Burnham LEDV SERIES manual

1 Price - $3.00 INST ALLA TION, OPERA TING AND SER VICE INSTRUCTIONS FOR LEDV SERIES DIRECT VENT OIL FIRED BOILER 81433101R3-3/00 As an ENERGY STAR Partner, Burnham Corporation has determined that the LEDV-1, fired at the 0.60 GPH rate, meets the ENERGY STAR guidelines for Energy efficiency established by the United States Environmental Protection [...]

2 IMPORT ANT INFORMA TION - PLEASE READ THIS P AGE CAREFULL Y The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DA NG ER DO N OT sto r e o r use g aso li n e o r o th er flam m ab l e vapo r s o r l iq uids in the v ici n ity[...]

3 NOT I CE T h is b o ile r h a s a lim ite d w a r r a n t y , a co py of w h ic h is p rint e d o n t h e back o f th is m a nua l. It is t h e r es p o n sib ilit y of t h e in s t allin g c o n tract or to s ee th a t a ll co n tr o ls a re corr ec tly in st a lled an d are oper a t in g p rop e r ly wh en t h e in s t a llat io n is co m p le [...]

4 NO TIC E Al l bo il er s m ust be install ed i n a cco rd an ce wi th Nati o n al, S t ate a n d L o cal P lum b ing, H eat i n g an d E le ct r ical C o d e s a n d t h e r e g u lat io n s of t h e se r vin g u t ilities w hic h m ay d iff e r f r o m th is m a n u a l. Aut h o r itie s h a v ing ju risd ic t io n s h o u ld b e co ns u lte d b[...]

5 Figure 1: LEDV Packaged Boiler T able of Contents I. Pre-Installation ......................................... 6 II. Unpack Boiler ........................................... 7 III. Water Piping and Trim ............................ 9 IV. Venting/Air Intake Piping ..................... 12 V. Electrical and Sequence of Operations .. 18 VI. Oil Pi[...]

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

7 II. Unpack Boiler CAUTION Do not drop boiler. Do not bump boiler jacket against floor. A . REMOVE CRATE 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove vacuum relief valve and miscellaneous trim bag containing safety/relief valve, and pipe fittings. B . REMOVAL OF[...]

8 Figure 4: Hinge Assembly Figure 3: Proper Hinge Bracket Installation TS-98-14-A Figure 2: Minimum Clearances to Combustible Materials[...]

9 III. W ater Piping and T rim A . Design and install boiler and system piping to prevent oxygen contamination of boiler water. There are many possible causes of oxygen contamination such as: 1 . Addition of excessive make-up water as a result of system leaks. 2. Absorption through open tanks and fittings. 3. Oxygen permeable materials in the distr[...]

10 Figure 5: Recommended Boiler Piping for Zoning with Valves D . Install Drain Valve in return piping. See figure 5. E. Oil, grease, and other foreign materials which accumulate in new hot water boilers and a new or reworked system should be boiled out, and then thoroughly flushed. A qualified water treatment chemical specialist should be consulte[...]

11 Figure 6: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems Figure 7: Recommended Boiler Piping for Zoning with Circulators[...]

12 IV . V enting / Air Intake Piping 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 LEDV Series is designed as a Direct Vent boiler. In thi[...]

13 6 . Intake Terminal Location (Direct Vent only) - Locate Air Intake Terminal not less than 12 inches to the left, right, or bottom of the vent terminal. Do not locate air intake terminal above vent terminal. Intake terminal must be at least 12 inches above grade plus snow accumulation. See Figure 9. 7. The LEDV must be vented with 4" Z-Flex[...]

14 Figure 10: Vent Installation Figure 11: Vent Connector, Un-Assembled[...]

15 Figure 13: Air Intake Installation Figure 12: Vent Connector, Assembled[...]

16 e. Secure the inside trim plate to inside wall. f . Tighten the gear clamp to the terminal pipe. g. Seal all external joints with a weatherproof caulk. 2 . Cut vent pipe to length with a hack saw. 3. Install Vent Connector/Appliance Adaptor. See Figures 11 and 12. a . Apply a continuous bead of high temperature adhesive/sealant (supplied with bo[...]

