Price - $3.00
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
RSA BOILERS
1
IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be ins ta lled in accordance with Nati ona l, State and Local Plumbing,
He ating and Electrical Codes and the regulations of the serving utilities. These Codes and
Regulations may differ from this instruction manua l. Authorities hav ing jurisdiction should
be consulted before installa tions are made.
In a ll cases , re fe re nc e should be made to the following Standards:
All wiring on boilers installed in the USA shall be made in accorda nce with the National
Electrical Code and/or Loc al Regul ations.
Al l wiring on boilers installed in Canada shall be made in ac corda nce with the Canadian
Electrical Code and/or Loc al Regulations.
A.
B.
C.
A.
USA BOILERS
Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning
Equipment”, for recommended installation practices.
Current Edition of American National Standard ANSI/NFPA 2 11, “Chimne ys, Firepla ces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
Current Edition of American Society of Mechanical Engineers ASME CSD-1, "Controls and
Safety Devices for A utomatically Fired Boilers", for assembly and operations of controls
and safety devices.
CANADIAN BOILERS
Current Edition of Canadian Standards Association CSA B139, "Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
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.
CAUTION
DANGER
Indic ates a potentially ha zardous situation
which, if not av oided, may result in
modera te or minor injury or property
damage.
Indicates an imminently ha zardous situation
w hich, if not avoided, will re sult in death,
serious injury or substantial property
damage.
WARNING
NOTICE
Indic ates a potentially ha zardous situation
which, if not avoide d, could re sult in death,
serious injury or substantial property
damage.
Indicates spe cial instructions on
installation, operation, or ma intenance
w hich are importa nt but not related to
personal injury ha zards.
NOTICE
This boiler has a limited warranty, a copy of w hich is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed
and are operating properly when the installation is complete. The warranty for this boiler is valid
only if the boiler has been installed, maintained and operated in accordance with these
instructions.
2
DANGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.
WARNING
Improper installation, adjustment, alteration, servic e or mainte na nce can cause property
damage, personal injury or loss of life. Failure to follow all instructions in the proper order
can cause personal injury or death. Read and understand all instructions, inc luding all
those containe d in compone nt manufac turers manuals w hich are prov ided with the
appliance before instal ling, starting-up, opera ting, maintaining or servicing this applia nce.
Keep this manual and lite rature in legible condition and posted near appliance for reference
by owner and service technic ian.
This boiler requires regular maintenance and service to operate safely. Follow the instructions
contained in this manual. Installation, maintenance, and service must be performed only by an
experienced, skilled and knowledgeable installer or service agency. All heating systems should
be designed by c ompetent contrac tors and only persons k nowledge able in the la yout and
installa tion 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 w hen the installation is completed. Installation is not complete unless a
pressure relief valve is installed into the tapping located on top of appliance - See Section III of
this manual for details.
This boiler is not suitable for installation on c ombustible flooring, unless install ed with a
combustible floor shield (avai lable at extra cost). Do not ins tall boiler on carpeting.
Do not tam per wi th or alter the boiler or controls. Re tain your cont ra ctor or a compet ent
se rv ice man to assure that th e unit is p ro perly adjus ted an d main taine d.
Have Firetube s cleane d at leas t once a year - prefe rably at the start o f the he ating sea son
to re move soot a nd sca le. The inside of combustion cha mber sho uld also be cle aned and
ins pecte d at the same time .
Have Oil Burner and Controls ch ecke d at leas t once a ye ar or as may be nec ess itate d.
Do not operate unit w ith jumpere d or abs ent con tro ls or safety devices .
D o no t operate unit if any control, sw itc h, c omponent, or dev ice has b een s ubjec t to
w ate r.
3
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica,
he av y me tals, carb on mon oxide, nit rogen oxides , a ldehyd es a nd/or oth er tox ic or harm ful
substances which can cause death or serious injury and which are known to the state of California
to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing,
respirators and equipment when servicing or working nearby the appliance.
This boiler contains very hot water under high pressures. Do not unscrew any pipe fittings nor
attempt to disconnect any components of this boiler without positively assuring the water is cool
and has no pressure. Always w ear protective clothing and equipment when installing, starting
up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature
gauges to determine the temperature and pressure of the boiler. This boiler contains components
w hich become very hot w hen the boiler is operating. Do not touch any components unless they
are cool.
This appliance mus t be properly v ented and connected to an approved vent system in good
condition. D o not ope rate boiler with the absence of an unapproved ve nt s ystem.
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 systems are necessary to allow
noxious fumes that could cause injury or loss of life to vent safely and will contribute toward
maintaining the boiler's efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should
not be left unatttended in cold weather; or appropriate safeguards and alarms should be installed
on the heating system to prevent damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or
any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any
solid fuel (i. e. wood, coal) or gaseous fuel (i. e. natural gas, LP/propane). All flammable debris,
rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area
clean and free of fire hazards.
Do not operate boiler on combustible floor without a factory supplied floor shield. Concrete over
wood joists is considered combustible flooring. Do not operate on masonry floors, which may
contain moisture.
4
Tables of Contents
I.
Pre-Installation ..................................... 7
VI. Oil Piping ........................................... 28
II.
Knockdown Boiler Assembly ............... 9
VII. System Start-Up .................................. 30
III. Water Piping and Trim ...................... 12
VIII. Service and Cleaning .......................... 36
IV. Venting ............................................... 18
IX. Repair Parts ........................................ 38
V.
Electrical and Sequence of Operation 20
Figure 1: RSA Packaged Boiler (RSA85 / RSA135)
5
Figure 1A: RSA Packaged Boiler (RSA170 / RSA285)
M inim um Chimney Sizes
Boiler
Model
Num ber
B are Boiler
A ssem bly
(height)
In. (dia.) x Ft.
(height)
Water
Capacity
Gallons
Approx.
S hipping
Weight
RS A170
WV-29-10
8 x 8 x 20
7" x 20'
42.6
600 lb.
RS A195
WV-29-13A
8 x 8 x 20
8" x 20'
39.9
630 lb.
