U.S. Boiler Company LE DV Series, Installation, Operating And Service Instructions

Page 1: ... e e s n e h W r o t c a r t n o c g n i t a e h r u o y l l a c r e l i o b o t s r i a p e r r o e c i v r e s r o F l e b a L g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b r e b m u N l e d o M r e l i o B V D E L r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I r o t c a r t n o C g n i t a e H r e b m...

Page 2: ...y devices D All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and or Local Regulations DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or prop...

Page 3: ...see that all controls are correctly installed and are operating properly when installation is complete including verifying that the limit sensor is fully installed seated in bottom of Well Failure to properly install Limit Sensor may result in property damage personal injury or loss of life due to elevated operating temperatures and or pressures This boiler is suitable for installation on combusti...

Page 4: ...be installed so there are provisions for adequate combustion and ventilation air This boiler must be connected to an approved chimney or vent system in good condition Serious property damage could result if the boiler is connected to a dirty or inadequate chimney or vent system The interior of the chimney flue must be inspected and cleaned before the start of the heating season for any obstruction...

Page 5: ...5 I General Information Figure 1A LEDV Packaged Water Boiler with Beckett AFII Burner ...

Page 6: ...6 I General Information continued Figure 1B LEDV Packaged Water Boiler with Riello BF Burner ...

Page 7: ...ng Capacity MBH AHRI NET Ratings MBH Direct Vent System AFUE GPH MBH Vent Pipe Dia Inches Maximum Vent Length Feet LEDV1 0 60 84 74 64 4 20 86 7 Table 1 rating data Table 2 general information Boiler Model No Water Capacity Gallons Approximate Shipping Weight LBS LEDV1 6 1 325 ...

Page 8: ...nstalled in rooms with clearances from combustible material as listed above Listed clearances cannot be reduced for alcove or closet installations A INSPECT SHIPMENT carefully for any signs of damage 1 All equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of crated boiler to the carrier in good condition 2 Any claims for damage or shortage in shipment...

Page 9: ...ined space of a conven tionally constructed building the fresh air infiltration through cracks around windows and doors normally provides adequate air for combustion and ventilation 5 For boiler located in a confined space or an unconfined space in a building of unusually tight construction provide outdoor air with the use of two permanent openings which communicate directly or by duct with the ou...

Page 10: ...holes in Spacer Tubesheet or Door See Figure 4 Tighten all hex nuts and cap screws by hand only 7 Replace door assembly Hinge brackets attached to door must rest on top of hinge brackets attached to Tubesheet See Figure 4 Slide hinge pins through hinges from top and install cotter pins Close door and install 5 16 18 x 3 long hex head cap screws through flatwashers and left side of door and into ta...

Page 11: ...nt of L7248L Control Mount Control on factory installed immersion well located in center tapping on top of boiler with L7248L Boiler Control Transformer Relay Control Center Harness Assembly on the left hand side as shown in Figure 5B Step b Remove Transformer Relay Cover from Junction Box Locate 2 8 x 1 2 sheet metal screws SMS and 1 5 8 cable clamp in parts bag Use 8 x 1 2 SMS to secure Junction...

Page 12: ...12 Figure 5B Relief Valve and Boiler Control Assembly Details Riello BF Burner Figure 6 Limit Sensor Insertion III packaged boiler assembly trim and controls continued ...

Page 13: ...ator to supply sufficient flow GPM to allow a 20 F temperature differential in the system When sizing the system circulator the pressure drop of all radiators baseboard and radiant tubing and all connecting piping must be considered a 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 encountere...

Page 14: ...14 Iv WATER PIPING AND TRIM continued Figure 8A Recommended Water Piping for Circulator Zoned Heating Systems Supply Side Circulator ...

Page 15: ...15 Iv WATER PIPING AND TRIM continued Figure 8B Recommended Water Piping for Zone Valve Zoned Heating Systems Supply Side Circulator ...

Page 16: ...allation is NOT complete unless a safety relief valve is installed as shown in Figure 8A or 8B Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns Do not pipe in any area where freezing could occur Do not install any shut off valves plugs or caps Iv WATER PIPING AND TRIM continued C Install Drain Valve in return piping See Figures 8A and 8B D Oil gr...

Page 17: ... may form on surfaces around vent termination To prevent deterioration surfaces should be in good repair sealed painted etc 5 Locate the vent terminal so vent pipe is short and direct and at a place on the exterior wall that complies with the minimum distances as specified in Figure 9 and listed below The vent terminal must be located a Not less than 12 inches above grade plus snow accumulation as...

