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Burnham C3 and C4 Install and Operation
Burnham C3 and C4 Install and Operation
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
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
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
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
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.
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 .
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
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.
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 .
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.
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 .
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.
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.
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.
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
36 79