RS A240
WV-29-16A
8 x 12 x 20
8" x 20'
37.3
660 lb.
RS A285
WV-29-19A
8 x 12 x 20
9" x 20'
34.6
690 lb.
In. x In. x Ft.
6
I. Pre-Installation
supplied by Burnham, is used. DO NOT install on
carpeting.
A. INSPECT SHIPMENT carefully for any signs of
damage.
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.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of the crated boiler to the carrier in
good condition.
3. PROVIDE SERVICE CLEARANCE of at least 48”
from the front of the jacket for servicing of burner
and removal of tankless heater.
2. ANY CLAIMS for damage or shortage of shipment
must filed immediately against the carrier by the
consignee. No claims for variances from, or
shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after
receipt of goods.
For minimum clearances to combustible materials. See
Figure 2.
B. LOCATE BOILER in front of final position before
removing crate.
1. LOCATE so that smoke pipe connection to chimney will be short and direct. BOILER IS NOT
SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR unless combustible floor shield,
Figure 2: Minimum Clearances to Combustible Materials
NOTE:
1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.
2.
RSA boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances can not
be reduced for alcove or closet installations.
3.
For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31
standard.
7
C. PROVIDE AIR SUPPLY AND VENTILATION to
than 50 ft3/1000 BTU per hour then the space is
considered a confined space.
accommodate proper combustion. If natural ventilation is inadequate, provide a screened opening or duct
from the boiler room to the outside. The opening or
duct must be sized so the boiler input will not exceed
4,000 BTUH/Sq. In. of free area. If other air consuming appliances are near the boiler, the air inlet should
be larger. Consult respective manufacturers.
D. For boiler located in an unconfined space of a conventionally constructed building, the fresh air infiltration
through cracks around windows and doors normally
provides adequate air for combustion and ventilation.
E. For boiler located in a confined space or an unconfined
D. VENTILATION AIR must be provided to maintain
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 communicating with the outdoors. Locate one opening within 12
inches of top of space. Locate remaining opening
within 12 inches of bottom of space. Minimum
dimension of air opening is 3 inches. Size each
opening per following:
the ambient temperature at safe limits. 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
ventilation.
2. In confined spaces, two permanent openings, one
near the top of the enclosure and one near the
bottom, shall be provided. Each opening shall have
a free area of not less than 1 sq. inch per 1000
BTUH of the total input of all appliances in the
space.
1. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 BTU per hour
input of all equipment in space.
2. Vertical ducts. Minimum free area of 1 square
inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be
same as opening free area.
3. Horizontal ducts. Minimum free area of 1 square
inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be
same as opening free area.
Alternate method for boiler located within confined
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufficient volume such that combined volume of all
spaces meet criteria for unconfined space. Size each
opening for minimum free area of 1 square inch per
1,000 BTU per hour input of all equipment in spaces,
but not less than 100 square inches.
3. PROVIDE COMBUSTION AND VENTILATION
AIR. Local code provisions may apply and should be
referenced.
F. Louvers and Grilles of Ventilation Ducts
A. Determine volume of space (boiler room). Rooms
1.
All outside openings should be screened and
louvered. Screens used should not be smaller than
1/4 inch mesh. Louvers will prevent the entrance of
rain and snow.
2.
Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of the
louver or grille is not known, assume wood louvers
have 20-25 percent free area and metal louvers and
grilles have 60-75 percent free area.
3.
Louvers and grilles must be fixed in the open
position, or interlocked with the equipment to open
automatically during equipment operation.
communicating directly with the space in which the
appliances are installed, through openings not furnished with doors, are considered a part of the space.
Volume(ft3) = Length(ft) x Width(ft) x Height(ft)
B. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round the
result to the nearest 1000 BTU per hour.
C. Determine type of space. Divide Volume by total input
of all appliances in space. If the result is greater than
or equal to 50 ft3/1000 BTU per hour, then it is
considered an unconfined space. If the result is less
8
II. Knock-Down Boiler Assembly
A. REMOVAL OF BOILER.
1. Remove, all 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 supply tapping. Plug
remainder of tappings.
H. INSTALLING THE JACKET
1. Before jacket can be secured to boiler assembly
tankless heater coil or blank plate must be attached.
Using rubber gasket and bolts provided secure
heater coil or blank plate to boiler extension by
inserting the bolts from the backside of the extension. Refer to Figure 4.
2. Fill boiler with water and apply a pressure of at
least 10 psig but no more than 30 psig.
9
Figure 5: Burner Mounting
10
11
Figure 6: RSA Jacket Assembly
III. Water Piping and Trim
WARNING
Failure to properly pipe boile r may re sult in i mproper ope ration and da mage to boiler or
structure .
Oxyge n c onta mination of boi ler water will cause corrosion of iron a nd s te el boiler
c ompone nts , and can lead to boiler failure. Burnham's Standard Warranty does not cover
problems caused by oxy ge n contamination of boiler water or scale (lime ) bui ld-up c aused
by freque nt addition of w ater.
inch clearance from hot water piping to combustible materials.
A. Design a piping system and install boiler which will
prevent oxygen contamination of boiler water and
frequent water additions.
a. If this boiler is used in connection with refrigeration systems, the boiler must be installed so
that the chilled medium is piped in parallel with
the heating boiler using appropriate valves to
prevent the chilled medium from entering the
boiler. See Figure 7. Also, consult I=B=R
Installation and Piping Guides.
1. There are many possible causes of oxygen contamination such as:
a. Addition of excessive make-up water as a result
of system leaks.
b. Absorption through open tanks and fittings.
b. If this boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air, the boiler piping
must be equipped with flow control valves to
prevent gravity circulation of boiler water
during the operation of the cooling system.
c. Oxygen permeable materials in the distribution
system.
2. In order to insure long product life, oxygen sources
should be eliminated. This can be accomplished by
taking the following measures:
a. Repairing system leaks to eliminate the need for
addition of make-up water.
c. If boiler is used with an Alliance™ IndirectFired Domestic Water Heater, install the
Alliance™ as a separate heating zone. Refer to
the Alliance™ Installation, Operating, and
Service Instructions for additional information.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which
allow oxygen absorption.
d. 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 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 water temperature. Set the bypass
and return valves to a half throttle position to
start. Operate boiler until the system water
temperature reaches its normal operating range.
