8142768R6-3/07 Price - $3.00

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IMPORTANT INFORMATION - READ CAREFULLY

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.

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4

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Table of ConTenTs

I. General Information ........................5

II. Installation Instructions ...................8

III. operating and service Instructions .....................................15

IV. boiler Cleaning ................................21

V. Repair Part .......................................24

VI. appendix low Water Cut off ...........................34

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7

A. INSPECTSHIPMENTcarefullyforanysignsofdamage.

1. ALLEQUIPMENTiscarefullymanufactured,inspectedandpacked.Ourresponsibilityceasesupondeliveryofcratedboilertothecarrieringoodcondition.

2. ANYCLAIMSfordamageorshortageinshipmentmust be filed immediately against the carrier by the consignee.Noclaimsforvariancesfrom,orshortageinorders,willbeallowedbythemanufacturerunlesspresentedwithinsixty(60)daysafterreceiptofgoods.

B. LOCATE BOILER in front of final position before removingcrate.SeeFigures1Aand1B.1. LOCATEsothatsmokepipeconnectiontochimney

willbeshortanddirect.BOILERISSUITABLEFORINSTALLATIONONCOMBUSTIBLEFLOOR.Boilercannotbeinstalledoncarpeting.

2. FORBASEMENTINSTALLATION,provideasolid base, such as concrete, if floor is not level, or if water may be encountered on floor around boiler.

3. PROVIDESERVICECLEARANCEofatleast24”onrightsideofboilerforremovalofreartanklessheater.Provideatleast24”clearancefromfrontjacketpanelforservicing.Provideatleast24"clearancefromrightsideofboilerortopofboilerfor cleaning flueways. Boiler flueways may be cleanedeitherfromthetoporfromtheside.

4. Forminimumclearancestocombustiblematerials.SeeTable2.

C. PROVIDEAIRSUPPLYANDVENTILATIONtoaccommodatepropercombustion.Ifnaturalventilationisinadequate,provideascreenedopeningorductfromtheboilerroomtotheoutside.Theopeningorductmustbesizedsotheboilerinputwillnotexceed4,000BTUH/Sq.In.offreearea.Ifotherairconsumingappliancesareneartheboiler,theairinletshouldbelarger.Consultrespectivemanufacturers.

TAbLe 2: minimum insTALLATion CLeARAnCes To CombusTibLe mATeRiALs (inCHes)

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8

seCTion ii: insTALLATion insTRuCTions

A. REMOVECRATE1. Removeallfastenersatcrateskid.2. Liftoutsidecontainerandremoveallotherinside

protectivespacersandbracing.Removedraftregulatorboxandmiscellaneoustrimbagcontainingsafety/relief valve, and pipe fittings.

B. REMOVALOFBOILERFROMSKID1. Boilerissecuredtobasewith4bolts,2onleftside

and2onrightside,seeFigure2.Removeallbolts.2. Tiltboilertorightandtorear.Usingrightrearleg

aspivot,rotateboiler90°inaclockwisedirection,and lower left side of boiler to floor. Tilt boiler andremovecrateskid.Careshouldbeexercisedtopreventdamagetojacketorburner.

3. InstallSafetyValvein¾"TappingontopoftheFrontSection.Use¾NPTx8"nippleand¾NPTcouplingincludedintrimbag.SafetyValvemustbeinstalledwithspindleinverticalposition.

4. Ifthisboilerisusedinconnectionwithrefrigerationsystems,theboilermustbeinstalledsothatthechilledmediumispipedinparallelwiththeheatingboilerusingappropriatevalvestopreventthechilledmediumfromenteringtheboiler,seeFigure4.AlsoconsultI=B=RInstallationandPipingGuides.

5. Ifthisboilerisconnectedtoheatingcoilslocatedinairhandlingunitswheretheymaybeexposedtorefrigeratedair,theboilerpipingmustbeequipped with flow control valves to prevent gravity circulationofboilerwaterduringtheoperationofthecoolingsystem.

6. Useaboilerbypassiftheboileristobeoperatedinasystemwhichhasalargevolumeorexcessiveradiationwherelowboilerwatertemperaturesmaybeencountered(i.e.convertedgravitycirculationsystem,etc.).

ThebypassshouldbethesamesizeasthesupplyandreturnlineswithvalveslocatedinthebypassandsupplyoutletasillustratedinFigures3aand3bin order to regulate water flow for maintenance of higherboilerwatertemperature.

