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IN S TAL L AT ION , OP E R AT IN G AN D

S E R V IC E IN S T R U C T ION S F OR
C 3 & C 4 S E R I E S PAC K AG E D
O I L - F I R E D BO I L E R

F o r s e rvi c e o r re p a i r s to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r. W he n s e e k i ng i nfo r ma ti o n o n


b o i le r, p ro vi d e B o i le r Mo d e l Numb e r a nd S e r i a l Numb e r a s s ho wn o n Ra ti ng L a b e l.
B o i le r Mo d e l Numb e r B o i le r S e r i a l Numb e r Ins ta lla ti o n D a te

P C _ W _ -_ _ _ _ _ 6_ _ _ _ _ _ _
He a ti ng C o ntra c to r P ho ne Numb e r

A d d re s s

8142768R6-3/07 Price - $3.00


IMPORTANT INFORMATION - READ CAREFULLY

All b o ile rs mu s t b e in s ta lle d in a c c o rd a n c e w ith N a tio n a l, S ta te a n d L o c a l P lu mb in g ,


H e a tin g a n d E le c tric a l C o d e s a n d th e re g u la tio n s o f th e s e rv in g u tilitie s . T h e s e C o d e s
a n d R e g u la tio n s ma y d iffe r fro m th is in s tru c tio n ma n u a l. Au th o ritie s h a v in g
ju ris d ic tio n s h o u ld b e c o n s u lte d b e fo re in s ta lla tio n s a re ma d e .
In a ll c a s e s , r e f e r e n c e s h o u ld b e m a d e t o t h e fo llo w in g S t a n d a r d s :
A. C u rre n t E d itio n o f Ame ric a n N a tio n a l S ta n d a rd AN S I/N F PA 3 1 , “In s ta lla tio n o f Oil
B u rn in g E q u ip me n t” , fo r re c o mme n d e d in s ta lla tio n p ra c tic e s .
B . C u r r e n t E d i t i o n o f A m e r i c a n N a t i o n a l S t a n d a r d A N S I / N F P A 2 11 , “ C h i m n e y s ,
F ire p la c e s , Ve n ts , a n d S o lid F u e l B u rn in g Ap p lia n c e s ”, F o r Ve n tin g re q u ire me n ts .
C. C u r r e n t E d it io n o f Am e r ic a n S o c ie t y o f Me c h a n ic a l E n g i n e e r s AS M E C S D - 1 ,
" C o n t r o l s a n d S a f e t y D e v i c e s f o r Au t o m a t i c a l l y F i r e d B o i l e r s " , f o r a s s e m b l y a n d
o p e r a tio n s o f c o n tr o ls a n d s a fe t y d e v ic e s .
D . All w irin g o n b o ile rs in s ta lle d in th e U S A s h a ll b e ma d e in a c c o rd a n c e w ith th e
N a tio n a l E le c tric a l C o d e a n d /o r L o c a l R e g u la tio n s .

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 CAUTION
In d ic a t e s a n im m in e n t ly h a z a r d o u s In d ic a t e s a p o t e n t ia lly h a z a r d o u s
s it u a t io n w h ic h , if n o t a v o id e d , w ill r e s u lt s it u a t io n w h ic h , if n o t a v o id e d , m a y r e s u lt
in d e a t h , s e r io u s in ju r y o r s u b s t a n t ia l in m o d e r a t e o r m in o r in ju r y o r p r o p e r t y
p ro p e rty d a ma g e . d a ma g e .

WARNING NOTICE
In d ic a t e s a p o t e n t ia lly h a z a r d o u s In d ic a t e s s p e c ia l in s t r u c t io n s o n
s it u a t io n w h ic h , if n o t a v o id e d , c o u ld in s t a lla t io n , o p e r a t io n , o r m a in t e n a n c e
r e s u lt in d e a t h , s e r io u s in ju r y o r w h ic h a r e im p o r t a n t b u t n o t r e la t e d t o
s u b s t a n t ia l p r o p e r t y d a m a g e . p e r s o n a l in ju r y h a z a r d s .

NOTIC E
T h is b o ile r h a s a limite d w a rra n ty, a c o p y o f w h ic h is p rin te d o n th e b a c k o f th is ma n u a l.
T h e w a rra n ty fo r th is b o ile r is v a lid o n ly if th e b o ile r h a s b e e n in s ta lle d , ma in ta in e d a n d o p e ra te d in
a c c o rd a n c e w ith th e s e in s tru c tio n s .


D AN GER
D O N OT s t o r e o r u s e g a s o li n e o r o t h e r fl a m m a b le v a p o r s o r li q u id s in t h e v ic in i ty o f t h is o r
a n y o t h e r a p p lia n c e .

WAR N IN G
Im p r o p e r i n s t a ll a t io n , a d j u s t m e n t , a l te r a t io n , s e r v ic e o r m a in t e n a n c e c a n c a u s e p r o p e r t y
d a m a g e , p e r s o n a l in ju r y o r lo s s o f li fe . F a i lu r e to f o ll o w a ll in s t r u c t io n s in t h e p r o p e r
o r d e r c a n c a u s e p e r s o n a l i n ju r y o r d e a t h . R e a d a n d u n d e r s t a n d a l l in s tr u c ti o n s ,
in c lu d i n g a l l th o s e c o n ta in e d in c o m p o n e n t m a n u fa c tu r e r s m a n u a ls w h ic h a r e p r o v i d e d
w it h th e a p p lia n c e b e f o r e i n s ta ll in g , s t a r ti n g - u p , o p e r a t in g , m a in t a in i n g o r s e r v ic in g t h is
a p p lia n c e . K e e p t h i s m a n u a l a n d li te r a t u r e i n le g ib l e c o n d it io n a n d p o s t e d n e a r
a p p lia n c e f o r r e fe r e n c e b y o w n e r a n d s e r v ic e t e c h n ic ia n .
T h i s b o i le r r e q u ir e s r e g u la r m a i n t e n a n c e a n d s e r v ic e t o o p e r a t e s a f e ly. F o ll o w t h e
in s t r u c ti o n s c o n t a in e d in t h is m a n u a l.
In s t a l la ti o n , m a i n t e n a n c e , a n d s e r v ic e m u s t b e p e r f o r m e d o n ly b y a n e x p e r i e n c e d ,
s k il le d a n d k n o w l e d g e a b l e in s t a l le r o r s e r v ic e a g e n c y.
All h e a ti n g s y s t e m s s h o u l d b e d e s ig n e d b y c o m p e te n t c o n tr a c t o r s a n d o n l y p e r s o n s
k n o w le d g e a b le in th e la y o u t a n d in s t a ll a t i o n o f h y d r o n i c h e a t in g s y s t e m s s h o u l d
a t t e m p t in s t a lla t io n o f a n y b o ile r.
In s t a l la ti o n is n o t c o m p le t e u n l e s s a p r e s s u r e r e li e f v a lv e i s in s t a l le d in t o th e t a p p i n g
lo c a t e d o n to p l e f t c o r n e r o f fr o n t s e c t i o n - S e e In s t a l la t io n In s t r u c t io n s S e c ti o n o f t h is
m a n u a l f o r d e ta il s .
It i s t h e r e s p o n s ib ili ty o f t h e i n s t a lli n g c o n tr a c t o r t o s e e t h a t a ll c o n t r o ls a r e c o r r e c t ly
in s t a l le d a n d a r e o p e r a t in g p r o p e r ly w h e n t h e in s t a ll a t i o n i s c o m p le t e d .
T h i s b o i le r is s u it a b le fo r i n s ta ll a t io n o n c o m b u s t ib l e f lo o r i n g . D o n o t in s t a ll b o i le r o n
c a r p e t in g .
D o n o t t a m p e r w it h o r a l te r t h e b o ile r o r c o n t r o ls .
In s p e c t fl u e w a y s a t le a s t o n c e a y e a r - p r e f e r a b ly a t t h e s t a r t o f th e h e a t in g s e a s o n .
T h e in s id e o f t h e c o m b u s t io n c h a m b e r, t h e v e n t s y s t e m a n d b o i le r fl u e w a y s s h o u ld b e
c l e a n e d if s o o t o r s c a le h a s a c c u m u la t e d .
W h e n c le a n in g t h is b o il e r, d o n o t d a m a g e c o m b u s t io n c h a m b e r l in e r a n d /o r r e a r ta r g e t
w a l l. If d a m a g e d , c o m b u s t io n c h a m b e r in s u la t io n m u s t b e r e p la c e d im m e d ia t e ly.
Oil B u r n e r a n d C o n t r o l s m u s t b e c h e c k e d a t le a s t o n c e a y e a r o r a s m a y b e
n e c e s s i ta t e d .
D o n o t o p e r a t e u n i t w it h j u m p e r e d o r a b s e n t c o n t r o l s o r s a f e t y d e v i c e s .
D o n o t o p e r a t e u n i t if a n y c o n tr o l, s w i tc h , c o m p o n e n t , o r d e v ic e h a s b e e n s u b j e c t to
w a t e r.
Ap p li a n c e m a t e r ia ls o f c o n s tr u c ti o n , p r o d u c t s o f c o m b u s t io n a n d t h e fu e l c o n t a i n
a l u m in a , s ili c a , h e a v y m e t a l s , c a r b o n m o n o x id e , n i tr o g e n o x id e s , a ld e h y d e s a n d /o r
o t h e r t o x ic o r h a r m fu l s u b s t a n c e s w h ic h c a n c a u s e d e a t h o r s e r i o u s in ju r y a n d w h ic h
a r e k n o w n t o th e s ta t e o f C a li fo r n ia to c a u s e c a n c e r, b i r t h d e f e c ts a n d o t h e r
r e p r o d u c t i v e h a r m . Al w a y s u s e p r o p e r s a f e t y c l o t h i n g , r e s p i r a t o r s a n d e q u i p m e n t
w h e n s e r v ic in g o r w o r k i n g n e a r b y t h e a p p li a n c e .