Adjust the valves to maintain 180°F to 200°F
boiler water temperature and greater the 120°F
return temperature. Adjust both valves simultaneously. Closing the boiler return valve while
opening the bypass valve will raise the boiler
return temperature. Opening the boiler return
valve while closing the by-pass valve will lower
the boiler return temperature.
d. Use of non-permeable materials in the distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
WARNING
System supply and return piping must
be connected to correct boiler pipe.
Burnham re commends s izing the
s ystem circulator to s upply sufficient
flow (GPM) to allow a 20 °F temperature
differential in the s ystem. When s izing
the system circulator, the pressure
drop of all radiators, baseboard and
radiant tubing and a ll connecting
piping must be considered.
e. A water boiler installed above radiation level
must be provided with a low water cutoff device
as part of the installation.
3. Connect System supply and return piping to boiler.
See Figures 8 and 9. Also, consult I=B=R Installation and Piping Guides. Maintain minimum ½
12
Figure 7: Recommended Piping for Combination Heating and Cooling (Refrigeration) System
C. Install Drain Valve in return piping. See Figures 8
and 9.
B. Install Pressure Relief Valve. See Figures 8 and 9.
Pressure Relief Valve must be installed with spindle in
the vertical position. Installation of the relief valve
must be consistent with ANSI/ASME Boiler and
Pressure Vessel Code, Section IV.
D. Oil, grease, and other foreign materials which accumulate 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 appropriate
chemical compounds and concentrations which are
compatible with local environmental regulations.
E. After the boiler and system have been cleaned and
flushed, and before refilling the entire system add
appropriate water treatment chemicals, if necessary, to
bring the pH between 7 and 11.
13
14
Figure 8: Recommended Boiler Piping for Circulator Zoned Heating Systems
15
Figure 9: Boiler Piping for Zone Valve Zoned Heating Systems
F. CONNECT TANKLESS HEATER PIPING AS
2. TEMPERING OF HOT WATER — Installation of
an automatic mixing valve will lengthen the
delivery of the available hot water by mixing some
cold water with the hot. This prevents the possibility of scalding hot water at the fixtures. In addition,
savings of hot water will be achieved since the user
will not waste as much hot water while seeking a
water temperature. Higher temperature hot water
required by dishwashers and automatic washers is
possible by piping the hot water from the heater
prior to entering the mixing valve. The mixing
valve should be “trapped” by installing it below the
cold water inlet to heater to prevent lime formation
in the valve. Refer to Figure 11.
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 pressure drop.
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.
SHOWN IN FIGURE 11. See Table 1 for Tankless
Heater Rating.
WARNING
Install automatic mixing v alve at tankless
hea ter outle t to av oid ris k of burns or
scalding due to ex cessive ly hot water at
fixtures. Adjus t a nd ma intain the mixing
valv e in accordance with the ma nufa cturer's
instructions. Do not operate tankless
heater without mixing valve.
THE FOLLOWING GUIDELINES SHOULD BE
FOLLOWED 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 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 10: Recommended System Bypass Piping
16
Figure 11: Schematic Tankless Heater Piping
Table 1: Tankless Heater Ratings
S350
Boiler Model
S375
GPM
PSID
GPM
PSID
RSA(H)85 & 110
3
12
3½
15
RSA110(H)125 & 135
3¼
16
3¾
25
RSA125 & 135
3½
19
STD. #7524
Boiler Model
OPT. #7530
GPM
PSID
GPM
PSID
RSA170
3¾
25½
4
26½
RSA195, 240, & 285
4
29
4¼
31
17
IV. Venting
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 combination of a large uninsulated chimney, reduced
firing rate, reduced firing time, lower stack
temperature and less dilution air can, in some
cases, contribute to the condensing of small
amounts of water vapor in the chimney. Such
condensation, when it occurs, can cause chimney deterioration. In extreme cases, the chimney may have to be lined to insulate the chimney
and thus prevent the condensation. The
addition of dilution air into the chimney may
assist in drying the chimney interior surfaces.
A massive chimney on a cold, or exposed
outside 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, the draft may be severely
affected. In one instance our research showed a
new chimney of adequate sizing produced only .035” W.C. after 30 minutes of continuous firing
at 13.0% CO2. Outside wall chimneys take
longer to heat up and can have .00” W.C. draft
at burner start-up. You may have to consider a
special alloy chimney flue liner with insulation
around it and stabilizing draft cap or even a
draft inducing fan in severe cases.
A. General Guidelines.
1. Vent system installation must be in accordance with
these instructions and applicable provisions of local
building codes. Contact local building or fire
officials about restrictions and installation inspection in your area.
2. The RSA Series is designed to be vented into a
fireclay tile-lined masonry chimney or chimney
constructed from type-L vent or a factory built
chimney that complies with the type HT requirements of UL103. The chimney or vent pipe shall
have a sufficient draft at all times, to assure safe
proper operation of the boiler. See Figure 12 for
recommended installation.
a. Install a draft regulator (supplied by installer)
following the instructions furnished with the
regulator. See Figure 13 for alternate regulator
locations.
b. With any new or replacement installation the
chimney has to be considered. Chimneys that
have a high heat loss become less suitable as the
heat loss of the home goes down and the
efficiency of the boiler goes up. Most homes
have a chimney appropriate for the fuel and the
era in which the home was built. That may
have been a coal fired or an inefficient oil fired
boiler built into a home without insulation or
storm windows. With increasing fuel prices that
home probably has been insulated and fitted
with storm windows so that the heat loss of the
home has been reduced. This requires less fuel
to be burned and sends less heat up the chimney.
A new boiler probably has a higher efficiency
c. For the same reasons as in (2.) above, heat
extractors mounted into the breeching are not
recommended.
3. For minimum clearances to combustible materials
refer to Figure 2.