Settheby-passandboilersupplyvalvestoahalfthrottlepositiontostart.Operateboileruntilthesystemwatertemperaturereachesitsnormaloperatingrange.

Adjustthevalvestomaintain180°Fboilerwatertemperature.Adjustbothvalvessimultaneously.Closingtheboilersupplyvalveandopeningtheby-passvalvewillraisetheboilerwatertemperatureandlowerthesupplytemperature.Openingtheboilersupplyvalvewhileclosingtheby-passvalvewilllowertheboilerwatertemperatureandraisethesupplytemperature.

7. Ahotwaterboilerinstalledaboveradiationlevelmustbeprovidedwithalowwatercutoffdeviceaspartoftheinstallation.

Ifalowwatercut-offisrequired,itmustbemountedinthesystempipingabovetheboiler.Theminimumsafewaterlevelofahotwaterboilerisjustabovethehighestwatercontainingcavityoftheboiler;thatis,ahotwaterboilermustbefullofwatertooperatesafely.

C. MOVEBOILERTOPERMANENTPOSITIONbyslidingorwalking.

D. INSPECTCOMBUSTIONTARGETWALLANDCOMBUSTIONCHAMBERLINER1. OPENFLAMEOBSERVATIONDOORAND/

ORBURNERSWINGDOORonfrontofboiler.Use flashlight to inspect target wall secured to rearsectionwithsilasticsealant.Inspectceramicfiber blanket secured to floor of boiler with water glassadhesive.Ifeitherisdamagedtheymustbereplaced.

E. CONNECTSUPPLYANDRETURNPIPINGTOHEATINGSYSTEM.1. Hotwaterpipesshallhaveclearancesofatleast½”

fromallcombustibleconstruction.2. WithForcedCirculationHOTWATERHEATING,

seeFigures3aand3b.ConsultI=B=RInstallationandPipingGuideNo.200.

Figure 2: burner mounting

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

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

10

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Therearemanypossiblecausesofoxygencontamina-tionsuchas:

1.Additionofexcessivemake-upwaterasaresultofsystemleaks.

2. Absorption through open tanks and fittings.3.Oxygenpermeablematerialsinthedistributionsystem.

Inordertoinsurelongproductlife,oxygensourcesshouldbeeliminated.Thiscanbeaccomplishedbytakingthefollowingmeasures:

1.Repairingsystemleakstoeliminatetheneedforaddi-tionofmake-upwater.

2.Eliminatingopentanksfromthesystem.3. Eliminating and/or repairing fittings which allow oxy-

genabsorption.4.Useofnon-permeablematerialsinthedistribution

system.5. Isolatingtheboilerfromthesystemwaterbyinstalling

aheatexchanger.F. CONNECTTANKLESSHEATERPIPINGAS

SHOWNINFigure6.SeeTable3forTanklessHeaterRatings.

Figure 4: Recommended Piping for Combination Heating & Cooling (Refrigeration) systems

THEFOLLOWINGGUIDELINESSHOULDBEFOL-LOWEDWHENPIPINGTHETANKLESSHEATER:

1. FLOW REGULATION — If flow through the heater isgreaterthanitsrating,thesupplyofadequatehotwatermaynotbeabletokeepupwiththedemand.For this reason a flow regulator matching the heater ratingshouldbeinstalledinthecoldwaterlinetothe heater. The flow regulator should preferably be locatedbelowtheinlettotheheaterandaminimumof3’awayfromtheinletsothattheregulatorisnotsubjectedtoexcesstemperaturesthatmayoccurduring“off”periodswhenitispossibleforheattobeconductedbackthroughthesupplyline.Theflow regulator also limits the flow of supply water regardlessofinletpressurevariationsintherangeof20to125psi.

Figure 6: schematic Tankless Heater Piping

2. TEMPERINGOFHOTWATER—Installationofanautomaticmixingvalvewilllengthenthedeliveryoftheavailablehotwaterbymixingsomecoldwaterwiththehot.Thispreventsexcessiveand possibly scalding hot water at the fixtures. In addition,savingsofhotwaterwillbeachievedsincetheuserwillnotwasteasmuchhotwaterwhileseekingwatertemperaturetohisliking.Highertemperaturehotwaterrequiredbydishwashersandautomaticwashersispossiblebypipingthehotwaterfromtheheaterpriortoenteringthemixingvalve.Themixingvalveshouldbe“trapped”byinstallingitbelowthecoldwaterinlettoheatertopreventlimeformationinthevalve.