WAR N IN G
T h is b o il e r c o n t a in s v e r y h o t w a t e r u n d e r h ig h p r e s s u r e . D o n o t u n s c r e w a n y p i p e
f it ti n g s n o r a t t e m p t t o d is c o n n e c t a n y c o m p o n e n ts o f t h is b o il e r w it h o u t p o s it iv e l y
a s s u r in g t h e w a t e r is c o o l a n d h a s n o p r e s s u r e . Alw a y s w e a r p r o t e c ti v e c l o t h in g a n d
e q u i p m e n t w h e n in s t a lli n g , s ta r t in g u p o r s e r v ic in g t h is b o ile r t o p r e v e n t s c a ld in ju r ie s .
D o n o t r e ly o n t h e p r e s s u r e a n d t e m p e r a tu r e g a u g e s t o d e te r m i n e t h e t e m p e r a tu r e a n d
p r e s s u r e o f t h e b o ile r. T h i s b o i le r c o n ta in s c o m p o n e n t s w h ic h b e c o m e v e r y h o t w h e n
t h e b o i le r is o p e r a t in g . D o n o t to u c h a n y c o m p o n e n t s u n le s s th e y a r e c o o l.
H i g h w a t e r t e m p e r a t u r e s in c r e a s e t h e r is k o f s c a ld i n g i n ju r y. I f t h is b o ile r is e q u ip p e d
w i th a t a n k le s s h e a t e r fo r d o m e s t ic w a te r s u p p ly, a fl o w r e g u la t o r a n d a u t o m a ti c m i x in g
v a lv e m u s t b e in s t a lle d p r o p e r ly in t a n k l e s s h e a t e r p i p in g . S e e In s t a l la ti o n In s t r u c ti o n s
S e c t io n o f t h is m a n u a l f o r d e t a il s .
T h is a p p lia n c e m u s t b e p r o p e r ly v e n t e d a n d c o n n e c t e d t o a n a p p r o v e d v e n t s y s t e m i n
g o o d c o n d it io n . D o n o t o p e r a t e b o ile r w i t h t h e a b s e n c e o f a n a p p r o v e d v e n t s y s t e m .
T h is b o il e r n e e d s f r e s h a ir f o r s a f e o p e r a t io n a n d m u s t b e in s ta ll e d s o th e r e a r e
p r o v i s io n s fo r a d e q u a te c o m b u s ti o n a n d v e n ti la ti o n a i r.
A c l e a n a n d u n o b s t r u c t e d c h i m n e y fl u e i s n e c e s s a r y t o a ll o w n o x io u s fu m e s th a t c o u l d
c a u s e in j u r y o r l o s s o f li fe t o v e n t s a fe ly a n d w i ll c o n t r ib u te t o w a r d m a in t a i n in g t h e
b o ile r ' s e ff ic ie n c y.
T h is b o il e r i s s u p p li e d w it h c o n tr o ls w h ic h m a y c a u s e t h e b o ile r t o s h u t d o w n a n d n o t
r e - s t a r t w i th o u t s e r v ic e . If d a m a g e d u e t o fr o z e n p ip e s i s a p o s s ib ili ty, t h e h e a t in g
s y s t e m s h o u ld n o t b e le ft u n a t te n d e d in c o ld w e a th e r ; o r a p p r o p r ia t e s a fe g u a r d s a n d
a la r m s s h o u ld b e i n s t a lle d o n t h e h e a ti n g s y s te m to p r e v e n t d a m a g e if th e b o i le r i s
i n o p e r a ti v e .
T h is b o il e r i s d e s ig n e d to b u r n N o . 2 f u e l o i l o n ly. D o n o t u s e g a s o l in e , c r a n k c a s e
d r a i n in g s , o r a n y o i l c o n ta in i n g g a s o l in e . N e v e r b u r n g a r b a g e o r p a p e r in th is b o i le r.
D o n o t c o n v e r t t o a n y s o li d fu e l ( i.e . w o o d , c o a l) . D o n o t c o n v e r t t o a n y g a s e o u s f u e l
( i. e . n a t u r a l g a s , L P ) . All f la m m a b le d e b r is , r a g s , p a p e r, w o o d s c r a p s , e t c ., s h o u ld b e
k e p t c le a r o f t h e b o i le r a t a l l ti m e s . K e e p t h e b o ile r a r e a c l e a n a n d f r e e o f fi r e h a z a r d s .
Al l b o i l e r s e q u i p p e d w i t h b u r n e r s w i n g d o o r h a v e a p o t e n t i a l h a z a r d w h i c h i f i g n o r e d
c a n c a u s e s e v e r e p r o p e r t y d a m a g e , p e r s o n a l in j u r y o r l o s s o f l if e . B e fo r e o p e n in g
s w in g d o o r, t u r n o f f s e r v i c e s w it c h t o b o i le r to p r e v e n t a c c id e n t a l fi r in g o f b u r n e r
o u ts id e t h e c o m b u s t io n c h a m b e r. B e s u r e to t ig h t e n s w in g d o o r f a s t e n e r c o m p le t e l y
w h e n s e r v i c e is c o m p l e t e d .

I M P O R TA N T
B e fo r e s ta r tin g to in s ta ll th is o il b o ile r, r e a d th e s e in s tr u c tio n s c a r e fu lly. K e e p in s tr u c tio n s in
le g ib le c o n d it io n a n d p o s t e d n e a r o il b o ile r fo r r e fe r e n c e b y o w n e r a n d s e r v ic e t e c h n ic ia n .

Table of Contents
I. General Information.........................5 IV. Boiler Cleaning.................................21
II. Installation Instructions....................8 V. Repair Part........................................24
III. Operating and Service VI. Appendix
Instructions......................................15 Low Water Cut Off............................34


Section I: General Information

Mi ni mum A p p ro xi ma te
B o i le r D i me ns i o ns Wa te r C o nte nt -
C hi mne y S hi p p i ng We i g ht
Mo d e l Ga llo ns
S i ze ( L B .)
Figure 1A: Less Tankless Heater "A" "B"
C3 16" 8-3/4" 8" x 8" x 15' 13.5 525

C4 20" 10-3/4" 8" x 8" x 15' 15.9 580

NOTE: Maxi mum Allowable Working Pressure: 30 PSI

Table 1A: Dimensional Data



Mi ni mum A p p ro xi ma te
B o i le r D i me ns i o ns Wa te r C o nte nt -
C hi mne y S hi p p i ng We i g ht
Figure 1B: With Tankless Heater Mo d e l Ga llo ns
S i ze ( L B .)
"A" "B"
C3 16" 8-3/4" 8" x 8" x 15' 13.5 525

C4 20" 10-3/4" 8" x 8" x 15' 15.9 580

NOTE: Maxi mum Allowable Working Pressure: 30 PSI

Table 1B: Dimensional Data


A. INSPECT SHIPMENT carefully for any signs of 2. FOR BASEMENT INSTALLATION, provide a
damage. solid base, such as concrete, if floor is not level, or if
water may be encountered on floor around boiler.
1. ALL EQUIPMENT is carefully manufactured, 3. PROVIDE SERVICE CLEARANCE of at least 24”
inspected and packed. Our responsibility ceases on right side of boiler for removal of rear tankless
upon delivery of crated boiler to the carrier in good heater. Provide at least 24” clearance from front
condition. jacket panel for servicing . Provide at least 24"
2. ANY CLAIMS for damage or shortage in shipment clearance from right side of boiler or top of boiler
must be filed immediately against the carrier by the for cleaning flueways. Boiler flueways may be
consignee. No claims for variances from, or shortage cleaned either from the top or from the side.
in orders, will be allowed by the manufacturer 4. For minimum clearances to combustible materials.
unless presented within sixty (60) days after receipt See Table 2.
of goods.
C. PROVIDE AIR SUPPLY AND VENTILATION to
B. LOCATE BOILER in front of final position before accommodate proper combustion. If natural ventilation
removing crate. See Figures 1A and 1B. is inadequate, provide a screened opening or duct from
1. LOCATE so that smoke pipe connection to chimney the boiler room to the outside. The opening or duct
will be short and direct. BOILER IS SUITABLE must be sized so the boiler input will not exceed 4,000
FOR INSTALLATION ON COMBUSTIBLE BTUH/Sq. In. of free area. If other air consuming
FLOOR. Boiler cannot be installed on carpeting. appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.

Table 2: Minimum Installation Clearances NOTE 1: Listed clearances comply with American
To Combustible Materials (Inches) National Standard ANSI/NFPA 31, Installation of Oil
Burning Equipment.

NOTE 2: C3 & C4 Series boilers can be installed in


rooms with clearances from combustible material as
C listed above. Listed clearances cannot be reduced for
A B Chimney D E alcove or closet installations.
Above Front C onnector Rear S i des
NOTE 3: For reduced clearances to combustible
6 24 18 6 6 material, protection must be provided as described in
the above ANSI/NFPA 31 standard.


SECTION II: INSTALLATION INSTRUCTIONS
A. REMOVE CRATE 3. Install Safety Valve in ¾" Tapping on top of the
1. Remove all fasteners at crate skid. Front Section. Use ¾ NPT x 8" nipple and ¾ NPT
coupling included in trim bag. Safety Valve must be
2. Lift outside container and remove all other inside
installed with spindle in vertical position.
protective spacers and bracing. Remove draft
regulator box and miscellaneous trim bag containing 4. If this boiler is used in connection with refrigeration
safety/relief valve, and pipe fittings. systems, the boiler must be installed so that the
chilled medium is piped in parallel with the heating
B. REMOVAL OF BOILER FROM SKID
boiler using appropriate valves to prevent the chilled
1. Boiler is secured to base with 4 bolts, 2 on left side medium from entering the boiler, see Figure 4. Also
and 2 on right side, see Figure 2. Remove all bolts. consult I=B=R Installation and Piping Guides.
2. Tilt boiler to right and to rear. Using right rear leg
5. If this boiler is connected to heating coils located
as pivot, rotate boiler 90° in a clockwise direction,
in air handling units where they may be exposed
and lower left side of boiler to floor. Tilt boiler
to refrigerated air, the boiler piping must be
and remove crate skid. Care should be exercised to
equipped with flow control valves to prevent gravity
prevent damage to jacket or burner.
circulation of boiler water during the operation of
the cooling system.
6. Use a boiler 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 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 supply outlet as illustrated in Figures 3a and 3b
in order to regulate water flow for maintenance of
higher boiler water temperature.
Set the by-pass and boiler supply valves to a half
throttle position to start. Operate boiler until the
system water temperature reaches its normal
Figure 2: Burner Mounting
operating range.
C. MOVE BOILER TO PERMANENT POSITION by Adjust the valves to maintain 180°F boiler water
sliding or walking. temperature. Adjust both valves simultaneously.
Closing the boiler supply valve and opening the
D. INSPECT COMBUSTION TARGET WALL AND
by-pass valve will raise the boiler water temperature
COMBUSTION CHAMBER LINER
and lower the supply temperature. Opening the
1. OPEN FLAME OBSERVATION DOOR AND/ boiler supply valve while closing the by-pass valve
OR BURNER SWING DOOR on front of boiler. will lower the boiler water temperature and raise the
Use flashlight to inspect target wall secured to supply temperature.
rear section with silastic sealant. Inspect ceramic
7. A hot water boiler installed above radiation level
fiber blanket secured to floor of boiler with water
must be provided with a low water cutoff device as
glass adhesive. If either is damaged they must be
part of the installation.
replaced.
If a low water cut-off is required, it must be
E. CONNECT SUPPLY AND RETURN PIPING TO
mounted in the system piping above the boiler. The
HEATING SYSTEM.
minimum safe water level of a hot water boiler is
1. Hot water pipes shall have clearances of at least ½” just above the highest water containing cavity of
from all combustible construction. the boiler; that is, a hot water boiler must be full of
2. With Forced Circulation HOT WATER HEATING, water to operate safely.
see Figures 3a and 3b. Consult I=B=R Installation
and Piping Guide No. 200.


