Bumham RSA Installation, Operating And Service Instructions Download

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INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

RSA BOILERS

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 _ _ _ _ _ _ _ _

6 _ _ _ _ _ _ _

Heating Contractor

Phone Number

Address

8143508R3-10/99

Summary of Contents for RSA

Page 1: ...rs 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 _ _ _ _ _ _ _ _ 6 _ _ _ _ _ _ _ Heating Contractor Phone Number Address 8143508R3 10 99 ...

Page 2: ...ted in accordance with these instructions All boilers must be installed in accordance with National State and Local Plumbing Heating and Electrical Codes and the regulations of the serving utilities These Codes and Regulations may differ from this instruction manual Authorities having jurisdiction should be consulted before installations are made In all cases reference should be made to the follow...

Page 3: ... 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 S...

Page 4: ...e 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 inju...

Page 5: ...I Knockdown Boiler Assembly 9 III Water Piping and Trim 12 IV Venting 18 V Electrical and Sequence of Operation 20 Figure 1 RSA Packaged Boiler RSA85 RSA135 VI Oil Piping 28 VII System Start Up 30 VIII Service and Cleaning 36 IX Repair Parts 38 ...

Page 6: ...imum Chimney Sizes Water Capacity Gallons Approx Shipping Weight 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 lb RSA195 WV 29 13A 8 x 8 x 20 8 x 20 39 9 630 lb RSA240 WV 29 16A 8 x 12 x 20 8 x 20 37 3 660 lb RSA285 WV 29 19A 8 x 12 x 20 9 x 20 34 6 690 lb ...

Page 7: ...tible floor shield I Pre Installation supplied by Burnham is used DO NOT install on carpeting 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 3 PROVIDE SERVICE CLEARANCE of at least 48 from the front of the jacket for servicing of burner and removal of tankless heater For minimum clearances to combustible...

Page 8: ...ugh cracks around windows and doors normally provides adequate air for combustion and ventilation E 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 communi cating with the outdoors Locate one o...

Page 9: ...ll boiler to skid hold down fasteners Refer to Figure 3 2 Carefully walk boiler to the edge of skid Tilt the boiler back allowing an edge to rest on the floor and remove the skid Figure 3 Base on Skid B TEST HEAT EXCHANGER FOR LEAKS before proceeding with jacket assembly Heat exchanger canopy and base are preassembled 1 Install pressure gauge supplied a hose to the city water and a valve in the su...

Page 10: ...ns Make sure that the jacket is at least to off of the floor before attaching 4 Attach top panel with provided screws I 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 1...

Page 11: ...11 Figure 6 RSA Jacket Assembly ...

Page 12: ...f 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 and return line as illustrated in Figure 10 in order to regulate water flow for maintenance of higher boiler ...

Page 13: ...n cleaned and flushed and before refilling the entire system add appropriate water treatment chemicals if necessary to bring the pH between 7 and 11 D Oil grease and other foreign materials which accumu late 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...

Page 14: ...14 Figure 8 Recommended Boiler Piping for Circulator Zoned Heating Systems ...

Page 15: ...15 Figure 9 Boiler Piping for Zone Valve Zoned Heating Systems ...

Page 16: ... city water and particu larly to well water An appropriate water softener should be installed based on the analysis and dealer s recommendation This is not only benefi cial to the tankless heater but to piping and fixtures plus the many other benefits derived from soft water THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER 1 FLOW REGULATION If flow through the heater is ...

Page 17: ...r Piping Table 1 Tankless Heater Ratings Boiler Model STD 7524 OPT 7530 GPM PSID GPM PSID RSA170 3 25 4 26 RSA195 240 285 4 29 4 31 Boiler Model S350 S375 GPM PSID GPM PSID RSA H 85 110 3 12 3 15 RSA110 H 125 135 3 16 3 25 RSA125 135 3 19 ...

Page 18: ...rned and sends less heat up the chimney A new boiler probably has a higher efficiency 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 combina tion of a large uninsulated chimney reduced firing rate reduced firing time lower st...

Page 19: ...19 Figure 12 Recommended Smokepipe Arrangement and Chimney Requirements Figure 13 Draft Regulator Locations ...

Page 20: ...w all of the instructions provided with the Honeywell R8888 control 7 Conventional Zone Valve Zoned System Refer to Figure 17 Wiring to the most popular models of zone valves are given in Figure 18 Locate C1 and C2 inside the L8124C Honeywell control Connect the two 2 terminals to the system circulator wire leads supplied with boiler Connect the H1 and H2 terminals inside the R8889 to the T T term...

Page 21: ...21 Figure 14 RSAL Wiring Less Tankless Single Circulator Figure 15 RSAT or RSAR Wiring with Tankless Single Circulator ...

Page 22: ...22 Figure 16 Circulator Zoned Wiring for Honeywell R8888 ...

Page 23: ...23 Figure 17 Zone Valve Zoned Wiring for R8889 ...

Page 24: ...tain 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...

Page 25: ...his 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 20 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...

Page 26: ...26 Figure 19 Circulator Zoning with EC5000 Wiring Schematic ...

Page 27: ...27 Figure 20 Zone Valve Zoned with EC5000 Wiring Schematic ...

Page 28: ...se of a high efficiency micron filter Garber or equivalent in addition to conventional filter is highly recommended VI Oil Piping Figure 21 Single Pipe Installation NOTICE Oil piping must be absolutely airtight or leaks or loss of prime may result Bleed line and fuel unit completely B Single pipe Oil Lines 1 Standard burners are provided with single stage 3450 rpm fuel units with the bypass plug r...