Page 18: ...m must be completed with the Direct Oil Vent Kit which is shipped with the boiler Components of this kit are listed in the Repair Parts Section of this manual DANGER Vent pipe may not be spliced Do not drill through vent pipe Do not operate boiler if vent pipe has been crushed Vent pipe must be completely sealed Do not operate boiler if vent pipe insulation sleeve is damaged frayed or missing B Ve...

Page 19: ...19 v venting continued Figure 11 Vent Installation Figure 12 Vent Connector Un Assembled ...

Page 20: ...20 v venting continued Figure 13 Vent Connector Assembled Figure 14 Air Intake Installation ...

Page 21: ...traps a All horizontal runs must rise at least inch per foot toward vent terminal b Avoid any sags or dips in vent pipe C Air Intake Installation Direct Vent only See Figure 14 WARNING Do not reduce size of air intake pipe Read understand and follow combustion air instruction restrictions contained in the Pre Installation Section of this manual 1 General a Use 4 inch diameter single wall metal pip...

Page 22: ...ack plastic inlet cover from the right side of the Beckett AFII burner 2 Attach the Air Intake Terminal directly to the burner intake collar 3 Discard the Vacuum Relief Valve Alternate to 1 2 and 3 Keep the black plastic inlet cover in place and discard the Air Intake Terminal and the Vacuum Relief Valve WARNING Do not locate air intake termination into a crawl space or under a deck that also incl...

Page 23: ...et junction boxes and or control boxes 3 Use armored cable BX over all exposed line voltage wiring 4 If an indirect water heater is used use priority zoning Do not use priority zoning for Hydro Air Systems 5 Single Multiple Zone System Refer to Figures 15A or 15B for the electrical diagram for this type of system Connect the system circulator wire leads to the proper terminal on the L7248 Aquastat...

Page 24: ...vI electrical continued Figure 15A Schematic Wiring Diagram Cold Start Control with Beckett AFII Burner Refer to Figure 16 for Schematic wiring diagram of appropriate burner and oil primary control option ...

Page 25: ...5 vI electrical continued Figure 15B Schematic Wiring Diagram Cold Start Control with Riello BF Burner Refer to Figure 16 for Schematic wiring diagram of appropriate burner and oil primary control option ...

Page 26: ... STEAM OR WATER BOILER CONTROL SCHEMATIC REFER TO FIGURES 15A AND 15B NOTE APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC REFER TO FIGURES 15A AND 15B Figure 16 Schematic Wiring Diagrams For All Burner Options w Various Oil Primary Controls ...

Page 27: ...on fittings 4 Use of a high efficiency micron filter Garber or equivalent in addition to conventional filter is highly recommended B Single pipe Oil Lines 1 Standard burners are provided with single stage 3450 rpm fuel units with the bypass plug removed for single pipe installations 2 The single stage fuel unit may be installed single pipe with gravity feed or lift Maximum allowable lift is 8 feet...

Page 28: ...0 11 26 100 12 21 83 13 62 14 41 Lift H See Figure Maximum Length of Tubing H R See Figure 3 8 OD Tubing 3 GPH 1 2 OD Tubing 3 GPH 0 93 100 2 85 100 4 77 100 6 69 100 8 60 100 10 52 100 12 44 100 14 36 100 16 27 100 18 76 C Two Pipe Oil Lines 1 For two piped systems where more lift is required the two stage fuel unit is recommended Table 4 single stage and Table 5 two stage show allowable lift and...

Page 29: ...sion tank g Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds h When zone valve is completely purged of air close zone valve or shut off valve Open zone valve to the next zone to be purged Repeat this step until all zones have been purged At completion open all zone valves i Close purge valve continue filling the system until the pressure gauge reads 12 ps...

Page 30: ... of the nozzle line assembly check that head air plate setting number pointer lines up with a number on the scale which matches a value shown in Table 6 for Beckett AFII burner Refer to Table 7 and Figure 21 for Riello BF burner 2 Open all shut off valves in the oil supply line to the burner 3 Attach a plastic hose to fuel pump vent fitting and provide a container to catch the oil 4 REMOVE GAUGE P...

Page 31: ...ld start immediately after prepurge is completed Prepurge prevents burner flame until 15 seconds has elapsed after initial power is applied to burner During prepurge the motor and igniter will operate but the oil valve will remain closed Refer to Oil Primary Control Instructions for more details 5 Adjust oil pressure a When checking a fuel unit s operating pressure a reliable pressure gauge may be...

Page 32: ...failure Figure 22 Checking Adjusting Fuel Pump Pressure Refer to Oil Primary Control features Paragraph L Step 2 of this section and Section XII Troubleshooting Paragraph B If the failure re occurs call your heating contractor immediately before pressing the reset button WARNING Do not attempt to start the burner when excess oil has accumulated when the boiler is full of vapor or when the combusti...

