrants to the original owner that its residential grade  
water and steam boilers and parts/accessories comply at the time of manufacture with  
recognized hydronic industry standards and requirements then in effect and will be  
free of defects in material and workmanship under normal usage for a period of one  
year from the date of original installation. If any part of a residential grade boiler or  
any part or accessory provided by U.S. Boiler Company, Inc. is found to be defective  
in material or workmanship during this one year period, U.S. Boiler Company, Inc.  
will, at its option, repair or replace the defective part.  
HEAT EXCHANGER WARRANTIES  
U.S. Boiler Company, Inc. warrants to the original owner that the heat exchanger of its  
residential grade boilers will remain free from defects in material and workmanship  
under normal usage for time period specified in the chart below of the original owner at  
the original place of installation. If a claim is made under this warranty during the “No  
Charge” period from the date of original installation, U.S. Boiler Company, Inc. will, at its  
option, repair or replace the heat exchanger. If a claim is made under this warranty after  
the expiration of the “No Charge” period from the date of original installation, U.S. Boiler  
Company, Inc. will, at its option and upon payment of the pro-rated service charge set  
forth below, repair or replace the heat exchanger. The service charge applicable to a  
heat exchanger warranty claim is based upon the number of years the heat exchanger  
has been in service and will be determined as a percentage of the retail price of the heat  
exchanger model involved at the time the warranty claim is made as follows:  
i. Any damage resulting from combustion air contaminated with particulate  
which cause clogging of the burner or combustion chamber including but  
not limited to sheetrock or plasterboard particles, dirt, and dust particulate.  
j. Any damage, defects or malfunctions resulting from improper operation,  
maintenance, misuse, abuse, accident, negligence including but not limited to  
operation with insufficient water flow, improper water level, improper water  
chemistry, or damage from freezing.  
k. Any damage caused by water side clogging due to dirty systems or  
corrosion products from the system.  
l. Any damage resulting from natural disaster.  
m.Damage or malfunction due to the lack of required maintenance outlined in  
the Installation and Operating Manual furnished with the unit.  
6. Exclusive Remedy: U.S. Boiler Company, Inc. obligation for any breach of  
these warranties is limited to the repair or replacement of its parts in  
accordance with the terms and conditions of these warranties.  
7. Limitation of Damages: Under no circumstances shall U.S. Boiler Company, Inc.  
be liable for incidental, indirect, special or consequential damages of any kind  
whatsoever under these warranties, including, but not limited to, injury or damage  
to persons or property and damages for loss of use, inconvenience or loss of time.  
U.S. Boiler Company, Inc. liability under these warranties shall under no  
circumstances exceed the purchase price paid by the owner for the residential  
grade boiler involved. Some states do not allow the exclusion or limitation of  
incidental or consequential damages, so the above limitation or exclusion may not  
apply to you.  
Service Charge as a % of Retail Price  
Years in Service 1-5  
Cast Iron Water  
Cast Iron Steam*  
Carbon Steel  
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25+  
No Charge  
No Charge  
No Charge  
No Charge  
5
10  
15 20 25 30 40 45 50 55 60 65 70 75  
100  
10  
5
15 20 25 30 40 45 50 55 60 65 70 75  
100  
Cast Aluminum  
30 40 50 60 70  
No Charge  
100  
Stainless Steel  
30 40 50 60 70  
NOTE: If the heat exchanger involved is no longer available due to product obsolescence  
or redesign, the value used to establish the retail price will be the published price as  
shown in the Burnham Repair Parts Pricing where the heat exchanger last  
appeared or the current retail price of the then nearest equivalent heat exchanger.  
*MegaSteam Waterside Corrosion Warranty: U.S. Boiler Company, Inc. warrants the  
cast iron sections of the MegaSteam boiler to resist Temperature Induced Chloride  
Activated Graphitic Corrosion for a period of five years from the date of original  
installation. In the event that any cast iron section of a Mega Steam boiler fails due to  
this corrosion mechanism during this period, U.S. Boiler Company, Inc. will repair or  
replace, at its option, the cast iron section assembly.  