18
Figure 12: Recommended Smokepipe Arrangement and Chimney Requirements
Figure 13: Draft Regulator Locations
19
V. Electrical
DANGER
Positively assure all electrical connecti ons are unpow ered before attempting installation or
service of elec tric al components or connections of the boiler or bui lding. Lock out all ele ctrical
boxes wi th pa dlock once power is turned off.
WARNING
Failure to properly wire electrical connections to the boiler may result in serious physical
harm.
Electrical pow er may be from more than one source. Make sure all power is off before
attempting any electrical work.
Each boiler must be protected with a properly sized fused disconnect.
Never jump out or make inoperative any safety or operating controls.
The w iring diagrams contained in this manual are for reference purposes only. Refer to the
w iring diagram of any controls used with the boiler. Read, understand and follow all wiring
instructions supplied with the controls.
this manual for the electrical diagram for this type
of system. Connect the system circulator wire leads
to the proper locations on the Aquastat control,
L8124C/L8148A. See Figure 14 or 15. Connect
the thermostat to the ‘T-T’ terminals on the
L8124C/L8148A control. Set thermostat heat
anticipator settings to 0.60 amps.
A. General
1. Install wiring and electrically ground boiler in
accordance with requirements of the authority
having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA
70, and/or the CSA C22.1 Electric Code.
2. A separate electrical circuit should be run from the
main electrical service with a fused disconnect
switch in the circuit.
6. Conventional Circulator Zoned System – Refer to
Figure 16 of this manual for the electrical diagram
for this type of system.
Read, understand and follow all of the instructions
provided with the Honeywell R8888 control.
3. Wiring should conform to Figure 14 and/or 15.
B. System Controls and Wiring
7. Conventional Zone Valve Zoned System – Refer to
Figure 17. Wiring to the most popular models of
zone valves are given in Figure 18.
1. Refer to National Electric Code or Local Electric
Codes for proper size and type of wire required.
Follow Code.
Locate C1 and C2 inside the L8124C Honeywell
control. Connect the two (2) terminals to the
system circulator wire leads, supplied with boiler.
2. Use anti-short bushings on all wiring passing
through boiler jacket, junction boxes and/or control
boxes.
Connect the H1 and H2 terminals inside the R8889
to the ‘T-T’ terminals in the L8124C Honeywell
Control. Refer to Figure 17.
3. Use armored cable (BX) over all exposed line
voltage wiring.
Connect the thermostat of each zone and the
circulator for that zone to R8889 panel. If an
Alliance indirect water heater is used, connect the
Alliance thermostat and circulator to the Zone 1
terminals of the R8889. Set thermostat anticipator
settings to 0.12 amps.
4. If an Alliance indirect water heater is used, use
priority zoning. Do not use priority zoning for
Hydro-Air Systems.
5. Single Zone System – Refer to Figure 14 or 15 of
20
Figure 14: “RSAL” Wiring Less Tankless, Single Circulator
Figure 15: “RSAT” or “RSAR” Wiring with Tankless, Single Circulator
21
22
Figure 16: Circulator Zoned Wiring for Honeywell R8888
23
Figure 17: Zone Valve Zoned Wiring for R8889
Figure 18: Different Manufacturer’s Zone Valve Connections to Honeywell R8889
24
NOTICE
The Burnham EC50 00 Control includes a water temperature sensor. Mount this sensor to the
sys te m s upply piping.
8. Burnham EC5000 Circulator Zoned System – Refer
to Figure 19 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 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
operation and setup details.
25
26
Figure 19: Circulator Zoning with EC5000 Wiring Schematic
27
Figure 20: Zone Valve Zoned with EC5000 Wiring Schematic
VI. Oil Piping
A. General.
B. Single-pipe Oil Lines.
1. Use flexible oil line(s) so that burner can be
removed without disconnecting the oil supply.
1. Standard burners are provided with single-stage
3450 rpm fuel units with the bypass plug removed
for single-pipe installations.
2. A supply line fuel oil filter is recommended as a
minimum for all firing rates but a pleated paper
fuel oil filter is recommended for the lowest firing
rate application to prevent nozzle fouling.
2. The single-stage fuel unit may be installed singlepipe with gravity feed or lift. Maximum allowable
lift is 8 feet. See Figure 21.
3. Use Flared fittings only. Do not use compression
fittings.
NOTICE
4. Use of a high efficiency micron filter (Garber or
equivalent) in addition to conventional filter is
highly recommended.
Oil piping must be absolutely airtight or
leaks or loss of prime may result. Bleed line
and fuel unit completely.
Figure 21: Single-Pipe Installation
28
TABLE 2: SINGLE STAGE UNITS (3450 RPM)
TWO PIPE SYSTEMS
Lift "H"
(See Figure)
TABLE 3: TWO-STAGE UNITS (3450 RPM)
TWO-PIPE SYSTEMS
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'
3'
Lift "H"
(See Figure)
Maximum Length of Tubing
"H" + "R" (See Figure)
3/8" OD
Tubing
1/2" OD
Tubing
0'
93'
100'
100'
2'
85'
100'
68'
100'
4'
77'
100'
4'
63'
100'
6'
69'
100'
5'
57'
100'
8'
60'
100'
6'
52'
100'
10'
52'
100'
7'
47'
100'
12'
44'
100'
8'
42'
100'
14'
36'
100'
9'
36'
100'
16'
27'
100'
10'
31'
100'
18'
---
76'
11'
26'
100'
12'
21'
83'
13'
---
62'
14'
---
41'
C. Two-Pipe Oil Lines
1. For two-piped systems, where more lift is required,
the two-stage fuel unit is recommended. Table 2
(single-stage) and Table 3 (two-stage) show
allowable lift and lengths of 3/8 inch and 1/2 inch
OD tubing for both suction and return lines. Refer
to Figure 22.
Figure 22: Two-Pipe Installation
29
VII. System Start-Up
10. Open isolation valve in boiler supply piping.
A. Verify that the venting, water piping, oil piping, and
electrical system are installed properly. Refer to
installation instructions contained in this manual.
11. Remove hose from bib cock.
D. CONFIRM that the boiler and system have no water
B. Confirm all electrical, water and oil supplies are turned
leaks.
off at the source and that the vent is clear from
obstructions.