Figure 3a: Recommended Water Piping for Circulator Zoned Heating Systems

Figure 3b: Recommended Water Piping for Zone Valve Zoned Heating Systems

THE FOLLOWING GUIDELINES SHOULD BE FOL-
LOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOW REGULATION — If flow through the heater
is greater than its rating, the supply of adequate hot
water may not be able to keep up with the demand.
For this reason a flow regulator matching the heater
rating should be installed in the cold water line to
the heater. The flow regulator should preferably be
located below the inlet to the heater and a minimum
TS-O-62-B of 3’ away from the inlet so that the regulator is not
subjected to excess temperatures that may occur
during “off” periods when it is possible for heat
to be conducted back through the supply line. The
flow regulator also limits the flow of supply water
regardless of inlet pressure variations in the range of
20 to 125 psi.
Figure 4: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems

C AU T ION
Ox y g e n c o n t a m in a t io n o f b o ile r w a t e r w ill
c a u s e c o r r o s io n o f ir o n a n d s t e e l b o ile r
c o m p o n e n t s , a n d c a n le a d t o b o ile r fa ilu r e .
B u rn h a m' s s ta n d a rd w a rra n ty d o e s n o t
c o v e r p r o b le m s c a u s e d b y o x y g e n
c o n ta m in a tio n o f b o ile r w a te r.

There are many possible causes of oxygen contamina- Figure 6: Schematic Tankless Heater Piping
tion such as:
1. Addition of excessive make-up water as a result of 2. TEMPERING OF HOT WATER — Installation
system leaks. of an automatic mixing valve will lengthen the
2. Absorption through open tanks and fittings. delivery of the available hot water by mixing some
cold water with the hot. This prevents excessive
3. Oxygen permeable materials in the distribution system.
and possibly scalding hot water at the fixtures. In
In order to insure long product life, oxygen sources addition, savings of hot water will be achieved since
should be eliminated. This can be accomplished by taking the user will not waste as much hot water while
the following measures: seeking water temperature to his liking. Higher
1. Repairing system leaks to eliminate the need for addi- temperature hot water required by dishwashers and
tion of make-up water. automatic washers is possible by piping the hot
2. Eliminating open tanks from the system. water from the heater prior to entering the mixing
valve. The mixing valve should be “trapped” by
3. Eliminating and/or repairing fittings which allow oxy- installing it below the cold water inlet to heater to
gen absorption. prevent lime formation in the valve.
4. Use of non-permeable materials in the distribution
system. Table 3: TANKLESS HEATER DATA:
5. Isolating the boiler from the system water by installing
He a te r P re ssure D ro p
a heat exchanger. B o i le r He a te r
Ra ti ng thru He a te r
Mo d e l No .
F. CONNECT TANKLESS HEATER PIPING AS ( GP M ) (P S I)
SHOWN IN Figure 6. See Table 3 for Tankless Heater
C3 V 1 -2 3 .2 5 5 .6
Ratings.
C4 V 1 -1 3 .5 4 .4

10
WAR N IN G
In s ta ll a u to m a t ic m ix in g v a lv e a t ta n k le s s
h e a te r o u tl e t to a v o id r is k o f b u r n s o r
s c a ld in g d u e to e x c e s s iv e ly h o t w a t e r a t
fi x tu r e s . Ad ju s t a n d m a in t a in th e m ix in g
v a l v e in a c c o r d a n c e w ith t h e m a n u fa c t u r e r ' s
in s tr u c tio n s . D o n o t o p e r a te ta n k le s s
h e a te r w i th o u t m ix in g v a lv e .

3. FLUSHING OF HEATER — All water contains


some sediment which settles on the inside of the
coil. Consequently, the heater should be periodically
backwashed. This is accomplished by installing
hose bibs as illustrated and allowing water at city
pressure to run into hose bib A, through the heater,
and out hose bib B until the discharge is clear. The
tees in which the hose bibs are located should be
the same size as heater connections to minimize Figure 7: Recommended Smokepipe Arrangement
pressure drop. and Chimney Requirements
4. HARD WATER — A water analysis is necessary to
determine the hardness of your potable water. This
is applicable to some city water and particularly to
well water. An appropriate water softener should
be installed based on the analysis and dealer’s
recommendation. This is not only beneficial to the
tankless heater but to piping and fixtures plus the
many other benefits derived from soft water.
5. If it is required to perform a long term pressure test
of the hydronic system, the boiler should first be
isolated to avoid a pressure loss due to the escape of
air trapped in the boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must first be removed from
the boiler.
A loss of pressure during such a test, with no visible Figure 8: Proper and Improper Locations
water leakage, is an indication that the boiler of Draft Regulator
contained trapped air.
coal fired or an inefficient oil fired boiler built into
G. INSTALL SMOKEPIPE — The C3 & C4 Series boiler a home without insulation or storm windows. With
should be vented into a fireclay tile-lined masonry increasing fuel prices that home probably has been
chimney or chimney constructed from type L vent or insulated and fitted with storm windows so that
a factory built chimney that complies with the type the heat loss of the home has been reduced. This
HT requirements of UL103. The chimney and vent requires less fuel to be burned and sends less heat up
pipe shall have a sufficient draft at all times, to assure the chimney.
safe proper operation of the boiler. See Figure 7 for
recommended installation. A new boiler probably has a higher efficiency than
the boiler being replaced. That probably means that
1. Install a draft regulator (supplied with boiler) the stack temperature from the new boiler will be
following the instructions furnished with the lower than that from the old boiler and with less
regulator. See Figure 8 for alternate draft regulator room air being drawn up the chimney to dilute the
locations. stack gases. The combination of a large uninsulated
2. Consider the chimney overall. Chimneys that have chimney, reduced firing rate, reduced firing time,
a high heat loss may become less suitable as the lower stack temperature and less dilution air can,
heat loss of the home goes down and the efficiency in some cases, contribute to the condensing of
of the boiler installed goes up. Most homes have small amounts of water vapor in the chimney. Such
a chimney appropriate for the fuel and the era in condensation, when it occurs, can cause chimney
which the home was built. That may have been a deterioration. In extreme cases, condensed water

11
may be visible on the outside of the breeching or I. FUEL UNITS AND OIL LINES
chimney. In those extreme cases, the chimney may SINGLE-PIPE OIL LINES ­ Standard burners are
have to be lined to insulate the chimney and thus provided with single-stage 3450 rpm fuel units with the
prevent the condensation. The addition of dilution by-pass plug removed for single-pipe installations.
air into the chimney may assist in drying the
The single-stage fuel unit may be installed single-pipe
chimney interior surfaces.
with gravity feed or lift. Maximum allowable lift is 8
A massive chimney on a cold, or exposed outside feet. See Figure 9.
wall may have produced adequate draft when it
was fired with a higher input and greater volumes
of heated gases. With reduced input and volume, I M P O R TA N T
the draft may be severely affected. In one instance S in g le - p ip e in s t a lla t io n s m u s t b e a b s o lu t e ly
our research showed a new chimney of adequate a ir t ig h t o r le a k s o r lo s s o f p r im e m a y r e s u lt .
sizing produced only ­.035" W.C. after 30 minutes B le e d lin e a n d fu e l u n it c o m p le te ly.
of continuous firing at 13.0% CO2. Outside wall
chimneys take longer to heat up and can have .00" TWO-PIPE OIL LINES ­ For two-pipe systems
W.C. draft at burner startup. You may have to where more lift is required, the two-stage fuel unit is
consider a special alloy chimney flue liner with recommended. Table 4 (single-stage) and Table 5 (two-
insulation around it and a stabilizing draft cap or stage) show allowable lift and lengths of 3/8-inch and
even a draft inducing fan in severe cases. 1/2-inch OD tubing for both suction and return lines.
3. For the same reasons as in (2.) above, heat extractors Refer to Figure 10.
mounted into the breeching are not recommended. Be sure that all oil line connections are absolutely
H. INSTALL ELECTRIC WIRING in accordance with airtight. Check all connections and joints. Flared
National Electrical Code and local regulations. A fittings are recommended. Do not use compression
separate electrical circuit must be run from the main fittings or PTFE ("Teflon®") tape.
electrical service with an over-current device/disconnect Open the air-bleed valve and start the burner. For clean
in the circuit. A service switch is recommended and bleed, slip a 3/16" ID hose over the end of the bleed
may be required by some local jurisdictions. Wiring valve and bleed into a container. Continue to bleed for
should conform to Figure 11 or 12. 15 seconds after oil is free of air bubbles. Stop burner
and close valve.

