Burnham RSA manual

1 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S S E I R E S ™ A S R R E L I O B D E R I F - L I O n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o b o t s r i a p e r r o e c i v r e s r o F . l e b a L g n i t a R n o n w o h s s a r e [...]

2 The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. IMPOR T ANT INFORMA TION - READ CAREFULL Y DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial prop[...]

3 DANGER DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance. W ARNING 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 dea[...]

4 W ARNING This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings 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[...]

5 T able of Contents I. Pre-Installation ....................................... 7 II. Knockdown Boiler Assembly ................ 9 III. W ater Piping and T rim ......................... 12 IV . V enting ................................................. 18 V . Electrical and Sequence of Operation .. 20 Figure 1: RSA Packaged Boiler (RSA85 / RSA135)[...]

6 Figure 1A: RSA Packaged Boiler (RSA170 / RSA285) Boiler Model Number Bare Boiler Assembly Minimum Recommended Chimney Sizes W ater Capacity (gallons) Approx. Shipping Weight (lb.) In. x In. x Ft. (height) In. (dia.) x Ft. (height) RSA170 WV -29-10 8 x 8 x 20 7 x 20 42.6 600 RSA195 WV -29-13A 8 x 20 39.9 630 RSA240 WV -29-16A 8 x 12 x 20 37.3 660 [...]

7 A . INSPECT SHIPMENT carefully for any signs of damage. 1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of the crated boiler to the carrier in good condition. 2. ANY CLAIMS for damage or shortage of shipment must led immediately against the carrier by the consignee. No claims for varian[...]

8 C. PROVIDE COMBUSTION AND VENTILA TION AIR. Local code provisions may apply and should be referenced. W ARNING Ade quate combu stion and ven tilat ion air must be provided to assure proper combustio n and to maintain safe ambient air temperatures. Do not install boiler where gasoline or other amma ble v apors or li quids, or so urces of hydroc[...]

9 II. Knock-Down Boiler Assembly W ARNING Do not apply more than 30 psig to boiler . W ARNING 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. W ARNING Do not assemble boiler without cerafelt gaskets between heat exchanger and combust[...]

10 Figure 5: Burner Mounting 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 t proper into there corresponding clearance holes. Continue bending jacket around until front panels meet. 3. Attach jacket to boiler assembly with provi[...]

1 1 THIS P AGE IS LEFT INTENTIONALL Y BLANK[...]

12 Figure 7: Recommended Piping for Combination Heating and Cooling (Refrigeration) System III. W ater Piping and T rim A. Design a piping system and install boiler which will prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up[...]

13 and return line as illustrated in Figures 8 and 9 in order to regulate water ow 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 w[...]

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

15 Figure 9: Recommended W ater Piping for Zone V alve Zoned Heating Systems[...]

16 F . CONNECT T ANKLESS HEA TER PIPING AS SHOWN IN FIGURE 10. See T able 1 for T ankless Heater Rating. W ARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at xtures. Adjust and maintain the mixing valve in accordance with the manufacturer's instructions. Do not [...]

17 Figure 10: Schematic T ankless Heater Piping T able 1: T ankless Heater Ratings Boiler Model S350 S375 GPM PSID GPM PSID RSA85 & 1 10 3 12 3½ 15 RSA1 10, 125 & 135 3¼ 16 3¾ 25 RSA125 & 135 3½ 19 Boiler Model STD. #7524 OPT . #7530 GPM PSID GPM PSID RSA170 3¾ 25½ 4 26½ RSA195, 240 & 285 4 29 4¼ 31[...]

18 IV . V enting A . General Guidelines. 1. V ent system installation must be in accordance with these instructions and applicable provisions of local building codes. Contact local building or re ofcials about restrictions and installation inspection in your area. 2. The RSA Series is designed to be vented into a reclay tile-lined masonry [...]