Page 33: ...een held long enough Release the reset button The yellow light will turn off and the burner will start up again At burner start up click the reset button while the igniter is till on This will transition the control to a dedicated Pump Prime mode during which the motor igniter and valve are powered for four 4 minutes The yellow light will be on At the end of four 4 minutes the yellow light will tu...

Page 34: ...ket around perimeter of ignitor lid for proper seal If gasket is missing or damaged replace gasket Room light can effect cad cell resistance Reset safety switch Close line switch to boiler If burner starts and runs beyond safety switch cut off time cell is good If not install new cell Close hand valve in oil supply line Failure occurs device enters Recycle Mode Device tries to restart system after...

Page 35: ...entation c When the thermostat calls for heat the boiler control starts the system circulator and the thermal purge circulator pre purge time begins If the time is completed or boiler temperature is less than the Start Temperature 140 F default the start sequence continues by energizing the oil primary to operate the following sequence blower is started and operates for pre purge time spark is ene...

Page 36: ...The Boiler Control is factory programmed with a High Limit Setpoint of 180 F The boiler turns off when the boiler water temperature bt is above this value The High Limit setpoint is adjustable between 140 and 240 F The Operating Setpoint SP will equal the High Limit Setpoint b High Limit Differential HdF The Cold Start Boiler Control is factory pro grammed with a Differential of 15 F The Different...

Page 37: ...tart with no delay TT on 140 Start after 2 minute delay ZR on ZC_ ZR 140 Start with no delay ZR on ZC_ ZR 140 Start after 2 minute delay ZR on ZC_ DH 140 Start with no delay ZR on ZC_ DH 140 Start with no delay Table 9 Circulator Pre purge Time Example Parameter PP_ 2 Minutes g ZC and ZR Terminal Function ZC_ The boiler control allows configuration of the ZC output functionality to help the LEDV b...

Page 38: ...all for heat and energizes the System Circulator output to service heating zone 1 A second zone s thermostat may be wired to the ZR input to energize heating zone 2 circulator wired to the ZC output Both outputs function independently TT input controls only the System Circulator output and the ZR input controls only the ZC output Both inputs cause a boiler call for heat iii External Low Limit Para...

Page 39: ...and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except it gives specific read ings A color chart on the side of the small hydrion dispenser gives the reading pH Hydrion paper is inexpensive and obtainable from any chemical sup...

Page 40: ...orners 3 Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time 4 To recondition the heating system in the fall season after a prolonged shut down follow the instructions outlined in Section VIII System Start Up Paragraphs A through N WARNING This boiler contains controls which may cause the boiler to shut down and not restart without service If...

Page 41: ... gaskets and combustion chamber liner for damage Replace any damaged pieces immediately E CLOSE AND SECURE BURNER SWING DOOR CAUTION Do not start burner unless burner swing door is securely closed Close door install 5 16 18 lg cap screws and washers and tighten securely Door should be parallel to tubesheet when viewed from top and sides Reconnect two halves of Swing Door Interlock F Vent Air Intak...

Page 42: ...he oil supply line filter 2 Remove and clean the pump strainer if applicable 3 Replace the nozzle with an equivalent nozzle Refer to Table 6 for Beckett Burner Settings Refer to Table 7 for Riello BF Burner Settings 4 Clean and inspect the electrodes for damage replacing any that are cracked or chipped 5 Clean the combustion head of all lint and soot 6 Inspect the transformer cables and connectors...

Page 43: ... 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 airtight plastic bag RCF and crystalline silica are not clas...

Page 44: ...ray pattern from the nozzle The smaller the firing rate the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt 6 WATER Water in the fuel in large amounts will stall the fuel pump Water in the fuel in smaller amounts will cause excessive wear on the pump but more importantly water doesn t burn It chills the flame and causes smoke and unburn...

Page 45: ...ed within 15 seconds of oil valve actuation known as Trial For Ignition TFI lockout will occur Lockout is indicated by a red LED solid on located on the oil primary control Hard Lockout will occur if the Oil Primary Control locks out three 3 times during a call for heat This is indicated by red light reset button solid on C INTELLIGENT OIL BOILER CONTROL Cold Start Boiler Control is used on Boiler...

Page 46: ...ring safety output relay check sequence or un powered during running or powered in idle in combination with water temperature above 264 F limit Cycle power to the control Replace control if problem persists Err 5 Line Voltage Fault 80 Vac AC voltage out of specification high or low check L1 L2 110 VAC Err 6 Fuse missing Internal fuse is blown or missing The fuse protects the Aquastat from miswirin...

Page 47: ... Company Wholesale distributor Should you require assistance in locating a U S Boiler Company Distributor in your area or have questions regarding the availability of U S Boiler Company products or repair parts please contact U S Boiler Company Customer Service at 717 481 8400 or Fax 717 481 8408 ...