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 and
oil lines have been tested.
F. LUBRICATION. Follow instruction on burner and
circulator label to lubricate, if oil lubricated. Most
motors currently used on residential type burners
employ permanently lubricated bearings and thus do
not require any field lubrication. Water lubricated
circulators do not need field lubrication.
C. Fill entire heating system with water and vent air from
system. Use the following procedure on a Series Loop
or multi-zoned system installed as per Figure 8 or 9.
1. Close isolation valve in boiler supply piping.
G. SET CONTROLS with burner service switch turned
2. Isolate all circuits by closing zone valves or
balancing valves.
“OFF”.
1. SET ROOM THERMOSTAT about 10° above
room temperature.
3. Attach a hose to bib cock located just below
isolation valve in boiler supply piping. (Note Terminate hose at a suitable floor drain or outdoor
area).
2. PRESS RED RESET BUTTON on R4184D Oil
Primary Control and release.
4. Starting with one circuit at a time, open zone valve
or valve.
3. SET HIGH LIMIT dial on L8124C/L8148A at
temperature to suit requirements of installation.
5. Open bib cock.
H. REMOVE GUN ASSEMBLY
6. Open fill valve (Make-up water line should be
located directly after isolation valve in boiler supply
piping between air scoop and expansion tank).
1. Check nozzle size, head size, gun setting, and
positioning of electrodes. This information is
shown in Figure 23, and Tables 4 and 4A.
7. Allow water to flow into drain until discharge from
hose is bubble free for 30 seconds.
2. Reinstall gun assembly.
I. VERIFY OIL BURNER SETTINGS BEFORE
8. When zone is completely purged of air, close zone
valve or balancing valve. Open the zone valve for
the next zone to be purged. Repeat this step until
all zones have been purged. At completion, open
all zone valves or valves.
STARTING
1. BURNER AIR BAND AND AIR SHUTTER
SETTINGS, see Tables 4 and 4A.
2. OPEN ALL OIL LINE VALVES.
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.
J. START OIL BURNER
9. Close bib cock, continue filling the system until the
pressure gauge reads 12 psig. Close fill valve.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
fill to 12 psig.
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
30
Table 4: Beckett AFG, AF, & SF Burners
Air
Settings
Boiler Model
Firing Rate
(GPH)
Hago
Nozzle
Shutter
Band
Head (stop screw)
Pump Pressure
RSA85
.85
.75 x 70B
10
0
N/A
140
RSA110
1.10
.90 x 80B
8
0
N/A
140
RSA125
1.25
1.0 x 80B
7
0
N/A
140
RSA135
1.35
1.10 x 80B
9
0
N/A
140
RSA170
1.70
1.65 80 A
7
0
N/A
100
RSA195
1.95
2.00 80 B
7
0
N/A
100
RSA240
2.40
2.50 80 B
7
0
N/A
100
RSA285
2.85
3.00 80 B
7
0
N/A
100
Table 4A: Becket AFG Burner
Air
Settings
Boiler Model
Firing Rate
(GPH)
Hago
Nozzle
Shutter
Band
Head (stop screw)
Pump Pressure
RSAH85
.75
.65 x 80B
6
0
N/A
140
RSAH110
1.0
.85 x 80B
7
0
N/A
140
RSAH125
1.1
.90 x 80B
7
0
N/A
140
RSAH135
1.25
1.0 x 80B
9
0
N/A
140
SOLID stream without air bubbles for approximately 10 seconds.
L. OTHER ADJUSTMENTS
1. ADJUST THE AIR BAND AND/OR AIR SHUTTER.
3. Close vent fitting and burner flame should start
immediately.
Beckett Burners:
a. Adjust air supply by loosening lock screws and
moving the air shutter and if necessary the air
band. Refer to Table 4 and 4A preliminary
settings.
4. If the burner does not start immediately, check the
manual overload switch on the motor, if so
equipped, and the safety switch on the burner
primary control.
2. ADJUST DRAFT REGULATOR for a draft of
-.02” (water gauge) over the fire after chimney has
reached operating temperature and while burner is
running.
K. ADJUST OIL PRESSURE
1. Locate oil pressure adjusting screw and turn
screw until Pressure Gauge reads the correct
pump pressure required for the specific boiler.
Refer to table 4 & 4A.
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 minimum of excess air. Make final check using suitable
2. DO NOT REMOVE PRESSURE GAUGE until
later.
31
(Non-Burnham Drawing
Copy from other Manual)
Figure 23: Electrode / Head Setting
2. IF NOZZLE CONTINUES TO DRIP, repeat step
N.1. If this does not stop the dripping, remove cut
off valve and seat, and wipe both with a clean cloth
until clean. Then replace and readjust oil pressure.
If dripping or after burn persist replace fuel pump.
instrumentation to obtain a CO2 of 11.5 to 12.5%
with draft of -.02” w.c. in fire box. These settings
will assure a safe and efficient operating condition.
If the flame appears stringy instead of a solid flame,
try another nozzle of the same type. Flame should
be solid and compact. After all adjustments have
been made, recheck for a draft of -.02” w.c. over the
fire.
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 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 protected from dirt and
abuse. Nozzles are mass produced and can vary
from sample to sample. For all of those reasons
a spare nozzle is a desirable item for a serviceman to carry.
4. TURN “OFF” BURNER and remove pressure
gauge. Install gauge port plug and tighten. Start
burner again.
M. FLAME FAILURE
The RSA boiler controls operate the burner automatically. If for unknown reasons the burner ceases to fire
and the rest button on the primary control has tripped,
the burner has experienced ignition failure. Before
pressing the rest button, call your serviceman immediately.
b. FLAME SHAPE — Looking into the combustion chamber through the flame plug hole, the
flame should appear straight with no sparklers
rolling up toward the top of the chamber. If the
flame drags to the right or left, sends sparklers
upward or makes wet spots on the combustion
chamber, the nozzle should be replaced. If the
condition persists look for fuel leaks, air leaks,
water or dirt in the fuel as described below.