19 Figure 1 1: Recommended Smoke Pipe Arrangement and Chimney Requirements Figure 12: Draft Regulator Locations[...]

20 A . General 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFP A 70, and/or the CSA C22.1 Electric Code. 2. A separate electrical circuit must be run from the main electrical service with an over-current [...]

21 Figure 13: “RSAL” Wiring Less T ankless, Single Circulator Figure 14: “RSA T” or “RSAR” Wiring with T ankless, Single Circulator Sequence of Operation A call for heat by the thermostat energizes the L7224C/L7248C control which in turn ener gizes the Honeywell R4184D primary control to turn on the burner . If burner ignites within app[...]

22 Figure 15: Circulator Zoned Wiring for Honeywell R8888[...]

23 Figure 16: Zone V alve Zoned Wiring for R8889[...]

24 Figure 17: Different Manufacturer ’ s Zone V alve Connections to Honeywell 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[...]

25 8. Burnham EC5000 Circulator Zoned System – Refer to Figure 18 of this manual for the electrical diagram for this type of system. W ire 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 V alve Zoned System – Refer to Figure 19 [...]

26 Figure 18: Circulator Zoning with EC5000 Wiring Schematic[...]

27 Figure 19: Zone V alve Zoned with EC5000 Wiring Schematic[...]

28 A . General. 1. Use exible oil line(s) so that burner can be removed without disconnecting the oil supply . 2. A supply line fuel oil lter is recommended as a minimum for all ring rates but a pleated paper fuel oil lter is recommended for the lowest ring rate application to prevent nozzle fouling. 3. Use Flared ttings only . Do[...]

29 C . T wo-Pipe Oil Lines 1. For two-piped systems, where more lift is required, the two-stage fuel unit is recommended. T able 2 (single-stage) and T able 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. Figure 21: T wo-Pipe Installation Lift "H" (See[...]

30 VII. System Start-Up A . V erify that the venting, water piping, oil piping, and electrical system are installed properly . Refer to installation instructions contained in this manual. B . Conrm all electrical, water and oil supplies are turned off at the source and that the vent is clear from obstructions. W ARNING Completely read, understan[...]

31 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. 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 Limi[...]

32 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 Action System Response Thermostat calls for heat. Circulator starts when water temperature is above Low Limit setting (if applicable). Boiler temperatur[...]

33 Figure 25: Electrode / Head Setting for Beckett Burner Figure 25A: Electrode / Head Setting for Carlin EZ-1HP Burner T able 7A: Becket AFG Burner T able 7: Beckett AFG, AF , & SF Burners T able 7B: Carlin EZ-2HP Burner Boiler Model Firing Rate Manufacturer GPH Angle T ype Head Bar Air Band Setting RSA85 .85 Delavan .75 60° A .75 .60 RSAH85 [...]

34 H. REMOVE GUN ASSEMBL Y 1. Check nozzle size, head size, gun setting, and positioning of electrodes. This information is shown in Figure 25 and T ables 7 and 7A for Beckett burner , Figure 25A and T able 7B for Carlin EZ-1HP burner . 2. Reinstall gun assembly . I. VERIFY OIL BURNER SETTINGS BEFORE ST AR TING 1. BURNER AIR BAND AND AIR SHUTTER SE[...]

35 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[...]

36 trapped in the nozzle line. It may take several ring cycles for that air to be fully vented through the nozzle. W ater in the fuel or poor ame shape can also cause shut down noises. P . TEST CONTROLS W ARNING Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the pri[...]

37 INST ALLA TION INSTRUCTIONS FOR SHIELD REQUIRED FOR COMBUSTIBLE FLOOR This shield for combustible oors is intended for use only with the following Burnham oil-red boilers: Use Part Number 6183504 for the following models: RSA85 RSA1 10 RSA125 RSA135 ADDS 4-3/16” TO BOILER HEIGHT Use Part Number 6183505 for the following models: RSA170 RS[...]