Figure 9 Figure 10

12
Table 4: Single-Stage Units (3450 RPM) - Table 5: Two-Stage Units (3450 RPM) -
Two-Pipe Systems Two-Pipe Systems

Ma xi mum L e ng th o f Tub i ng Ma xi mum L e ng th o f Tub i ng


L i ft " H" " H" + " R" (S e e F i g ure 2 5 ) L i ft " H" " H" + " R" (S e e F i g ure 2 5 )
(S e e F i g . 2 5 ) 3 /8 " OD 1 /2 " OD (S e e F i g . 2 5 ) 3 /8 " OD 1 /2 " OD
Tub i ng (3 GP H) Tub i ng (3 GP H) Tub i ng (3 GP H) Tub i ng (3 GP H)
0' 8 4' 10 0 ' 0' 9 3' 1 00 '
1' 78 ' 10 0 ' 2' 8 5' 1 00 '
2' 73 ' 10 0 ' 4' 7 7' 1 00 '
3' 68 ' 10 0 ' 6' 6 9' 1 00 '
4' 63 ' 10 0 ' 8' 6 0' 1 00 '
5' 57 ' 10 0 ' 1 0' 5 2' 1 00 '
6' 52 ' 10 0 ' 1 2' 44 ' 1 00 '
7' 47 ' 10 0 ' 1 4' 3 6' 1 00 '
8' 42 ' 10 0 ' 1 6' 2 7' 1 00 '
9' 36 ' 10 0 ' 1 8' - -- 7 6'
1 0' 3 1' 10 0 '
11 ' 26 ' 10 0 '
1 2' 2 1' 83 '
1 3' --- 62 '
1 4' --- 41 '

13
Figure 11: Wiring Diagram without Tankless Heater
SEQUENCE OF OPERATION
A call for heat by the thermostat energizes the L7248C control which in turn energizes the R7184B primary control. The burner will initiate ignition after com-
pleting a 10 second pre-purge cycle. If burner ignites within approximately 45 seconds and the cad cell sees flame, the burner will continue to operate until
the call for heat is satisfied or the setting of the high limit is reached. The circulator will operate as long as the thermostat is calling for heat. If the thermostat
is not satisfied and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high limit is closed by a drop in boiler
water temperature.

Figure 12: Wiring Diagram with Tankless Heater


SEQUENCE OF OPERATION
A call for heat by the thermostat energizes the L7224C control which in turn energizes the R7184B primary control. The burner will initiate ignition after
completing a 10 second pre-purge cycle. If burner ignites within approximately 45 seconds and the cad cell sees flame the burner will continue to operate
until the call for heat is satisfied. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the
low limit in the L7224C control. If boiler water temperature is below the low limit setting the burner will operate but the circulator will not, giving preference to
the domestic hot water demand.
On call for heat by the thermostat the burner will continue to operate until the thermostat is satisfied or the setting of the high limit is reached. If the thermostat
is not satisfied when the high limit is reached the burner will stop but the circulator will continue to operate until the thermostat is satisfied. Any time the boiler
water temperature drops below the setting of the low limit the burner will be energized in order to maintain domestic water temperature.
14
Section III: Operating and Service Instructions

WAR N IN G
All b o ile r s e q u ip p e d w ith b u r n e r s w in g d o o r h a v e a p o te n t ia l h a z a r d w h ic h c a n c a u s e s e v e r e
p r o p e r ty d a m a g e , p e r s o n a l in ju r y o r lo s s o f li fe if ig n o r e d . B e f o r e o p e n in g s w in g d o o r, tu r n o ff
s e r v ic e s w i tc h t o b o ile r to p r e v e n t a c c i d e n t a l fir in g o f b u r n e r o u ts id e th e c o m b u s tio n c h a m b e r.
B e s u r e t o tig h te n s w in g d o o r fa s te n e r c o m p le te ly w h e n s e r v ic e is c o m p le t e d .

A. ALWAYS INSPECT INSTALLATION BEFORE C. CHECK CONTROLS, WIRING AND BURNER to be


STARTING BURNER. sure that all connections are tight and burner is rigid,
that all electrical connections have been completed and
B. FILL HEATING SYSTEM WITH WATER.
fuses installed, and that oil tank is filled and oil lines
NOTE: It is important to properly remove the oil and have been tested.
dirt from the system. Failure to clean the system can
D. LUBRICATION — Follow instruction on burner and
result in erratic water lines and surging.
circulator label to lubricate, if oil lubricated. Most
1. CLEAN HEATING SYSTEM IF boiler water or motors currently used on residential type burners
condensate return water is dirty or if erratic water employ permanently lubricated bearings and thus do
lines or surging exist after a few days of boiler not require any field lubrication. Water lubricated
operation. circulators do not need field lubrication.
Refer to step "N" for proper cleaning instructions for Do not over-lubricate. This can cause as much trouble
steam and water boilers. as no lubrication at all.
2. Fill entire heating system with water and E. Adjust control settings with burner
vent air from system. Use the following procedure service switch turned “ON” and room thermostat set
on a series loop or multi-zoned system installed 10° below room temperature.
as per Figure 3, to remove air from system when
1. Adjustment and display modes of the L7248/
filling:
L7224 Oil Electronic Aquastat Controller.
a. Close isolation valve in boiler supply piping.
a. On the L7248/L7224, the overall range of the
b. Isolate all circuits by closing zone valves or
High Limit is from 180°F to 240°F (82°C to
balancing valves.
116°C).
c. Attach a hose to hose bib located just below
isolation valve in boiler supply piping. b. Set the High Limit (designated HL) on the
L7248/L7224 Aquastat Control at 180°F. This
(Note - Terminate hose in five gallon bucket at a
temperature setting may be varied to suit
suitable floor drain or outdoor area).
requirements of installation. Differential is fixed
d. Starting with one circuit, open zone valve. at 15°F.
e. Open hose bib. i. Adjusting Settings:
f. Open fill valve (make-up water line should be To discourage unauthorized changing of
located directly above isolation valve in boiler Aquastat settings, a procedure to enter the
supply piping). adjustment mode is required. To enter the
g. Allow water to overflow from bucket until adjustment mode, press the UP, DOWN,
discharge from hose is bubble free for 30 and I buttons (see Figure S1) simultaneously
seconds. for three (3) seconds. Press the ‘I’ button
h. Open zone valve to the second zone to be until the feature requiring adjustment is
purged, then close the first. Repeat this step until displayed (press the “I” button again and
all zones have been purged, but always have one will display LL (Low Limit on L7224):
zone open. At completion, open all zone valves.
· High Limit
i. Close hose bib, continue filling the system until
the pressure gauge reads 12 psi. Close fill valve. · °F -- °C (Toggle)
(Note - If make-up water line is equipped Then press the UP and/or DOWN buttons
with pressure reducing valve, system will to move the set point to the desired value.
automatically fill to 12 psi. Leave globe valve After 60 seconds without any button inputs,
open). the control will automatically return to the
j. Open isolation valve in boiler supply piping. READ mode.
k. Remove hose from hose bib.
15
c. Error: The controller has detected an error
condition (e.g., open sensor) and has shut down
the burner output. The controller continues to
monitor the system and automatically restarts if
the error condition clears. See Table S1.
d. Low-Limit: Boiler temperature has gone
below the low limit setting (minus the low limit
differential) and has not gone above the low limit
setting.
Table S1: LEd error codes

E rro r
C a us e /A c ti o n
Code
Figure S1: L7248 Circuit Board Layout -
Horizontal Mount E rr1 S e nso r fa ult; che ck se nso r.

ii. Display: E rr2 E C OM fa ult; chec k E nvi raC OM™ wi ri ng .