N. CHECK FOR CLEAN CUT OFF OF BURNER
1. AIR IN THE OIL LINE between fuel unit and
nozzle will compress when burner is on and will
expand when burner stops, causing oil to squirt
from nozzle at low pressure as burner slows down
and causing nozzle to drip after burner stops.
Usually cycling the burner operation about 5 to 10
times will rid oil line of this air.
c. FUEL LEAKS— Any fuel leak between the
pump and the nozzle will be detrimental to good
combustion results. Look for wet surfaces in the
air tube, under the ignitor, and around the air
inlet. Any such leaks should be repaired as they
may cause erratic burning of the fuel and in the
32
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 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.
extreme case may become a fire hazard.
d. AIR LEAKS— Any such leaks should be
repaired, as they may cause erratic burning of
the fuel and in extreme cases may become a fire
hazard.
There may be many possible causes of leaks in
oil lines such as:
i.
i. HIGH ALTITUDE INSTALLATIONS
Fitting leaks due to misflared tubing or
damaged fitting.
Typically, the rule to use for high altitudes is to
increase the air supply by 4% per each 1000 ft.
above 2000 ft. altitude from sea level. This
means that the air setting will have to be higher
than the calibration marks in proportion to the
altitude. Use instruments and set for 11.5 to
12.5% CO2.
ii. Fuel line leak due to crushed or bent tubing.
iii. Filter connection leaks.
iv. Tank connection leaks.
The following actions can eliminate air leaks:
i.
Bleed pump as detailed in System Start-Up
Section of this manual.
j. START-UP NOISE — Late ignition is the cause
of start-up noises. If it occurs recheck for
electrode settings, flame shape, air or water in
the fuel lines.
ii. Replace flare fittings.
iii. Replace oil supply line.
k. SHUT DOWN NOISE — If the flame runs out
of air before it runs out of fuel, an after burn
with noise may occur. That may be the result of
a faulty cut-off valve in the fuel pump, or it may
be air trapped in the nozzle line. It may take
several firing cycles for that air to be fully
vented through the nozzle. Water in the fuel or
poor flame shape can also cause shut down
noises.
P. TEST CONTROLS
iv. Repair oil filter leaks
v.
Replace or repair tank fittings.
e. GASKET LEAKS— If 11.5% to 12.5% CO2
with a #1 smoke cannot be obtained in stack,
look for air leaks around the canopy seal. Such
air leaks will cause a lower CO2 reading in the
stack. The smaller the firing rate the greater
effect an air leak can have on CO2 readings.
f. DIRT— A fuel filter is a good investment.
Accidental accumulation of dirt in the fuel
system can clog the nozzle strainer and produce
a poor spray pattern from the nozzle.
g. WATER— Water in the fuel, in large amounts,
will stall the fuel pump. Water in the fuel
pump, in smaller amounts, will cause excessive
wear on the pump, but more importantly water
does not burn. It chills the flame, causes smoke,
and allows unburned fuel to pass through the
combustion chamber and clog the flueways of
the boiler.
1. CHECK THERMOSTAT OPERATION. Raise and
lower thermostat setting as required to start and
stop burner.
h. COLD OIL— If the oil temperature approaching the fuel pump is 40°F or lower, poor
combustion or delayed ignition may result. Cold
2. VERIFY PRIMARY CONTROL SAFETY FEATURES using procedures outlined in Instructions
furnished with control (See back of Control Cover)
or Instructions as follows:
NOTICE
CHECK TEST PROCEDURE. A v ery go od
tes t f or isolat ing fue l side problem s is to
d is conn ec t th e f uel s ystem an d w ith a 24 "
le ngth of tubing, fi re out of a n a ux iliar y
five gallon p ail o f c le an, fre sh , w ar m # 2
oil f rom anot her sou rce . I f t he burne r
r uns suc ce ss fully w hen dra wing out of
the a uxili ary pa il th en the prob le m is
iso la ted to the fue l or f uel line s b eing
us ed on the jo bsi te .
33
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.
a. Simulate flame failure:
•
•
•
•
Follow the starting procedure to turn on the
burner.
Close the hand valve in the oil supply line.
Safety switch should lock out in approximately 15 seconds. Ignition should stop
and oil valve should close. Blower will stop
after postpurge period.
Push red reset button to reset safety switch.
d. Adjust thermostat to lowest setting. Refill
boiler.
Q. Boiler is now ready to be put into service.
b. Simulate ignition failure:
•
•
•
Follow the starting procedure to turn on the
burner, but do not open the oil supply hand
valve.
Safety switch should lock out in approximately 15 seconds. Ignition and motor
should stop and oil valve should close.
Push red reset button to reset safety switch.
A leaky system will increase the volume of make-up
water supplied to the boiler which can significantly
shorten the life of the boiler. Entrained in make-up
water are dissolved minerals and oxygen. When the
fresh, cool make-up water is heated in the boiler the
minerals fall out as sediment and the oxygen escapes
as a gas. Both can result in reduced boiler life. The
accumulation of sediment can eventually isolate the
water from contacting the steel. When this happens
the steel in that area gets extremely hot and eventually
cracks. The presence of free oxygen in the boiler
creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the steel
through from the inside. Since neither of these failure
types are the result of a manufacturing defect the
warranty does not apply. Clearly it is in everyone’s
best interest to prevent this type of failure. The
maintenance of system integrity is the best method to
achieve this.
c. Simulate power failure:
•
•
•
•
Follow the starting procedure to turn on the
burner.
With the burner running, turn off the power
to the system by tripping the circuit breaker
or removing the fuse.
Burner should stop.
Restore power. Burner should start.
3. VERIFY HIGH LIMIT OPERATION.
a. Adjust thermostat to highest setting.
b. Observe temperature gauge. When temperature
is indicated, adjust limit to setting below
observed temperature. Burner should stop.
c. Adjust limit to setting above observed temperature. Burner should start.
d. Adjust thermostat to lowest setting. Adjust limit
to desired setting.