17 6. Install air intake terminal. See Figure 13. 7. Seal all external joints with weatherproof caulk. D. Air Intake Installation (Indoor Air for Combustion) 1 . Remove the black plastic inlet cover from the right side of the Beckett AFII burner. 2 . Attach the Air Intake Terminal directly to the burner intake collar. 3 . Discard the Vacuum Relief [...]

18 V . Electrical and Sequence of Operations A . ELECTRICAL 1. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electric Code. 2. A separate electrical circuit should be run from the main electrical s[...]

19 Figure 15: Schematic Wiring Diagram[...]

20 VI. Oil Piping A. General 1. Use flexible oil line(s) so that Swing Door can be opened without disconnecting 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 (.6 GPH) firing rate application to prevent nozzle fouling. 3. Use Flared fitt[...]

21 C . Two-Pipe Oil Lines. 1. For two-pipe 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 ½-inch OD tubing for both suction and return lines. Refer to Figure 17. T ABLE 3: T WO -S T A GE U NI TS (3450 R P M ) TW O- P IPE S Y[...]

22 VII. System Start-up A. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER. B . FILL HEATING SYSTEM WITH WATER. Refer to Section III, G. C. CHECK CONTROLS, WIRING AND BURNER to be sure that all connections are tight and burner is rigid, that all electrical connections have been completed and fuses installed, and that oil tank is filled and oil l[...]

23 7. Bleed the fuel unit when the burner motor starts rotating. To bleed, loosen the vent fitting (with plastic hose attached) and catch the oil in an empty container. Continue to bleed for 15 seconds after oil is free of air bubbles. Tighten the vent fitting when all the air is purged. NOTE: Bleeding might not be necessary with a two pipe system.[...]

24 i . Fitting leaks due to mis-flared tubing or damaged fitting. ii . Fuel line leak due to crushed or bent tubing. iii. Filter connection leaks. iv . Tank connection leaks. There are various test kits available to trace air leaks, such as electronic sight glasses. Follow the manufacturers' instructions to find air leaks. The following action[...]

25 FOR HEATING SERVICEMAN ONLY a. Simulate flame failure: • Follow the starting procedure to turn on the burner. • Close the hand valve in the oil supply line. • Safety switch should lock out in approximately 15 seconds. Ignition should stop and oil valve should close. Blower will stop after postpurge period. • Push red reset button to rese[...]

26 Section VIII: Service and Cleaning A . General . Inspection, service and cleaning should be conducted annually. Turn off electric power and close oil supply valve while conducting service or maintenance. B . Firetubes and Combustion Chamber . 1. CLEAN THE FIRETUBES a . For access to fireside of boiler, pull two halves of Burner Swing Door Interl[...]

27 2. Remove and clean the pump strainer (if applicable). 3. Replace the nozzle with an equivalent nozzle. See Table 4. 4. Clean and inspect the electrodes for damage, replacing any that are cracked or chipped. 5. Clean the combustion head of all lint and soot. 6. Inspect the transformer cables and connectors. 7. Remove and clean the cad cell. 8. C[...]

28 Service Notes[...]

29 IX. Repair Parts All LEDV Series Repair Parts may be obtained through your local Burnham Wholesale Distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the avail- ability of Burnham products or repair parts, please contact your Burnham Regional Sales Office as listed below. Bur nh[...]

30 Figure 19: LEDV Boiler Trim & Controls[...]

31 Figure 20: LEDV Boiler Jacket & Insulation[...]

32 Figure 21: LEDV Bare Boiler Assembly[...]

33 Figure 22: Vent Kit Repair Parts[...]

34 Figure 23: Beckett AFII Oil Burner Repair Part For replacement oil burner parts, contact your wholesaler or the burner manufacturer: R.W. Beckett Co., P.O. Box 1289, Elyria, OH 44036 (216) 327-1060 or (800) OIL BURN(645-2876)[...]

35 BEC K ET T A F II BU R NER REPLA CEMEN T P A RTS Pa r t Descr i p ti o n LE DV 1 LE DV 2 LE DV 3 Be c k e tt P a r t N u mb e r Co m pl ete B u rner (wi thout Pr i mar y Co nt rol ) B CB 5 4 06 B CB 5 4 07 B CB 5 4 08 A i r T ube Comb i n atio n H LX 50 HD H L X5 0H E A i r T ube Sc rews 4 3 52 B l ower W heel 21 4 39 21 4 38 Co upl in g (M otor[...]

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