In the RUN mode, the Aquastat will
E rr3 Ha rdware fa ult; rep la ce contro l.
flash “bt” (boiler temp.) followed by the
temperature (i.e., 220), followed by °F or
e. The operating sequence for L7248/L7224 is
°C.
described below and shown in Table S2.
To read boiler settings, press the ‘I’ key to
read the parameter of interest. For example, Table S2: L7248/L7224 Controller
press I (HL) High Limit is displayed, Operating Sequence
followed by a three-digit number, i.e., 220,
followed by °F or °C. A c ti o n S ys te m Re s p o ns e
See Figure S2 for Display Readout The rmos ta t C i rcula to r sta rts.
Definitions. ca lls fo r B o i le r te mp e ra ture i s check ed . B urne r
he at re sta rts whe n the water te mp e ra ture i s
Display
b e lo w hi gh li mi t se tti ng .
Text Description Shows
B o i le r B urne r i s turne d off. B urner re sta rts whe n
bt Boiler Temperature
e xce e ds the the wa te r te mp e ra ture d ro ps be lo w the
HL High Limit hi g h li mi t hi g h li mi t s etti ng mi nus the d i ffe re nti a l.
err Error Code
The rmos ta t C i rcula to r a nd burner turn o ff.
f Degrees Fahrenheit i s sa ti sfi e d
c Degrees Celsius
E rro r If a n e rror co nd i ti o n i s d e te cte d , a ll outp uts
LL Low Limit
co nd i ti o n a re shut d o wn. B urner i s o ff. C o ntro l
co nti nue s to functi o n and re starts whe n
Figure S2: Display Readout Definitions
e rro r i s co rre cte d .
After approximately 60 seconds without D uri ng the e rro r che ck se q ue nce , the
any key pressed, the display will enter a syste m che cks for d ri ft i n the se nso r a nd
dim display mode. To return to the bright co rro si o n i n the connecti o ns.
display mode, simply press any key.
The switching action in the L7248/L7224 control
2. Control Operating Characteristics has one setting, the high limit, see Figure S3.
The L7248/L7224 can be in any three (3) The switching relay is controlled by the low
operational states: Normal, High-Limit and Error. voltage room thermostat. On a call for heat, the
The controller moves back and forth from High- relay contacts make to complete the line voltage
Limit to Normal state as part of normal operation. circulator circuit and also the burner circuit if the
The controller will enter the Error state when there boiler water temperature is below the high limit
is an abnormal condition. The operating states are: setting. The high limit switch shuts off the burner
if boiler water temperature exceeds the high limit
a. Normal: Boiler temperature has gone below the setting. The circulator will continue to operate
high limit setting (minus the differential) and has as long as the thermostat is calling for heat. The
not exceeded the high limit setting. high limit automatically resets after the water
b. High-Limit: Boiler temperature has gone above temperature drops past the setpoint and through
the high limit setting and has not dropped below the differential.
the high limit setting (minus the differential).
16
4. REMOVE GAUGE PORT PLUG from fuel pump
and install pressure gauge capable of reading at least
150 PSI.
5. OPEN FLAME OBSERVATION DOOR on front of
boiler.
H. START OIL BURNER.
1. Open vent fitting on fuel pump.
2. TURN ‘ON’ BURNER service switch and allow
burner to run until oil flows from vent fitting
in a SOLID stream without air bubbles for
approximately 10 seconds.
3. Close vent fitting and burner flame should start
immediately after pre-purge is complete. Pre-purge
prevents burner flame until 10 seconds has elapsed
after initial power is applied to burner. During
Figure S3: L7248/L7224 Setpoint and Differential pre-purge, the motor and ignitor will operate but the
Switching Action oil valve will remain closed. Refer to Oil Primary
Control Instructions for more details.
F. REMOVE GUN ASSEMBLY
I. ADJUST OIL PRESSURE.
1. Items to be checked are nozzle size, type, and angle;
head size; gun setting; and positioning of electrodes. 1. Locate oil pressure adjusting screw and turn screw
This informations is shown in Figure 13 and Table to obtain 140 PSI pressure.
6. 2. DO NOT REMOVE PRESSURE GAUGE until
later.
2. Reinstall gun assembly.
J. OTHER ADJUSTMENTS
1. ADJUST THE AIR BAND AND/OR AIR
SHUTTER.
Adjust air supply by loosening lock screws and
moving the air shutter and if necessary the air band.
Refer to Table 6 for preliminary settings.
2. ADJUST DRAFT REGULATOR for a draft
of — .02” (water gauge) over the fire after chimney
has reached operating temperature and while burner
Figure 13: "F" Head Electrode Positioning and is running.
Gun Setting (Beckett AFG) 3. READJUST AIR BANDS on burner for a light
orange colored flame while the draft over the
Table 6: Burner specifications fire is —.02”. Use a smoke tester and adjust air
for minimum smoke (not to exceed #1) with a
B e c k e tt AF G minimum of excess air. Make final check using
B o i le r F i ri ng He a d Sta t i c S e tti ng s D e la va n suitable instrumentation to obtain a CO2 of 11.5 to
Ra t e D i sc No zzle 12.5% with draft of —.02” (water gauge) in fire
Mo d e l GP H Air A i r G P H x A ng le box. These settings will assure a safe and efficient
S hutte r B a nd Typ e
operating condition. If the flame appears stringy
* C3 0 .7 5 F3 3 - 3 /8 " 4 .5 0 0 .6 0 x 80 °A instead of a solid fire, try another nozzle of the same
C4 1 .2 0 F3 3 - 3 /8 " 10 0 1 .0 0 x 80 °A type. Flame should be solid and compact. After all
Oil P u mp P res su re : 14 0 P S I adjustments are made recheck for a draft of —.02”
* C 3 B o ile r u tiliz e s a lo w firin g ra te b affle over the fire.
G. ADJUST OIL BURNER BEFORE STARTING. 4. TURN “OFF” BURNER and remove pressure
gauge. Install gauge port plug and tighten. Start
1. SET BURNER AIR BAND AND AIR SHUTTER, burner again.
see Table 6.
5. CAD CELL LOCATION AND SERVICE
2. OPEN ALL OIL LINE VALVES. The burner is supplied with a cadmium sulfide flame
3. Attach a plastic hose to fuel pump vent fitting and detector mounted at the factory, mounted on the
provide a pan to catch the oil. bottom of the ignitor. See Figure 14. To service cad

17
lower thermostat setting as required to start and stop
burner.
2. VERIFY PRIMARY CONTROL SAFETY
FEATURES using procedures outlined in
Instructions furnished with control (See back of
control cover) or instructions as follows:

