Price - $3.00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR LEDV SERIES DIRECT VENT OIL FIRED BOILER 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 Agency (EPA). For service or repairs to boiler, call your heating contractor.
IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY 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. DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building.
WARNING Boiler materials of construction, products of combustion and the fuel contain alumina, silica, he av y met als, c arbo n mon oxide, nit rogen oxides , aldehyd es a nd/or othe r tox ic or harm ful 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.
NOTICE All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities which may differ from this manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards: USA BOILERS A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices. B.
Table 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 Piping ............................................... 20 VII. System Start-up ...................................... 22 VIII. Service and Cleaning ..............................
I. Pre-Installation A. INSPECT SHIPMENT carefully for any signs of C. PROVIDE COMBUSTION AIR SUPPLY to damage. accommodate proper combustion of oil. Local and national codes may apply and should be referenced. 1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition. 1.
II. Unpack Boiler 4. Remove 4 hex nuts from bolts that attach hinges and hinge spacers to left side of Tubesheet. Remove 4 hex head cap screws that attach hinges to door. CAUTION Do not drop boiler. Do not bump boiler jacket against floor. 5. Attach 2 hinge brackets & spacers to Tubesheet and 2 hinge brackets to Door on right side of boiler. 3 Holes in each Hinge Bracket must line up with 3 matching holes in Spacer, Tubesheet or Door. See Figure 3. Tighten hex nuts, bolts and screws by hand only. A.
TS-98-14-A Figure 3: Proper Hinge Bracket Installation Figure 4: Hinge Assembly Figure 2: Minimum Clearances to Combustible Materials 8
III. Water Piping and Trim 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. 3. 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. A.
Figure 5: Recommended Boiler Piping for Zoning with Valves isolation valve in boiler supply piping. (Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area). 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.
Figure 6: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems Figure 7: Recommended Boiler Piping for Zoning with Circulators 11
IV. Venting / 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 this configuration, all air for combustion is supplied directly to the burner from outdoors and flue gases are vented directly outdoors (through wall).
Components of this kit are listed in the Repair Parts Section of this manual. 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 Direct Oil™ Vent. 20 feet is the maximum vent length allowed.
Figure 10: Vent Installation Figure 11: Vent Connector, Un-Assembled 14
Figure 12: Vent Connector, Assembled Figure 13: Air Intake Installation 15
e. Secure the inside trim plate to inside wall. a. All horizontal runs must rise at least ¼ inch per foot toward vent terminal. f. Tighten the gear clamp to the terminal pipe. b. Avoid any sags or dips in vent pipe. g. Seal all external joints with a weatherproof caulk. C. Air Intake Installation (Direct Vent only) 2. Cut vent pipe to length with a hack saw. See Figure 13. 3. Install Vent Connector/Appliance Adaptor. See Figures 11 and 12. a.
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 Valve. 6. Install air intake terminal. See Figure 13. Alternate to 1., 2. and 3.: Keep the black plastic inlet cover in place and discard the Air Intake Terminal and the Vacuum Relief Valve. 7. Seal all external joints with weatherproof caulk.
V. Electrical and Sequence of Operations A. ELECTRICAL and ignition transformer. b. After a 15 second pre-purge period, in which time a draft is established in the flueways, the oil valve is opened. 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. c.
Figure 15: Schematic Wiring Diagram
VI. Oil Piping A. General TABLE 2: SING LE-STAGE UNITS (3450 RPM) TWO -PIPE SYSTEMS 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. Lift "H" (See Fig.
Figure 17: Two-Pipe Installation C. Two-Pipe Oil Lines. TABLE 3: TWO-STAGE UNITS (3450 RPM) TWO-PIPE SYTEMS 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. Lift "H" (See Fig.
VII. System Start-up WARNING All boilers equipped with burner swing door have a potential hazard w hich can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed. A. ALWAYS INSPECT INSTALLATION BEFORE F. BURNER START-UP STARTING BURNER. B. FILL HEATING SYSTEM WITH WATER.
Figure 18: Electrode / Head Setting 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. When vent fitting is closed, burner flame should start immediately.
i. is to bury the tank and lines deep enough to keep the oil above 40°F. Fitting leaks due to mis-flared tubing or damaged fitting. ii. Fuel line leak due to crushed or bent tubing. i. HIGH ALTITUDE INSTALLATIONS — Air settings must be increased at higher altitudes. Use instruments and set for 11.5 to 12.5% CO2. iii. Filter connection leaks. iv. Tank connection leaks. There are various test kits available to trace air leaks, such as electronic sight glasses.
temperature. Burner should start. FOR HEATING SERVICEMAN ONLY d. Adjust thermostat to lowest setting. Adjust limit to desired setting. 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 reset safety switch. 4. CHECK LOW WATER CUTOFF (if so equipped). a.
Section VIII: Service and Cleaning WARNING All boiler service and cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fasteners completely when service is completed. piece.
an external float type low water cutoff is on the boiler, the blow off valve should be opened once a month (use greater frequency where conditions warrant), to flush out the sediment chamber so the device will be free to function properly. 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. b. Annual Service.
Service Notes 28
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 availability of Burnham products or repair parts, please contact your Burnham Regional Sales Office as listed below. B urnh am Corpo rati on Regional Offices A. B urnham Cor poration - Centr al & Wes tern R egio ns C. Burnham Corporation - M etropolitan Region P.O. Box 3079 P.O.
Figure 19: LEDV Boiler Trim & Controls 30
Figure 20: LEDV Boiler Jacket & Insulation 31
Figure 21: LEDV Bare Boiler Assembly
Figure 22: Vent Kit Repair Parts
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.
BECKETT AFII BURNER REPLACEMENT PARTS LEDV1 LEDV2 LEDV3 Part Description Beckett Part Number Com plete B urner (without Primary Control) BCB5406 Air Tube Com bination HLX50HD Air Tube Screws Blower Wheel HLX50HE 21439 21438 21437 E lectrodes (Replacement Kit) 51484U Escutcheon Plate 31623 3166502 3166503 Fuel Line 5394 Fuel Pum p (Single Stage, with S olenoid Valve) 21757 Fuel Pump (Two Stage, with S olenoid Valve) 2583 Gasket, F lange 31658 Head A ssem bly (AFII 6 Slot) 51671 2139