34
INSTALLATION INSTRUCTIONS FOR SHIELD REQUIRED FOR COMBUSTIBLE FLOOR
This shield for combustible floors is intended for use only with the following Burnham oil-fired boilers:
Use Part Number 6183504 for the following models:
RSA(H)85
RSA(H)110
RSA(H)125
ADDS 4-3/16” TO BOILER HEIGHT
RSA(H)135
Use Part Number 6183505 for the following models:
RSA170
RSA195
RSA240
ADDS 5-3/8” TO BOILER HEIGHT
shifting position during setting of boiler.
1) Place shield on combustible floor with “TOP” surface
upward and “FRONT” surface directly below the
expected position of the oil burner.
2)
3)
RSA285
Locate shield 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
required by ANSI/NFPA 31.
4)
Set boiler squarely on top of shield such that base plate
of boiler rests flat on top surface of shield and does not
over-hang shield on any side. Confirm clearance to
combustible walls. Refer to Figure 2.
5)
Do not enclose boiler (including shield) on all four
sides. Boiler may be enclosed on any three sides while
maintaining minimum clearance shown in Figure 24
for each of those three sides.
Fasten shield to combustible floor to keep shield from
Figure 24
35
VIII. Service and Cleaning
1. CLEAN THE FIRETUBES
NOTICE
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.
BUR NER S HU TD O WN : O p e n S e rv ic e
Switch to turn off burner.
Manual Oil Supply Valve should be closed
and Electric Service to boiler turned off if
boiler will not be operated for an extended
period of time.
c. Remove turbulators.
d. Using a firetube brush clean firetubes. DO NOT
extend brush past the end of the bottom
tubesheet.
A. General. Inspection service and cleaning should be
e. Assemble the boiler in reverse order.
conducted annually. Turn off electric power and close
oil supply valve while conducting service or maintenance.
Units should be cleaned at least once a year, preferably
at the end of each heating season.
It is not necessary to remove burner to clean boiler.
Brush, scrape, or vacuum from top.
B. Firetubes and Combustion Chamber. (See Figure 25)
Figure 25: Cleaning of RSA Boiler
36
IX. Repair Parts
All RSA Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you
require assistance in locating a Burnham distributor in your area, or have questions regarding the availability
of Burnham products or repair parts, please contact your Burnham Regional Sales Office as listed below.
B urnh am Corpo rati on Regional Offices
A. B urnham Cor poration - Centr al & Wes tern R egio ns C. Burnham Corporation - M etropolitan Region
P.O. Box 3079
P.O. Box 3079
La ncast er, PA 17604 -3079
Lancas ter, PA 17604-3079
P hone: (717) 481 -8400
Phone: (717) 481-8400
FAX : (717) 481 -8408
FA X: (717) 481-8409
B. B urnham S ales Cor poration - Nort heast Region
19 -27 M yst ic Av enue
Som erv ille, M A 02145
P hone: (617) 625 -9735
FAX : (617) 625 -9736
D. B urnham Co rporat ion - Mid-A tlant ic Region
P.O. Box 3079
La ncast er, PA 17604 -3079
P hone: (717) 481 -8400
FAX : (717) 481 -8409
Contact Regional Office Indicat ed f or y our S tate
Al abam a
A
Ne bra ska
A
Oreg on
A
Ala ska
A
N eva da
A
P enns yl van ia
D
Arizo na
A
New Ha mps hire
B
Rh ode Isla nd
B
Arkan sas
A
Ne w Jersey
S outh Caroli na
A
Cal iforn ia
A
Atlan tic, Burlin gton, Camd en,
S outh Dakota
A
Col ora do
A
Ca pe May, C umbe rla nd,
Tennes see
A
Te xas
A
D
Conn ecticut
B
Glou cester, M erc er,
Del aware
D
Monm outh, Oce an, S ale m
Utah
A
Fl ori da
A
Co unties
Ve rm ont
B
Ge org ia
A
A ll other Co unties
Hawa ii
A
New Mexico
Ida ho
A
Ne w York
Ill inois
A
Alb any, Fulton , M ontgom ery,
India na
A
Re nss ela er, S ara to ga,
C
A
Virgin ia
Arling to n,Acco mac k,Cl arke,
Fairfax,Frederick,Fauq uier,
D
Lo udoun ,North ampto n a nd
Prince Wil liam Co unties
B
Io wa
A
S ch enec tady, S cho harie,
Kan sas
A
Warre n, Washingto n Co unties
K entuc ky
A
All Other Co unties
Loui sia na
A
Mai ne
A ll other Co unties
A
Was hing ton
A
C
Wash ington , D.C.
D
N orth Caroli na
A
West Virgin ia
D
B
No rth Dak ota
A
Wisc onsin
A
M aryla nd
D
Oh io
Wyomi ng
A
Ma ss ach use tts
B
A th ens , B elm ont, Gall ia,
Michig an
A
J effe rson, Lawrenc e, M eig s,
Min nes ota
A
Mo nro e, an d Was hing ton
M issis sip pi
A
Co unties
M iss ouri
A
A ll other Co unties
Monta na
A
Cana da
A
D
Okl ahom a
A
A
37
REPAIR PARTS
Figure 26: RSA85-135 Bare 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:
38
ITEM NO.
QTY.
DESCRIPTION
PART NO.
1
2
Wing Nut, 1/4 - 20
80860910
2
10
Washer, Flat 1/4 (SAE)
80860633
3
1
Canopy Assembly
6113509
4
2
1/2" Thick x 1" x 12-3/8" Cerafelt Strip
9206005
5
2
1/2" Thick x 1" x 13-3/8" Cerafelt Strip
9206005
6
2
Carriage Bolt, 1/4 - 20 x 3" Lg.
80860111
7
'A'
Turbulator
8113501
8
1
Heat Exchanger Assembly
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" Cerafelt Strip
9206003
17
1
Combustion Chamber
8203006
18
1
Cerablanket
8203512
19
1
Base Assembly
6183508
20
4
Machine Screw, Hex Head, 1/4 - 2 x 1/4"
80860810
21
4
Hex Nut, 1/4 - 20 (Heavy Hex)
80860407
'B'
BOILER MODEL
'A'
'B'
RSA85
12
603350112
RSA110
16
603350116
RSA125
12
603350212
RSA135
16
603350216
39
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 27: RSA170-285 Boiler Repair Parts
40
ITEM NO.