WARNING
S e r v ic e o n o f t h is b o ile r s h o u ld b e
u n d e r t a k e n o n ly b y t r a in e d a n d s k ille d
p e rs o n n e l fro m a q u a lifie d s e rv ic e a g e n c y.
Figure 14: Cad Cell Location
a. Check wiring connections. Close line switch.
cell or to replace the plug in portion, swing open the Check power at control.
ignitor. After service is complete, be sure to fasten
PRIMARY RELAY TEST
down the ignitor.
b. Disconnect cad cell leads from the underside of
6. FLAME FAILURE
the Primary Control. Reset safety switch.
The C3 & C4 Series boiler controls operate the
burner automatically. If for unknown reasons c. Set controller to call for heat. Burner should
the burner ceases to fire and the reset button on start.
the primary control has tripped, the burner has d. Jumper the two (2) quick connect terminals on
experienced ignition failure. Before pressing the the underside of the Primary Control within 15 to
reset button call your serviceman immediately. 30 seconds. Burner should run.
e. Remove Jumper. Burner shuts down in
CAUTION approximately 15 to 60 seconds.
f. If burner operates as described, relay is good. If
D o n o t a t te m p t t o s t a r t t h e b u r n e r w h e n not, install new relay.
e x c e s s o il h a s a c c u mu la te d , w h e n th e u n it is
fu ll o f v a p o r, o r w h e n th e c o mb u s tio n CAD CELL TEST
c h a mb e r is v e ry h o t. g. Open line switch. Clean cell face and see that
cell is securely in socket. Reconnect leads. Reset
K. CHECK FOR CLEAN CUT OFF OF BURNER. safety switch.
1. AIR IN THE OIL LINE between fuel unit and h. Close line switch. If burner starts and runs
nozzle will compress when burner is on and will beyond safety switch cut-out time, cell is good.
expand when burner stops, causing oil to squirt from If not, install new cell.
nozzle at low pressure as burner slows down and 3. VERIFY HIGH LIMIT OPERATION.
causing nozzle to drip after burner stops. Usually
a. Adjust thermostat to highest setting.
cycling the burner operation about 5 to 10 times will
rid oil line of this air. b. Observe temperature gauge. When temperature
is indicated, adjust limit to setting below
2. IF NOZZLE CONTINUES TO DRIP, repeat step
observed temperature. Burner should stop.
K.1. If this does not stop the dripping, remove cutoff
valve and seat, and wipe both with a clean cloth c. Adjust limit to setting above observed
until clean, then replace and readjust oil pressure. If temperature. Burner should start.
dripping or after burn persist replace fuel pump. d. Adjust thermostat to lowest setting. Adjust limit
L. TEST CONTROLS. to desired setting.
4. Check operating control. With burner off, draw hot
water until burner starts, then turn off hot water and
WAR N IN G check burner shut-down.
B e fo r e in s t a lla t io n o f t h e b o ile r is IF CONTROLS DO NOT MEET REQUIREMENTS
c o n s id e r e d c o m p le t e , t h e o p e r a t io n o f t h e OUTLINED IN PARAGRAPH L., REPLACE
b o ile r c o n t r o ls s h o u ld b e c h e c k e d , CONTROL AND REPEAT CHECK-OUT
p a r t ic u la r ly t h e p r im a r y c o n t r o l a n d h ig h PROCEDURES.
lim it c o n t r o l. M. BOILER AND SYSTEM CLEANING
INSTRUCTIONS FOR TROUBLE FREE
1. Check thermostat operation. Raise and
OPERATION.
1. Filling of Boiler and System — General —-In a hot
18
1. Filling of Boiler and System — General —-In a hot be exercised to eliminate all of the free oxygen in
water heating system, the boiler and entire system the system.
(other than the expansion tank) must be full of water 5. Boiler is now ready to be put into service.
for satisfactory operation. Water should be added to
the system until the boiler pressure gauge registers N. HINTS ON COMBUSTION
12 psi. To insure that the system is full, water should 1. NOZZLES — Although the nozzle is a relatively
come out of all air vents when opened. inexpensive device, its function is critical to the
2. Boiling Out of Boiler and System. The oil and grease successful operation of the oil burner. The selection
which accumulate in a new hot water boiler can be of the nozzle supplied with the C3 & C4 Series
washed out in the following manner. boiler is the result of extensive testing to obtain the
best flame shape and efficient combustion. Other
a. Remove safety relief valve using extreme care to brands of the same spray angle and spray pattern
avoid damaging it. may be used but may not perform at the expected
b. Add an appropriate amount of recommended boil level of CO2 and smoke. Nozzles are delicate and
out compound. should be protected from dirt and abuse. Nozzles are
mass-produced and can vary from sample to sample.
N OT IC E For all of those reasons a spare nozzle is a desirable
item for a serviceman to have.
C h e c k w i th lo c a l a u t h o r itie s o r c o n s u lt lo c a l
2. FLAME SHAPE — Looking into the combustion
w a t e r t r e a tm e n t s e r v ic e s fo r a c c e p ta b le
chamber through the observation door, the flame
c h e m ic a l c l e a n in g c o m p o u n d s .
should appear straight with no sparklers rolling up
toward the crown of the chamber. If the flame drags
c. Replace safety relief valve.
to the right or left, sends sparklers upward or makes
d. Fill the entire system with water. wet spots on the target wall, the nozzle should be
e. Start firing the boiler. replaced. If the condition persists look for fuel leaks,
f. Circulate the water through the entire system. air leaks, water or dirt in the fuel as described above.
g. Vent the system, including the radiation. 3. FUEL LEAKS — Any fuel leak between the
pump and the nozzle will be detrimental to good
h. Allow boiler water to reach operating combustion results. Look for wet surfaces in the air
temperature, if possible. tube, under the ignitor, and around the air inlet. Any
i. Continue to circulate the water for a few hours. such leaks should be repaired as they may cause
j. Stop firing the boiler. erratic burning of the fuel and in the extreme case
may become a fire hazard.
k. Drain the system in a manner and to a location
that hot water can be discharged with safety. 4. AIR LEAKS — Any such leaks should be repaired,
as they may cause erratic burning of the fuel and in
l. Remove plugs from all available returns and
extreme cases may become a fire hazard.
wash the water side of the boiler as thoroughly as
possible, using a high-pressure water stream. 5. GASKET LEAKS — If 11.5 to 12.5% CO2 with a
#1 smoke cannot be obtained in the breeching, look
m. Refill the system with fresh water.
for air leaks around the burner mounting gasket,
3. Add appropriate boiler water treatment compounds observation door, and canopy gasket. Such air leaks
as recommended by your qualified water treatment will cause a lower CO2 reading in the breeching. The
company. smaller the firing rate the greater effect an air leak
4. Make pH or Alkalinity Test. can have on CO2 readings.
After boiler and system have been cleaned and 6. DIRT — A fuel filter is a good investment.
refilled as previously described, test the pH of the Accidental accumulation of dirt in the fuel system
water in the system. This can easily be done by can clog the nozzle or nozzle strainer and produce a
drawing a small sample of boiler water and testing poor spray pattern from the nozzle. The smaller the
with hydrion paper which is used in the same firing rate, the smaller the slots become in the nozzle
manner as litmus paper, except it gives specific and the more prone to plugging it becomes with the
readings. A color chart on the side of the small same amount of dirt.
hydrion dispenser gives the reading pH. Hydrion 7. WATER — Water in the fuel in large amounts will
paper is inexpensive and obtainable from any stall the fuel pump. Water in the fuel in smaller
chemical supply house or thru your local druggist. amounts will cause excessive wear on the pump,
The pH should be higher than 7 but lower than but more importantly water doesn’t burn. It chills
11. Add appropriate water treatment chemicals, the flame and causes smoke and unburned fuel to
if necessary, to bring the pH within the specified pass out of the combustion chamber and clog the
range. With this lower level of protection, care must flueways of the boiler.
19
8. COLD OIL — If the oil temperature approaching the nozzle line. It may take several firing cycles for
the fuel pump is 40°F or lower poor combustion or that air to be fully vented through the nozzle. Water
delayed ignition may result. Cold oil is harder to in the fuel or poor flame shape can also cause shut
atomize at the nozzle. Thus, the spray droplets get down noises.
larger and the flame shape gets longer. An outside O. ATTENTION TO BOILER WHILE NOT IN
fuel tank that is above grade or has fuel lines in a OPERATION.
shallow bury is a good candidate for cold oil. The
best solution is to bury the tank and lines deep 1. IMPORTANT
enough to keep the oil above 40°F. IF BOILER IS NOT USED DURING WINTER
9. HIGH ALTITUDE INSTALLATIONS TIME, IT MUST BE FULLY DRAINED TO
PREVENT FREEZE DAMAGE.
Air openings must be increased at higher altitudes.
Use instruments and set for 11.5 to 12.5% CO2. 2. Spray inside surfaces with light lubricating or
crankcase oil using gun with extended stem so as to
10. START-UP NOISE — Late ignition is the cause of reach all corners.
start-up noises. If it occurs recheck for electrode
settings, flame shape, air or water in the fuel lines. 3. Always keep the manual fuel supply valve shut off
if the burner is shut down for an extended period of
I M P O R TA N T time.
4. To recondition the heating system in the fall season
S U C T ION L IN E L E AK S - W H AT E V E R IT after a prolonged shut down, follow the instructions
TA K E S , T H E O I L M U S T B E F R E E O F A I R . outlined in Section III, Items A through L.
T h is c a n b e a t o u g h p r o b le m , b u t it m u s t b e
r e s o l v e d . Tr y b l e e d i n g t h e p u m p t h r o u g h a
c le a r t u b e . T h e r e m u s t b e n o fr o t h v is ib le . C AU T I O N
T h e r e a r e v a r io u s t e s t k it s a v a ila b le t o
T h is b o ile r c o n t a in s c o n t r o ls w h ic h m a y
e n a b le y o u t o lo o k a t t h e o il t h r o u g h c le a r
c a u s e t h e b o ile r t o s h u t d o w n a n d n o t
t u b in g a d a p t e d t o t h e s u p p ly lin e a t t h e
r e s t a r t w it h o u t s e r v ic e . If d a m a g e d u e t o
p u m p f i t t i n g . Ai r e l i m i n a t o r s a r e o n t h e
fr o z e n p ip e s is a p o s s ib ility, th e h e a tin g
m a r k e t t h a t h a v e p o t e n t i a l . Al s o , e l e c t r o n i c
s y s t e m s h o u ld n o t b e le ft u n a t t e n d e d in
s ig h t g la s s e s a r e b e in g u s e d w it h g o o d
c o ld w e a t h e r ; o r a p p r o p r ia t e s a fe g u a r d s
s u c c e s s . At t i m e s , n e w t u b i n g m u s t b e r u n
a n d a la r m s s h o u ld b e in s t a lle d o n t h e
t o t h e t a n k o r n e w fit t in g s p u t o n . J u s t
h e a t in g s y s t e m t o p r e v e n t d a m a g e if t h e
m a k e s u r e y o u g e t t h e a ir o u t b e fo r e y o u
b o ile r is in o p e r a t iv e .
le a v e .
An y a i r l e a k s i n t h e f u e l l i n e w i l l c a u s e a n
u n s t a b le fla m e a n d m a y c a u s e d e la y e d P. FREQUENT WATER ADDITION
ig n it io n n o is e s . U s e o n ly fla r e fit t in g s in t h e A leaky system will increase the volume of make-up
fu e l lin e s . water supplied to the boiler which can significantly
shorten the life of the boiler. Entrained in make-up
I M P O R TA N T water are dissolved minerals and oxygen. When the
fresh, cool make-up water is heated in the boiler the
C H E C K T E S T P R OC E D U R E . A v e r y g o o d minerals fall out as sediment and the oxygen escapes
t e s t fo r is o la tin g fu e l s id e p r o b le m s is to as a gas. Both can result in reduced boiler life. The
d is c o n n e c t t h e fu e l s y s t e m a n d w ith a 2 ' accumulation of sediment can eventually isolate
le n g th o f tu b in g , fir e o u t o f a n a u x ilia r y fiv e the water from contacting the cast iron. When this
g a l lo n p a il o f c le a n , fr e s h , w a r m # 2 o i l fr o m happens the cast iron in that area gets extremely hot
a n o th e r s o u r c e . If th e b u r n e r r u n s and eventually cracks. The presence of free oxygen
s u c c e s s fu lly w h e n d r a w i n g o u t o f th e in the boiler creates a corrosive atmosphere which, if
a u x ilia r y p a il th e n th e p r o b l e m is is o la te d to the concentration becomes high enough, can corrode
t h e fu e l o r fu e l lin e s b e in g u s e d o n th e the cast iron through from the inside. Since neither of
jo b s it e . these failure types are the result of a casting defect the
warranty does not apply. Clearly it is in everyone’s best
11. SHUT DOWN NOISE — If the flame runs out of interest to prevent this type of failure. The maintenance
air before it runs out of fuel, an after burn with noise of system integrity is the best method to achieve this.
may occur. That may be the result of a faulty cut-off
valve in the fuel pump, or it may be air trapped in

20
Section IV: Boiler Cleaning

WAR NING
All b o ile r c le a n in g m u s t b e c o m p le te d w ith b u r n e r s e r v ic e s w itc h tu r n e d o ff. B o ile r s e q u ip p e d
w it h b u r n e r s w in g d o o r h a v e a p o te n tia l h a z a r d w h ic h c a n c a u s e s e v e r e p r o p e r ty d a m a g e ,
p e r s o n a l in ju r y o r lo s s o f life if ig n o r e d . B e fo r e o p e n in g s w in g d o o r, tu r n o ff s e r v ic e s w itc h to
b o ile r to p r e v e n t a c c id e n t a l fir in g o f b u r n e r o u ts id e th e c o m b u s tio n c h a m b e r. B e s u r e to tig h te n
s w in g d o o r fa s te n e r c o m p le t e ly w h e n s e r v ic e is c o m p le te d .

Figure 15: Cleaning of Boiler Flueways

A. CLEAN THE FLUEWAYS (See Figure 15). pulling hairpin cotter from bottom of hinge pin and
1. Prior to cleaning boiler, lay a protective cloth or removing pin from hinge. Set burner aside. Remove
plastic over combustion chamber blanket to collect swing door mounting plate, see Figure 2.
debris falling from flueways.
2. For access to firebox N OT IC E
On boilers with burner swing door and flexible
B o ile r flu e w a y s m a y b e c le a n e d fr o m t h e
fuel line(s), remove fastener securing door and
t o p o r fr o m t h e s id e , o r fr o m b o t h d ir e c t io n s
swing door open. For full access to firebox, remove
fo r t h e m o s t t h o r o u g h c le a n in g .
burner and swing door from mounting plate by

21
3. For cleaning from the side: E. REASSEMBLE BOILER.
a. Lift the jacket's upper right side access panel off CAUTION: Do not start the burner unless canopy,
to expose the flue cleanout plates. smokepipe, burner mounting plate, burner swing door
b. Loosen nuts securing the flue cleanout plates and all flue plates are secured in place.
and remove the plates. The insulation should 1. Install the canopy taking care to align the gaskets
be removed with the plates taking care not to without blocking the flueways. If gasket is damaged,
damage the insulation. replace as needed.
4. For cleaning from the top: 2. Reinstall flue plates, making sure gasket on each
a. Lift the jacket's upper right side access panel off plate is in place and forms gas tight seal. If damaged
to allow removal of the jacket top panel. replace as needed.
b. Remove as much smokepipe as necessary to 3. Reinstall jacket top panel and secure with sheet
allow removal of the jacket top panel and canopy metal screws. Replace jacket upper right side access
(smokebox). panel.
c. Remove the jacket top panel. 4. Reinstall smokepipe on canopy and secure to collar
with sheet metal screws.
d. Remove the canopy, being careful not to damage
the ceramic fiber gasket. 5. Install swing door mounting plate to front section
with fasteners, see Figure 2.
5. Using a 1¼” diameter wire or fibre bristle brush
(30” handle) clean the flueways. Brush from the top 6. Reinstall burner in reverse order of disassembly
and/or side using horizontal and diagonal strokes for outlined in paragraph A.2 above. For details, see
best results. DO NOT allow brush to strike the target Figure 2.
wall or liner in the chamber.
B. CLEAN TOP OF BOILER SECTIONS (if cleaning WAR N IN G
from the top). T h e b o ile r m u s t b e c o n n e c te d t o a n
Brush and vacuum the tops of the boiler sections. a p p r o v e d c h im n e y i n g o o d c o n d it io n .
C. CLEAN THE FIREBOX. S e r io u s p r o p e r t y d a m a g e c o u ld r e s u lt if th e
Using wire or fibre bristle brush, clean crown of boiler b o ile r is c o n n e c t e d to a d i r ty o r in a d e q u a te
and inside of water legs. DO NOT allow brush to strike c h im n e y. T h e in t e r io r o f th e c h im n e y flu e
target wall or blanket in the combustion chamber. m u s t b e in s p e c te d a n d c le a n e d b e fo r e t h e
s ta r t o f th e h e a t in g s e a s o n a n d s h o u ld b e
D. AFTER CLEANING, remove protective cloth with
in s p e c te d p e r io d ic a lly th r o u g h o u t t h e
debris and vacuum as necessary, but be careful not
h e a tin g s e a s o n fo r a n y o b s t r u c t io n s . A
to damage blanket. Inspect target wall, combustion
c le a n a n d u n o b s tr u c t e d c h im n e y f lu e is
chamber blanket, burner mounting plate insulation and
n e c e s s a r y to a llo w n o x io u s fu m e s th a t
burner swing door insulation for signs of damage. If
c o u ld c a u s e in ju r y o r lo s s o f life to v e n t
damaged, replace as needed.
s a fe ly a n d w ill c o n tr ib u te to w a r d
m a in ta in in g th e b o ile r ' s e ffic ie n c y.