38 VIII. Service and Cleaning NOTICE BURNER SHUTDOWN: Open Service Switch to turn off burner . Manu al Oil Supply V alve shoul d be close d 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 . T urn off electric power and [...]

39 Important Produc t Safety Information Refractory Ceram ic 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 know[...]

40 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) 481-84[...]

41 Fogire 28: Assembled Boiler ITEM DESCRIPTION P ART NUMBER 1 Jacket Rear T op Panel 604350864 2 Jacket Front T op Panel 604350863 3 Jacket Wrap-A-Round Panel, RSA85/1 10 60435087 Jacket Wrap-A-Round Panel, RSA125/135 60435088 4 T emperature / Pressure Gauge 100282-03 5 Honeywell L7248C1014 Hi-Limit Control 100059-01 Honeywell L7224C1004 Limit Con[...]

42 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 29: RSA85-135 Bare Boiler Repair Parts[...]

43 ITEM QTY . DESCRIPTION P ART NUMBER 1 2 Wing Nut, 1/4 -20 80860910 2 10 W asher , Flat 1/4 (SAE) 80860633 3 1 Canopy Assembly 61 13509 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. 808601 19 7 ‘A ’ T urbulator 71 16037 8 1 Heat Excha[...]

44 Figure 30: RSA170-285 Boiler Repair Parts NOTE: When ordering parts always give the serial number and model number shown on the boiler . Also provide the name of the part(s) shown below:[...]

45 ITEM DESCRIPTION P ART NUMBER 1 Jacket T op Panel Assembly 60435022 2 Canopy Assembly 61 13510 3 1/2” Thick x 1” x 23” Cerafelt Strip 9206005 4 1/2” Thick x 1” x 17” Cerafelt Strip 9206005 5 T urbulator , See ‘A ’ for Quantity 61 13504 6 T ankless Heater Gasket 8036025 7 #7524 T ankless Heater Assembly (Includes Item 6) 6033507 #[...]

46 BECKETT BURNER P AR TS LIST FOR RSA SERIES STEEL BOILERS FOR REPLACEMENT OIL BURNER P AR TS, CONT ACT YOUR WHOLESALER OR THE BURNER MANUF ACTURER: R. W . BECKETT CORP . 38251 CENTER RIDGE RD. P . O. BOX 1289 EL YRIA, OHIO 44036 1-800-645-2876 NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner . Also[...]

47 Ordering Information for Quality Replacement Parts Figure 31: BECKETT AFG MODEL BURNER[...]

48 BECKETT BURNER P AR TS LIST FOR RSA SERIES STEEL BOILERS FOR REPLACEMENT OIL BURNER P AR TS, CONT ACT YOUR WHOLESALER OR THE BURNER MANUF ACTURER: R. W . BECKETT CORP . 38251 CENTER RIDGE RD. P . O. BOX 1289 EL YRIA, OHIO 44036 1-800-645-2876 Boiler Model RSA170 RSA195 RSA240/285 Burner Model AF AF SF Air T ube Combination AF60XO AF60XP SF60FY S[...]

49 Figure 32: BECKETT AF and SF MODEL BURNERS[...]

50 A 24 V AC L WCO is used primarily for gas red boilers where a 24 volt control circuit exists within the boiler . However, a 24 V AC L WCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. How to T est Shut off fuel supply . Lower water level until water level[...]

51 SERVICE RECORD DA TE SERVICE PERFORMED[...]

52 L L i i m m i i t t e e d d W W a a r r r r a a n n t t y y F F o o r r R R e e s s i i d d e e n n t t i i a a l l G G r r a a d d e e W W a a t t e e r r a a n n d d S S t t e e a a m m B B o o i i l l e e r r s s Using Cast Iron, Carbon Steel, Cast Aluminum, or Stainless Steel Heat Exchangers a a n n d d P P a a r r t t s s / / A A c c c c e [...]