Page 29: ...n TABLE 2 SINGLE STAGE UNITS 3450 RPM TWO PIPE SYSTEMS Lift H See Figure Maximum Length of Tubing H R See Figure 3 8 OD Tubing 3 GPH 1 2 OD Tubing 3 GPH 0 84 100 1 78 100 2 73 100 3 68 100 4 63 100 5 57 100 6 52 100 7 47 100 8 42 100 9 36 100 10 31 100 11 26 100 12 21 83 13 62 14 41 TABLE 3 TWO STAGE UNITS 3450 RPM TWO PIPE SYSTEMS Lift H See Figure Maximum Length of Tubing H R See Figure 3 8 OD T...

Page 30: ... pressure reducing valve system will automatically fill to 12 psig 10 Open isolation valve in boiler supply piping 11 Remove hose from bib cock D CONFIRM that the boiler and system have no water 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...

Page 31: ...er gauge over the fire after chimney has reached operating temperature and while burner is running 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 minimum smoke not to exceed 1 with a mini mum of excess air Make final check using suitable Table 4A Becket AFG Burner Table 4 Beckett AFG AF SF Burners Boiler Model...

Page 32: ...adjust oil pressure If dripping or after burn persist replace fuel pump O HINTS ON COMBUSTION a 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 sa...

Page 33: ...plets 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 i HIGH ALTITUDE INSTALLATIONS Typically the rule to use for high altitudes is to increase the air supply by 4 per each 1000 ft ab...

Page 34: ...st limit to desired setting 4 CHECK LOW WATER CUTOFF if so equipped 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 d Adjust thermostat to lowest setting Refill boiler Q Boiler is now ready to be put into...

Page 35: ...ield such that clearances to combustible walls are as indicated in Figure 24 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 requiredbyANSI NFPA31 3 Fasten shield to combustible floor to keep shield from shifting position during setting of boiler 4 Set boiler squarely on top of shield such that base plate of boiler ...

Page 36: ...iod of time 1 CLEAN THE FIRETUBES a Disconnect electric to burner and remove stack 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 c Remove turbulators d Using a firetube brush clean firetubes DO NOT extend brush past the end of the bottom tubesheet e A...

Page 37: ...cated for your State Alabama A Nebraska A Oregon A Alaska A Nevada A Pennsylvania D Arizona A New Hampshire B Rhode Island B Arkansas A New Jersey South Carolina A California A Atlantic Burlington Camden D South Dakota A Colorado A Cape May Cumberland Tennessee A Connecticut B Gloucester Mercer Texas A Delaware D Monmouth Ocean Salem Utah A Florida A Counties Vermont B Georgia A All other Counties...

Page 38: ...38 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 26 RSA85 135 Bare Boiler Repair Parts REPAIR PARTS ...

Page 39: ...8 1 Heat Exchanger Assembly B 9 10 SA307B 3 8 16 x 1 1 4 Bolt 80861360 10 1 Tankless Heater Gasket 8206036 11 1 Tapped Heater Cover Plate 7036030 12 1 Tankless Heater Coil Standard S350 6036038 Tankless Heater Coil Optional S375 6036039 13 10 Washer Flat USS 3 8 80860600 14 10 Hex Nut 3 8 16 Steel Plain 80860400 15 2 1 2 Thick x 2 x 13 3 4 Cerafelt Strip 9206003 16 2 1 2 Thick x 2 x 18 1 2 Cerafel...

Page 40: ...40 Figure 27 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 ...

Page 41: ...7 7524 Tankless Heater Assembly 6036015 7530 Tankless Heater Assembly 6036016 8 Tapped Heater Cover Plate 7033501 9 Heat Exchanger Assembly B 10 x 2 x 25 Cerafelt Strip 9206003 11 x 2 x 21 Cerafelt Strip 9206003 12 Combustion Chamber 8203003 13 Block Insulation Assembly Supplied with Item 12 14 Jacket Left Side Panel Assembly 60435061 15 Jacket Upper Front Panel Assembly 60435033 16 Jacket Lower F...

Page 42: ...el RSA85 110 60435087 Jacket Wrap A Round Panel RSA125 135 60435088 3 Temperature Pressure Gauge 8056169U 4 Honeywell L8148A1090 Hi Limit Control 80160449U Honeywell L8124C1102 Limit Control 80160406 5 Observation Port Cover Hardware 8026015 6 Burner Primary Control R4184D1027 80160473 ...

Page 43: ...43 SERVICE SCHEDULE DATE SERVICE PERFORMED ...

Page 44: ... Bulkhead Fitting Locknut 3666 3666 3666 3666 9 Connector Tube Assembly 5636 5636 5636 5636 10 Coupling 2454 2454 2454 2454 11 Electrode Clamp 149 149 149 149 Electrode Clamp Screw 4219 4219 4219 4219 12 Electrode Insulator Assembly EA21502 EA21502 EA21502 EA21502 15 Spider Spacer Assembly 5653 5653 5653 5653 16 Escutcheon Plate 3493 3493 3493 3493 18 Flange and Air Tube Assembly 3146812 3146812 3...

Page 45: ...45 Ordering Information for Quality Replacement Parts Figure 29 BECKETT AFG MODEL BURNER ...

Page 46: ... 9 Connector Tube Assembly 5636 5636 5636 10 Coupling 2454 2454 2433 11 Electrode Clamp 149 149 149 Electrode Clamp Screw 4219 4219 4219 12 Electrode Insulator Assembly EA21502 EA21502 E21502 15 Spider Spacer Assembly 5653 5653 5653 16 Escutcheon Plate 3493 3493 3493 18 Flange and Air Tube Assembly 58115 58115 58115 Gasket 3616 3616 3616 19 Head 360012 360022 5434 Head Screws 4221 4221 4221 Hole P...

Page 47: ...47 Ordering Information for Quality Replacement Parts Figure 30 BECKETT AF and SF MODEL BURNERS ...

Page 48: ...48 ...

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