22
Warning:
This product contains refractory ceramic fibers (RCF). RCF has been classified as
a possible human carcinogen. After this product is fired, RCF may, when exposed
to extremely high temperature (>1800F), change into a known human carcinogen.
When disturbed as a result of servicing or repair, RCF becomes airborne and, if
inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:
Do not remove or replace previously fired RCF (combustion chamber insulation,
target walls, canopy gasket, flue cover gasket, etc.) or attempt any service or
repair work involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an air tight plastic bag.

First Aid Procedures:


• If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.

23
SECTION VI: Repair Parts
All C3 & C4 Series Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require as-
sistance in locating a Burnham distributor in your area, or have questions regarding the availability of Burnham products or repair
parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.

24
SERVICE RECORD
DATE SERVICE PERFORMED

25
26
BARE BOILER ASSEMBLY
Ite m
D e scri p ti o n P a rt No . C3 C4
No .
BARE BOILER ASSEMBLY
1 F ro nt S e c ti o n 7 17 27 01 5 1 1
3 C e nte r S e c ti o n 7 17 2 20 2 1 2
4 Na rro w B a c k S e c ti o n (No n-Htr.) 7 1 72 20 4 1 1
5 Re a r S e c ti o n w/Htr. Op e ni ng 7 17 2 20 3 1 1
7 2 ½" C a s t Iro n S li p Ni p p le 7 06 60 01 4 6
8 Re a r Ta rg e t Wa ll Ins ula ti o n 8 20 27 01 1 1
C o mb usti o n C ha mb e r L i ne r, ½" x 2 4 " x 5 " 8 20 22 03 3 1 ---
8A
C o mb usti o n C ha mb e r L i ne r, ½" x 2 4 " x 9 " 8 20 22 0 43 --- 1
Ti e Ro d , 3 /8 " -1 6 x 1 2 ½" L g . 8 08 61 01 0 2 ---
9
Ti e Ro d , 3 /8 " -1 6 x 1 7 " L g . 8 0 8 6 1 0 11 --- 2
10 F lue C o ve r P la te A s s e mb ly 6 11 6 0 3 9 2 3
11 He a te r Ga s k e t 8 0 36 05 8 1 1
B la nk 7 0 36 02 0
12 He a te r C o ve r P la te 1 1
Ta p p e d 7 03 60 21
1 3A V 1 -2 He a te r A s s e mb ly 6 03 60 31 1 ---
1 3B V 1 -1 He a te r A s s e mb ly 6 0 36 03 0 --- 1
14 B urne r S wi ng D o o r Mo unti ng P la te 7 17 2 70 5 1 1
1 4A B urne r S wi ng D o o r Mo unti ng P la te Ins ula ti o n 82 0 27 02 1 1 1
15 Ro p e Ga s k e t - B urne r Mo unti ng P la te - 5 3 " L g . 7 20 27 0 14 1 1
16 B urne r S wi ng D o o r 7 17 2 70 6 1 1
1 6A B urne r S wi ng D o o r Insula ti o n 8 20 27 02 2 1 1
1 6B Ro p e Ga s k e t (B urne r S wi ng D o o r) - 2 8 " L g . 7 20 27 0 15 1 1
16 C Hi ng e 7 02 27 01 2 2
16 D Hi ng e P i n 8 08 61 6 14 1 1
1 6E Ha i rp i n C o tte r 8 08 61 66 7 1 1
17 Ob s e rva ti o n P o rt C o ve r 7 02 60 01 1 1
18 Sp ri ng 3 /8 " I.D . x 1 /2 " L g . 8 0 26 01 5 1 1
19 C a no p y S e a li ng Stri p (1 /2 " x 1 " x 9 8 " ) 7 2 02 71 0 1 1
C 3 C a no p y A ss e mb ly 6 11 2 7 0 3 1 3 1 ---
20
C 4 C a no p y A ss e mb ly 6 11 2 7 0 4 1 3 --- 1

27
28
JACKET
Ite m No . D e s c ri p ti o n P a rt No . C3 C4
J a c k e t C o mp o ne nts - Ite ms 1 thru 6 Inc lud e Ins ula ti o n A s P a rt o f A s s e m b ly
1 J a c k e t F ro nt P a ne l A s s e mb ly 60427097 1 1
2 J a c k e t Re a r P a ne l A s s e mb ly 60427096 1 1
604270314 1 - --
3 J a c k e t L e ft S i d e /To p P a ne l A s s e mb ly
604270414 - -- 1
604270322 1 - --
4 J a c k e t To p P a ne l A s s e mb ly
604270422 - -- 1
604270337 1 - --
5 J a c k e t L o we r Ri g ht S i d e P a ne l A s s e mb ly
604270437 - -- 1

604270336 1 - --
J a c k e t Up p e r Ri g ht S i d e A c c e s s P a ne l A s s e mb ly wi tho ut He a te r Op e ni ng
604270436 - --
6
604270335 1 - --
J a c k e t Up p e r Ri g ht S i d e A c c e s s P a ne l A s s e mb ly wi th He a te r Op e ni ng
604270435 - -- 1
J a c k e t B ra c k e t, wi tho ut He a te r Op e ni ng 7042715
7 1 1
J a c k e t B ra c k e t, wi th He a te r Op e ni ng 7042714

29
30
TRIM AND CONTROLS
ITE M
D E S C RIP TION P a rt No . C3 C4
NO.
1 D ra ft Re g ula to r, 6 " 8 11 6 2 8 8 1 1

2 . IN S T R U C T ION E N V E L OP E C ON TAIN IN G:
2A Ins ta lla ti o n, Op e ra ti ng a nd S e rvi c e Ins truc ti o ns 8 14 27 68 1 1
2B L i mi te d Wa rra nty Ma i le r 8 14 60 13 5 1 1
2C I=B =R P a mp hle t 81 46 00 6 1 1 1
Ho ne ywe ll L 7 2 4 8 C 1 0 1 4 Hi L i mi t, C i rc . Re la y (wi tho ut He a te r) 1 0 0 0 5 9 -0 1 1 1
3A --OR --
Ho ne ywe ll L 7 2 2 4 C 1 0 0 4 Hi & L o L i mi t, C i rc . Re la y (wi th He a te r) 1 0 0 8 6 2 -0 1 1 1
Ho ne ywe ll # 1 2 3 8 7 0 A Imme rs i o n We ll, ¾ NP T x 1 ½ Ins ula ti o n (wi tho ut He a te r) 8 01 60 42 6 1 1
3B - - OR - -
Ho ne ywe ll # 1 2 3 8 7 2 A Imme rs i o n We ll, ½ NP T x 3 " Ins ula ti o n (wi th He a te r) 8 01 60 49 7 1 1
3C B urne r P ri ma ry C o ntro l, R7 1 8 4 B 8 01 60 84 7 1 1
4A C i rc ula to r
Ta c o 0 0 7 F (le s s g a sk e ts ) 8 05 60 0 7
- - OR - -
B e ll & Go s s e tt NRF 2 2 (w/g a s ke ts ) 8 05 6 17 4 1 1
- - OR - -
Grund fo s UP 1 5 -4 2 F (w/g a s k e ts ) 8 05 61 7 5
4B Ga s k e t, Ta c o " 0 0 " S e ri e s C i rc ula to r 80 66 02 0 06 2 2
4C C i rc ula to r F la ng e , 1 ½" NP T 80 66 0 20 14 2 2
4D C a p S c re w, He x He a d , 7 /1 6 " -1 4 x 1 ½" 80 86 13 0 1 4 4
4E He x Nut, 7 /1 6 " - 1 4 8 08 60 40 6 4 4
4F Ni p p le , 1 ½" NP T x1 8 " 8 0 6 6 0 0 0 11 1 1
4G Te e , 1 ½" x ¾" x 1 ½" NP T, B la c k 80 66 01 0 03 1 1
4H Ni p p le , 1 ½" NP T x 3 " 80 66 00 0 06 1 1
5A Re li e f Va lve , ¾" NP T, 3 0 P S I 8 16 60 31 9 1 1
5B Ni p p le , ¾" NP T x 8 " 8 06 6 00 22 1 1 1
5C Te mp /P re ss ure Ga ug e , 2 ½" D i a . 8 05 6 16 9U 1 1
5D D ra i n Va lve , ¾" NP T 8 0 6 6 0 3 0 11 1 1
5E P lug , S q ua re He a d , 1 ½" NP T 80 66 03 5 15 1 1

31
32
FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR
WHOLESALER OR THE BURNER MANUFACTURER:

R. W. BECKETT CORP.
P.O. BOX 1289
ELYRIA, OHIO 44036
1-800-645-2876
Beckett AFG Burner
BECKETT OIL BURNER PART NOS. FOR C3 &C4 SERIES BOILERS
NOTE: When ordering parts always give the serial and model numbers shown on the
boiler and burner. Also provide the name of the part(s) and part number as
listed below.

