Burnham LEDV SERIES Installation & Service Instructions Manual Download | Manualshive

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INSTALLATION, OPERATING AND

SERVICE 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
Agency (EPA).

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

LEDV__ - _______

Boiler Serial Number

6 _ _ _ _ _ _ _

Installation Date

Heating Contractor

Phone Number

Address

1
2
3
...
»

Summary of Contents for LEDV SERIES

Page 1: ...te 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 When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number LEDV__ _______ Boiler Serial Number 6 _ _ _ _ _ _ _ Installation Date Heating Contrac...

Page 2: ...nd 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 F...

Page 3: ...nt 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...

Page 4: ...nd operations of controls and safety devices CANADIAN BOILERS A Current Edition of Canadian Standards Association CSA B139 Installation Code for Oil Burning Equipment for recommended Installation Practices This boiler is suitable for installation on combustible flooring Boiler cannot be installed on carpeting For opti mum performance a nd servi ceability from this unit adhere to the following reco...

Page 5: ...f 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 26 IX Repair Parts 29 ...

Page 6: ...ombustion of oil Local and national codes may apply and should be referenced 1 In unconfined spaces basement in buildings of conventional frame brick or stone construction infiltration normally is adequate to provide air for combustion An unconfined space is a space whose volume is greater than or equal to 50 cubic feet per 1000 BTUH of the combined input of all air consuming appliances in the spa...

Page 7: ...ion Chamber Liner see Paragraph G 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 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 he...

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

Page 9: ...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 additionalinformation 4 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 enc...

Page 10: ...Close isolation valve in boiler supply piping 2 Isolate all circuits by closing zone valves or balancing valves 3 Attach a hose to bib cock located just below isolation valve in boiler supply piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area 4 Starting with one circuit open zone valve 5 Open bib cock 6 Open fill valve Make up water line should be located di...

Page 11: ...11 Figure 6 Recommended Piping for Combination Heating Cooling Refrigeration Systems Figure 7 Recommended Boiler Piping for Zoning with Circulators ...

Page 12: ...on may be used in installations where infiltration provides adequate air for combustion and ventilation Flue gases are still vented directly outdoors through wall 3 Forminimumclearancestocombustiblematerials refer to Figure 2 4 Maximum wall thickness that vent terminal may be installed through is 10 inches 5 Vent Terminal Location see Figure 8 Locate vent terminal so vent pipe is short and direct ...

Page 13: ...tallation DirectVentandSide WallVent 1 Install Vent Terminal See Figure 10 a After determining the location from previous Section cut an opening in the wall for the vent terminal Combustible wall 8 inches diameter hole is required to maintain a 1 inch clearance to combustiblematerials Non combustible wall 6 inches diameter hole is required b Secure trim plate to outside wall c Insert the vent term...

Page 14: ...14 Figure 10 Vent Installation Figure 11 Vent Connector Un Assembled ...

Page 15: ...15 Figure 13 Air Intake Installation Figure 12 Vent Connector Assembled ...

Page 16: ...on so that connector is completely covered e Secure each end of insulation sleeve with the gear clamps provided 6 Secure vent pipe in position with pipe straps a All horizontal runs must rise at least inch per foot toward vent terminal b Avoid any sags or dips in vent pipe C Air Intake Installation Direct Vent only See Figure 13 1 General a Use 4 inch diameter single wall metal pipe and fittings a...

Page 17: ...irforCombustion 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 intakecollar 3 DiscardtheVacuumReliefValve Alternate to 1 2 and 3 Keep the black plastic inlet cover in place and discard the Air Intake Terminal and the Vacuum ReliefValve ...

Page 18: ... circuit if the boiler water temperature is below the high limit setting The high limit switch shuts off the burner if boiler water temperature exceeds the high limit setting See Figure 14 3 R8184P Oil Primary Control The R8184P operates the oil burner motor solenoid oil valve and the ignition transformer in response to a call for heat from the L8148A limit control a A call for heat will energize ...