Page 48: ...48 xiii Repair Parts continued Figure 29 LEDV Bare Boiler Assembly ...

Page 49: ...Inner Insulation 1 8203301 4E Front Door and Furnace Rope Gasket 1 7203305 4F 6 x 3 4 Drive Screw 2 80860718 5A Hinge Bracket 4 7022701 5B Hinge Spacer 2 7303310 5C Hinge Pin 2 80861614 5D Hairpin Cotter 2 80861667 6A Rear Door Painted 1 7303314 6B Rear Door Insulation 1 8203303 6C Rear Door Rope Gasket 1 7203302 7 3 8 Brass Pipe Plug 1 806603596 8 5 16 18 x 1 2 Cap Screw 4 80861304 9 5 16 18 x 1 ...

Page 50: ...50 xiii Repair Parts continued Figure 30 LEDV Boiler Jacket Insulation ...

Page 51: ...A1052 Control Center Transformer Relay Required on Riello Burner Applications Only 1 80160235 2 Honeywell 123871A 3 4 NPT x 3 1 80160452 3 Conbraco 10 408 05 3 4 FPT 30 PSI Relief Valve 1 81660319 4 Temperature Pressure Gauge 2 1 2 DIA Long Shank 1 100282 02 5 Conbraco 35 302 03 3 4 FPT Drain Valve 1 806603061 6 Oil Primary Control Beckett GeniSys 7505B 1 103447 01 7 Burner Disconnect Harness Beck...

Page 52: ... BURNER PARTS CONTACT YOUR WHOLESALER OR THE BURNER MANUFACTURER R W BECKETT CORP 38251 CENTER RIDGE RD P O BOX 1289 ELYRIA OHIO 1 800 645 2876 44036 xiii Repair Parts continued FIGURE 32 BECKETT AFII OIL BURNER REPAIR PARTS ...

Page 53: ...placement Kit 51484U Escutcheon Plate 31623 Stop Screw 3166502 Fuel Line 5394 Fuel Pump Single Stage with Solenoid Valve 21757 Fuel Pump Two Stage with Solenoid Valve 21941 Gasket Flange 31658 Head Assembly AFII 51671 6 Slot Hole Plug 2139 Inlet Air Scoop 51485 Splined Nut 3666 Main Housing Assembly 51584 Motor 21444 Nozzle Adapter 213 Nozzle Line Heater 51621 Rear Access Door 51424GY Electronic I...

Page 54: ...s C6505027 for an exploded view of the burner and a list of spare parts Riello Corporation of America 35 Pond Park Road Hingham Massachusetts 02043 Telephone 617 749 8292 Facsimile 617 740 2069 Toll Free outside Massachusetts 800 992 7637 Riello Canada Inc 2165 Meadowpine Blvd Mississauga Ontario L5N 6H6 Telephone 905 542 0303 Facsimile 905 542 1525 Toll Free 800 387 3898 For replacement Riello oi...

Page 55: ...55 xiii Repair Parts continued Figure 33 Vent Kit Repair Parts ...

Page 56: ... connect the probe LWCO to the supply or return piping as shown below Select the appropriate size tee using the LWCO manufacturer s instructions Often the branch connection must have a minimum diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of ...

Page 57: ...gs Secured to Skid Section III Packaged Boiler Assembly Trim and Controls Figure 4 10 Hinge Installation Assembly LEDV Boiler Figure 5A 11 Relief Valve and Boiler Control Assembly Details Beckett AFII Burner Figure 5B 12 Relief Valve and Boiler Control Assembly Details Riello BF Burner Figure 6 12 Limit Sensor Insertion Section IV Water Piping and Trim Figure 7 13 Recommended Piping for Combinatio...

Page 58: ...505 Oil Primary Terminals LED s and Reset Button Section IX Operating Figure 26 35 Intelligent Oil Boiler Control Horizontal Mount Shown Figure 27 35 Boiler Control Key Function Orientation Section XI Boiler Cleaning Figure 28 42 Cleaning of LEDV Boiler Firetubes Combustion Chamber Section xiii Repair Parts Figure 29 48 LEDV Bare Boiler Assembly Figure 30 50 LEDV Boiler Jacket Insulation Figure 31...

Page 59: ...II Burner Specifications Table 7 30 Riello BF Burner Specifications Section IX Operating Table 8 35 Sequence of Operation Table 9 37 Circulator Pre purge Time Example Parameter PP_ 2 Minutes Table 10 37 Domestic Hot Water Demand Parameter ZC_ DH Table 11 38 Zone Request Parameter zc_ zr Table 12 38 External Low Limit Parameter zc_ ell Section XII Troubleshooting Table 13 45 Troubleshooting Guide T...

Page 60: ...60 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...