B o i le r Mo d e l C3 C4

A i r Tub e C o mb i na ti o n A F 4 4 YH

B e cke tt Sp e c No . B C B 6 11 8 B C B 6 11 9
A i r B a nd 3 49 2
A i r B a nd Nut 41 50
A i r B a nd S c re w 41 98
A i r S hutte r 3 70 9
A i r S hutte r S c re w 41 98
B lo we r 2 99 9
C o up li ng 2 45 4
B ulk he a d K nurle d L o c k nut 3 66 6
C o nne c to r Tub e A s s e mb ly 5 63 6
E le c tro d e C la mp 14 9
E le c tro d e C la mp S c re w 42 19
E le c tro d e Ins ula to r A ss e mb ly 5 78 0
Sp i d e r Sp a ce r A s s e mb ly 5 50 3
E s cutc he o n P la te 3 49 3
He a d 36 00 03
He a d S c re ws 42 21
F la ng e Ga s k e t 3 14 98
A F G Ho usi ng 5 87 4
M o to r 2 18 39
No zzle A d a p te r 21 3
No zzle L i ne E le c tro d e A s s e mb ly NL 4 4 YH
P ump (Inc lud e s Va lve ) 2 18 44
Sta ti c P la te 3 38 4
L o w F i r e B a ffl e 3 70 8 ---
Ig ni to r 7 44 0
Ig ni to r Hi ng e S c re w 42 17
Ig ni to r Ho ld i ng S c re w 42 9 2
Ig ni to r Ga s k e t K i t 5 13 04
Wi re Gua rd 1 02 51
J unc ti o n B o x 3 74 1
F la me D e te c to r 70 0 6Q

33
VI. Low Water Cut Off (LWCO)

WAR N IN G
D O N OT AT T E M P T t o c u t fa c t o r y w ir e s t o in s ta ll a n a fte r m a r k e t L o w Wa te r C u t Off ( LW C O).
On ly u s e c o n n e c ti o n s s p e c ific a lly id e n tifie d fo r L o w Wa te r C u t Off.
In a ll c a s e s , fo llo w th e L o w Wa te r C u t Of f (LW C O) m a n u fa c t u r e r ' s i n s tr u c tio n s .
When draining the heating system. Many probe LWCO
A low water cutoff is required to protect a hot water manufacturers recommend an annual inspection of the
boiler when any connected heat distributor (radiation) probe.
is installed below the top of the hot water boiler (i.e. How to Wire
baseboard on the same floor level as the boiler). In
LWCO’s are available in either 120 VAC or 24 VAC
addition, some jurisdictions require the use of a LWCO
configurations. The 120 VAC configuration can be
with a hot water boiler.
universally applied to both gas and oil boilers by wiring
Where it in the line voltage service to the boiler (after the
The universal location for a LWCO on both gas and oil service switch, if so equipped).
hot water boilers is above the boiler, in either the supply The presence of water in a properly installed LWCO
or return piping. The minimum safe water level of a will cause the normally open contact of the LWCO to
water boiler is at the uppermost top of the boiler; that is, close, thus providing continuity of the 120 VAC service
it must be full of water to operate safely. to the boiler.
It is recommended to supply power to the probe LWCO
What Kind with the same line voltage boiler service as shown
Typically, in residential applications, a probe type below.
LWCO is used instead of a float type, due to their
relative costs and the simplicity of piping for a probe
LWCO.
How to Pipe
A “tee” is commonly used to connect the probe LWCO
to the supply or return piping, as shown below.

Wiring of Typical LWCO


A 24 VAC LWCO is used primarily for gas fired
LWCO Location boilers where a 24 volt control circuit exists within the
boiler. However, a 24 VAC LWCO can only be used
Select the appropriate size tee using the LWCO if the boiler manufacturer has provided piping and
manufacturer’s instructions. Often, the branch wiring connections and instructions to allow for this
connection must have a minimum diameter to application.
prevent bridging between the probe and the tee. Also,
the run of the tee must have a minimum diameter to How to Test
prevent the end of the probe from touching or being Shut off fuel supply. Lower water level until water
located too close to the inside wall of the run of the tee. level is BELOW the LWCO. Generate a boiler demand
Ideally, manual shutoff valves should be located by turning up thermostat. Boiler should not attempt to
above the LWCO and the boiler to allow for servicing. operate. Increase the water level by filling the system.
This will allow probe removal for inspection without The boiler should attempt to operate once the water
level is above the LWCO.
34
SERVICE RECORD
DATE SERVICE PERFORMED

35
Limited Warranty
FOR RESIDENTIAL CAST IRON WATER BOILERS
Subject to the terms and conditions set forth below, U.S. Boiler™ water boiler for its intended purposes and its maintenance
Co., Inc. Lancaster, Pennsylvania hereby extends the following limited accordance with U. S. Boiler Co., Inc. recommendations and
warranties to the original owner of a residential grade water boiler hydronics industry standards. These warranties will be inapplicable if
manufactured and shipped on or after July 1,1991: the residential grade water boiler is used or operated over its rated
capacity, is subjected to unauthorized modification, or is damaged as
ONE YEAR LIMITED WARRANTY a result of being otherwise improperly operated or serviced including,
ON RESIDENTIAL GRADE WATER BOILERS but not limited to, damage from any of the following: operation with
U.S. Boiler Co., Inc. warrants to the original owner that its residential insufficient water, allowing the boiler to freeze, subjecting the boiler
grade water boilers comply at the time of manufacture with recognized to flood conditions, and operation with unapproved water or fuel
hydronic industry standards and requirements then in effect and will be additives which cause deposits or corrosion.
free of defects in material and workmanship under normal usage for a 5. Removal and Installation: These warranties do not cover expenses of
period of one year from the date of original installation. If any part of a removal or reinstallation. The owner is responsible for the cost of
water boiler is found to be defective in material or workmanship during removing and reinstalling any defective part and its replacements
this one year period, U.S. Boiler Co., Inc. will, at its option, repair or and all labor and material connected therewith.
replace the defective part. 6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach of
LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER these warranties is limited to the repair or replacement of its parts in
accordance with the terms and conditions of these warranties.
U.S. Boiler Co., Inc. warrants to the original owner that the heat
exchanger of its residential grade water boilers will remain free from 7. Limitation of Damages: Under no circumstances shall U.S. Boiler
defects in material and workmanship under normal usage for the lifetime Co., Inc. be liable for incidental, indirect, special or consequential
of the original owner at the original place of installation. If a claim is damages of any kind whatsoever under these warranties, including,
made under this warranty during the first ten years from the date of but not limited to, injury or damage to persons or property and
original installation, U.S. Boiler Co., Inc. will, at its option, repair or damages for loss of use, inconvenience or loss of time. U.S. Boiler
replace the heat exchanger. If a claim is made under this warranty after Co., Inc. liability under these warranties shall under no circumstances
the expiration of ten years from the date of original installation, U.S. exceed the purchase price paid by the owner for the residential grade
Boiler Co., Inc. will, at its option and upon payment of the pro-rated water boiler involved. Some states do not allow the exclusion or
service charge set forth below, repair or replace the heat exchanger. limitation of incidental or consequential damages, so the above
The service charge applicable to a heat exchanger warranty claim is limitation or exclusion may not apply to you.
based upon the number of years the heat exchanger has been in 8. Limitation of Warranties: These warranties set forth the entire
service and will be determined as a percentage of the retail price of the obligation of U.S. Boiler Co., Inc. with respect to any defect in a
heat exchanger model involved at the time the warranty claim is made residential grade water boiler and U.S. Boiler Co., Inc. shall have no
as follows: express obligations, responsibilities or liabilities of any kind
whatsoever other than those set forth herein. These warranties are
Years given in lieu of all other express warranties.
1-10 11 12 13 14 15 16 17
In Service ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING
Service Charge ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
No
as % of 5 10 15 20 25 30 35 PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION
Charge
Retail Price TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED
WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN
Years 25 and
18 19 20 21 22 23 24 A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE
In Service above
ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER
Service Charge AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO
as % of 40 45 50 55 60 65 70 75 NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY
Retail Price LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
NOTE: If the heat exchanger model involved is no longer available due PROCEDURE FOR OBTAINING WARRANTY SERVICE
to product obsolescence or redesign, the value used to establish the
retail price will be the published price as shown in the Burnham In order to assure prompt warranty service, the owner is requested to
Hydronics Repair Parts Price Sheet where the heat exchanger last complete and mail the attached Warranty Card within ten days after the
appeared or the current retail price of the then nearest equivalent heat installation of the boiler, although failure to comply with this request will
exchanger. not void the owner’s rights under these warranties.
Upon discovery of a condition believed to be related to a defect in
ADDITIONAL TERMS AND CONDITIONS material or workmanship covered by these warranties, the owner should
1. Applicability: The limited warranties set forth above are extended notify the installer, who will in turn notify the distributor. If this action is
only to the original owner at the original place of installation within the not possible or does not produce a prompt response, the owner should
United States and Canada. These warranties are applicable only to write to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079,
water boilers designated as residential grade by U.S. Boiler Co., Inc. Lancaster, PA 17604, giving full particulars in support of the claim.
and installed in a single or two-family residence and do not apply to The owner is required to make available for inspection by U.S. Boiler
steam boilers of any kind or to commercial grade boilers. Co., Inc. or its representative the parts claimed to be defective and, if
2. Components Manufactured by Others: Upon expiration of the one requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S.
year limited warranty on residential grade water boilers, all boiler Boiler Co., Inc. at the above address for inspection or repair. In
components manufactured by others but furnished by U.S. Boiler addition, the owner agrees to make all reasonable efforts to settle any
Co., Inc. (such as oil burner, circulator and controls) will be subject disagreement arising in connection with a claim before resorting to legal
only to the manufacturer’s warranty, if any. remedies in the courts.
3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND
are conditioned upon the installation of the residential grade water YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE
boiler in strict compliance with U.S. Boiler Co., Inc. installation TO STATE.
instructions. U. S. Boiler Co., Inc. specifically disclaims liability of any
kind caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by U.S.
Boiler Co., Inc. conditioned upon the use of the residential grade
03/03

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