Page 19: ...19 Figure 15 Schematic Wiring Diagram ...

Page 20: ...ition to conventional filter is highly recommended B Single pipe Oil Lines 1 Standard burners are provided with single stage 3450 rpm fuel units with the bypass plug removed for single pipe installations 2 The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet See Figure 16 Figure 16 Single Pipe Installation TABLE 2 SINGLE STAGE UNITS 345...

Page 21: ...le lift and lengths of 3 8 inch and inch OD tubing for both suction and return lines Refer to Figure 17 TABLE 3 TWO STAGE UNITS 3450 RPM TWO PIPE SYTEMS Lift H See Fig Maximum Length of Tubing H R See Figure 3 8 OD Tubing 3 GPH 1 2 OD Tubing 3 GPH 0 93 100 2 85 100 4 77 100 6 69 100 8 60 100 10 52 100 12 44 100 14 36 100 16 27 100 18 76 Figure 17 Two Pipe Installation ...

Page 22: ...ion F BURNERSTART UP 1 VERIFYburnersettings a Refer to Table 4 2 Open all shut off valves in the oil supply line to the burner 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 5 REMOVE TEST PLUG IN FLUE COLLAR 6 Close the service switch to start the burner If the burner does not start immed...

Page 23: ...The selection of the nozzle supplied with the microTEKDV 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 ...

Page 24: ...he combustion chamber and clog the flueways of the boiler h 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 in a shallow bury is a good candidate for cold o...

Page 25: ...er should start d Adjust thermostat to lowest setting Adjust 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 ...

Page 26: ...ss burner swing door is securely closed Close door install fasteners and tighten securely Door should be parallel to tubesheet when viewed from top and sides Reconnect two halves of Swing Door Interlock C Vent Air Intake System Inspect for obstructions soot accumulation proper support and deterioration of pipe fittings and joints 1 Inspect inside of vent pipe a Disconnect appliance adapter from bo...

Page 27: ...nditions warrant to flush out the sediment chamber so the device will be free to function properly b Annual Service Float type low water cutoffs should be dismantled annually by qualified personnel to the extent necessary to insure freedom from obstructions and proper functioning of the working parts Inspect connecting lines to boiler for accumulation of mud scale etc and clean as required Examine...

Page 28: ...28 Service Notes ...

Page 29: ... listed below Burnham Corporation Regional Offices A Burnham Corporation Central Western R egio ns P O Box 3079 La ncaster PA 17604 3079 Phone 717 481 8400 FAX 717 481 8408 C Burnham Corporation Metropolitan Region P O Box 3079 Lancaster PA 17604 3079 Phone 717 481 8400 FAX 717 481 8409 B Burnham Sales Corporation Northeast Region 19 27 Mystic Avenue Somerville MA 02145 Phone 617 625 9735 FAX 617 ...

Page 30: ...30 Figure 19 LEDV Boiler Trim Controls ...

Page 31: ...31 Figure 20 LEDV Boiler Jacket Insulation ...

Page 32: ...32 Figure 21 LEDV Bare Boiler Assembly ...

Page 33: ...33 Figure 22 Vent Kit Repair Parts ...

Page 34: ...ure 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 ...

Page 35: ...Electrodes Replacement Kit 51484U Escutcheon Plate 31623 Stop Screw 3166502 3166503 3166505 Fuel Line 5394 Fuel Pump Single Stage with Solenoid Valve 21757 Fuel Pump Two Stage with Solenoid Valve 2583 Gasket Flange 31658 Head Assembly AFII 6 Slot 51671 51672 Hole Plug 2139 Inlet Air Scoop 51485 Splined Nut 3666 Main Housing Assembly 51584 51476 Motor 21444 Nozzle Adapter 213 Nozzle Line Heater 516...

Page 36: ...36 ...

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