DESCRIPTION
PART NO.
1
Jacket Top Panel Assembly
2
Canopy Assembly
6113510
3
½" Thick x 1" x 23" C er afelt S trip
9206005
4
½" Thick x 1" x 17" C er afelt S trip
9206005
5
Turbulator, See 'A' for Quantity
6113504
6
Tankless Heater Gasket
8036025
#7524 Tankless Heater Assem bly
6036015
#7530 Tankless Heater Assem bly
6036016
8
Tapped Heater Cover Plate
7033501
9
Heat Exchanger Assembly
'B'
10
½ x 2" x 25" C er afelt S trip
9206003
11
½ x 2" x 21" C er afelt S trip
9206003
12
Combustion Chamber
8203003
13
Block Insulation Assembly
14
Jacket Left S ide Panel Assembly
60435061
15
Jacket Upper Front Panel Assembly
60435033
16
Jacket Lower Front Panel Assembly
60435042
17
Base Assembly
6186304
18
Jacket Rear Panel Assembly
60435071
19
Jacket Right S ide Panel Assembly
60435051
7
60435022
Supplied with Item #12
Boiler Model
'A'
'B'
RSA170
10
6306332
RSA195
13
6306329
RSA240
16
6306309
RSA285
19
6306310
41
ITEM
DESCRIPTION
PART NUMBER
1
Jacket Top Panel
60435086
Jacket Wrap-A-Round Panel, RSA85/110
60435087
Jacket Wrap-A-Round P anel, RSA125/135
60435088
Temperature / P ressure Gauge
8056169U
Honeywell L8148A1090 Hi-Limit Control
80160449U
Honeywell L8124C1102 Limit Control
80160406
5
Observation Port Cover / Hardware
8026015
6
Burner Primary Control, R4184D1027
80160473
2
3
4
42
SERVICE SCHEDULE
DATE
SERVICE PERFORMED
43
BECKETT BURNER PARTS LIST FOR RSA SERIES STEEL BOILERS
FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER
MANUFACTURER:
R. W. BECKETT CORP.
38251 CENTER RIDGE RD.
P. O. BOX 1289
ELYRIA, OHIO 44036
1-800-645-2876
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(s) number as listed below.
1)
2)
Boiler Model
RSA85
RSA110
RSA125
RSA135
Burner Model
AFG
AFG
AFG
AFG
Air Tube Combination
AF60BN
AF60XN
AF60J2
AF60JZSS
Spec. No.
BCB6201 BCB6202 BCB6203
BCB6204
Air Band
3492BKA
3492BKA
3492BKA
3492BKA
Air Band Nut
4150
4150
4150
4150
Air Band Screw
4198
4198
4198
4198
3709BK
3709BK
3709BK
3709BK
Air Shutter
Air Shutter Screw
4198
4198
4198
4198
6)
Blower
2999
2999
2999
2999
7)
Bulkhead Fitting
3488
3488
3488
3488
8)
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
3146812
3146812
3146812
3146812
31498
31498
31498
31498
18) Flange and Air Tube Assembly
Gasket
19) Head
360003
360003
360006
360006
Head Screws
4221
4221
4221
4221
Hole Plug
2139
2139
2139
2139
20) Housing Assembly w/Inlet Bell
5624
5624
5624
5624
21) Motor
2456
2456
2456
2456
22) Nozzle Adapter
213
213
213
213
NC6058
NC6058
NC6058
NC6048
25) Pump
2460
2460
2460
2460
27) Static Plate
31646
3383P
31646
31646
28) Ignitor
7440
7440
7440
7440
29) Ignito r Hinge Screw
4217
4217
4217
4217
30) Ignitor Holding Screw
4198
4198
4198
4198
23) Nozzle Line Electrode Assembly
31) Ignitor Gasket Kit
51304
51304
51304
51304
32) Wire G uard
3345
3345
3345
3345
33) Baffle
3708
N/A
N/A
N/A
44
Ordering Information for Quality Replacement Parts
Figure 29: BECKETT AFG MODEL BURNER
45
BECKETT BURNER PARTS LIST FOR RSA SERIES STEEL BOILERS
FOR REPLACEMENT OIL BURNER PARTS, CONTACT YOUR WHOLESALER OR THE BURNER MANUFACTURER:
R. W. BECKETT CORP.
38251 CENTER RIDGE RD.
P. O. BOX 1289
ELYRIA, OHIO 44036
1-800-645-2876
Boiler Model
RSA170
RSA195
RSA240/285
Burner Model
AF
AF
AF
Air Tube Combination
AF60XO
AF60XP
SF60FY
Spec. No.
647104
647106
647201
Air Band
3492
3492
3217
Air Band Nut
4150
4150
460
Air Band Screw
4198
4198
4219
Air Shutter
3494
3494
3215
Air Shutter Screw
4198
4198
493
6)
Blower
2459
2459
2288
7)
Bulkhead Fitting
3488
3488
3488
8)
Bulkhead Fitting Locknut
3666
3666
3666
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
3616
3616
3616
360012
360022
5434
Head Screws
4221
4221
4221
Hole Plug
2139
2139
2139
20) Housing Assembly w/Inlet Bell
5624
5624
53485
21) Motor
2456
2456
2364
22) Nozzle Adapter
213
213
213
NC6048
NC6058
NC6048
25) Pump
2460
2460
2460
27) Static Plate
3383
3383
3383
28) Ignitor
7440
7440
7440
29) Ignitor Hinge Screw
4217
4217
4217
30) Ignitor Holding Screw
4198
4198
4198
31) Ignitor Gasket Kit
51304
51304
51304
32) Wire Guard
3345
3345
3345
1)
2)
Gasket
19) Head
23) Nozzle Line Electrode Assembly
46
Ordering Information for Quality Replacement Parts
Figure 30: BECKETT AF and SF MODEL BURNERS
47
48