8. Limitation of Warranties: These warranties set forth the entire obligation of U.S.  
Boiler Company, Inc. with respect to any defect in a residential grade boiler, parts,  
or accessories and U.S. Boiler Company, Inc. shall have no express obligations,  
responsibilities or liabilities of any kind whatsoever other than those set forth  
herein. These warranties are given in lieu of all other express warranties.  
LIFETIME NIPPLE LEAKAGE WARRANTY  
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY  
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR  
PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE  
YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO  
THE HEAT EXCHANGER IN A RESIDENTIAL GRADE BOILER SHALL  
EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE  
HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE  
OF INSTALLATION. SOME STATES DO NOT ALLOW LIMITATION ON HOW  
LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY  
NOT APPLY TO YOU.  
U.S. Boiler Company, Inc. warrants the cast iron and steel nipples that join the cast iron  
boiler sections to be free of defects in material and workmanship for the lifetime of the  
original owner at the original place of installation. In the event that such nipples are  
found to be defective in material and workmanship during this period, U.S. Boiler  
Company, Inc. will repair or replace at its option, the cast iron section assembly.  
ADDITIONAL TERMS AND CONDITIONS  
1. Applicability: The limited warranties set forth above are extended only to the  
original owner at the original place of installation within the United States and  
Canada. These warranties are applicable only to boilers, parts, or accessories  
designated as residential grade by U.S. Boiler Company, Inc. and installed in a  
single or two-family residence and do not apply to commercial grade products.  
2. Components Manufactured by Others: Upon expiration of the one year limited  
warranty on residential grade boilers, all boiler components manufactured by  
others but furnished by U.S. Boiler Company, Inc. (such as oil burner, circulator  
and controls) will be subject only to the manufacturer’s warranty, if any.  
3. Proper Installation: The warranties extended by U.S. Boiler Company, Inc.  
are conditioned upon the installation of the residential grade boiler, parts, and  
accessories in strict compliance with U.S. Boiler Co., Inc. installation  
instructions. U.S. Boiler Company, Inc. specifically disclaims liability of any  
kind caused by or relating to improper installation.  
4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Company,  
Inc. conditioned upon the use of the residential grade boiler, parts, and  
accessories for its intended purposes and its maintenance accordance with U. S.  
Boiler Company, Inc. recommendations and hydronics industry standards. For  
proper installation, use, and maintenance, see all applicable sections of the  
Installation and Operating, and Service Instructions Manual furnished with the unit.  
5. This warranty does not cover the following:  
PROCEDURE FOR OBTAINING WARRANTY SERVICE  
In order to assure prompt warranty service, the owner is requested to complete  
and mail the Warranty Card provided with the product or register product online  
failure to comply with this request will not void the owner’s rights under these  
warranties. Upon discovery of a condition believed to be related to a defect in  
material or workmanship covered by these warranties, the owner should notify  
the installer, who will in turn notify the distributor. If this action is not possible or  
does not produce a prompt response, the owner should write to U.S. Boiler  
Company, Inc., C/O Burnham, P.O. Box 3079, Lancaster, PA 17604, giving  
full particulars in support of the claim. The owner is required to make available  
for inspection by U.S. Boiler Company, Inc. or its representative the parts  
claimed to be defective and, if requested by U.S. Boiler Company, Inc. to ship  
these parts prepaid to U.S. Boiler Company, Inc. at the above address for  
inspection or repair. In addition, the owner agrees to make all reasonable efforts  
to settle any disagreement arising in connection with a claim before resorting to  
legal remedies in the courts.  
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY  
ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.  
a. Expenses for removal or reinstallation. The homeowner will be responsible  
for the cost of removing and reinstalling the alleged defective part or its  
replacement and all labor and material connected therewith, and  
transportation to and from U.S. Boiler Company, Inc.  
b. Components that are part of the heating system but were not furnished by  
U.S. Boiler Company, Inc. as part of the residential boiler.  
c. Improper burner adjustment, control settings, care or maintenance.  

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