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TAbLe 3: TAnKLess HeATeR DATA:

11

coal fired or an inefficient oil fired boiler built into ahomewithoutinsulationorstormwindows.Withincreasingfuelpricesthathomeprobablyhasbeeninsulated and fitted with storm windows so that theheatlossofthehomehasbeenreduced.Thisrequireslessfueltobeburnedandsendslessheatupthechimney.

A new boiler probably has a higher efficiency than theboilerbeingreplaced.Thatprobablymeansthatthestacktemperaturefromthenewboilerwillbelowerthanthatfromtheoldboilerandwithlessroomairbeingdrawnupthechimneytodilutethestackgases.Thecombinationofalargeuninsulatedchimney, reduced firing rate, reduced firing time, lowerstacktemperatureandlessdilutionaircan,insomecases,contributetothecondensingofsmallamountsofwatervaporinthechimney.Suchcondensation,whenitoccurs,cancausechimneydeterioration.Inextremecases,condensedwater

GNINRAWsselknattaevlavgniximcitamotuallatsnI

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.evlavgniximtuohtiwretaeh

3. FLUSHINGOFHEATER—Allwatercontainssomesedimentwhichsettlesontheinsideofthecoil.Consequently,theheatershouldbeperiodicallybackwashed.ThisisaccomplishedbyinstallinghosebibsasillustratedandallowingwateratcitypressuretorunintohosebibA,throughtheheater,andouthosebibBuntilthedischargeisclear.Theteesinwhichthehosebibsarelocatedshouldbethesamesizeasheaterconnectionstominimizepressuredrop.

4. HARDWATER—Awateranalysisisnecessarytodeterminethehardnessofyourpotablewater.Thisisapplicabletosomecitywaterandparticularlytowellwater.Anappropriatewatersoftenershouldbeinstalledbasedontheanalysisanddealer’srecommendation. This is not only beneficial to the tankless heater but to piping and fixtures plus the many other benefits derived from soft water.

5. Ifitisrequiredtoperformalongtermpressuretestof the hydronic system, the boiler should first be isolatedtoavoidapressurelossduetotheescapeofairtrappedintheboiler.

Toperformalongtermpressuretestincludingtheboiler, ALL trapped air must first be removed from theboiler.

Alossofpressureduringsuchatest,withnovisiblewaterleakage,isanindicationthattheboilercontainedtrappedair.

G. INSTALLSMOKEPIPE—TheC3&C4Seriesboilershould be vented into a fireclay tile-lined masonry chimneyorchimneyconstructedfromtypeLventorafactorybuiltchimneythatcomplieswiththetypeHTrequirementsofUL103.Thechimneyandventpipe shall have a sufficient draft at all times, to assure safeproperoperationoftheboiler.SeeFigure7forrecommendedinstallation.1. Installadraftregulator(suppliedwithboiler)

followingtheinstructionsfurnishedwiththeregulator.SeeFigure8foralternatedraftregulatorlocations.

2. Considerthechimneyoverall.Chimneysthathaveahighheatlossmaybecomelesssuitableastheheat loss of the home goes down and the efficiency oftheboilerinstalledgoesup.Mosthomeshaveachimneyappropriateforthefuelandtheerainwhichthehomewasbuilt.Thatmayhavebeena

Figure 8: Proper and improper Locations of Draft Regulator

Figure 7: Recommended smokepipe Arrangement and Chimney Requirements

12

Figure � Figure 10

maybevisibleontheoutsideofthebreechingorchimney.Inthoseextremecases,thechimneymayhavetobelinedtoinsulatethechimneyandthuspreventthecondensation.Theadditionofdilutionairintothechimneymayassistindryingthechimneyinteriorsurfaces.

Amassivechimneyonacold,orexposedoutsidewallmayhaveproducedadequatedraftwhenitwas fired with a higher input and greater volumes ofheatedgases.Withreducedinputandvolume,thedraftmaybeseverelyaffected.Inoneinstanceourresearchshowedanewchimneyofadequatesizingproducedonly.035"W.C.after30minutesof continuous firing at 13.0% CO2.Outsidewallchimneystakelongertoheatupandcanhave.00"W.C.draftatburnerstartup.Youmayhavetoconsider a special alloy chimney flue liner with insulationarounditandastabilizingdraftcaporevenadraftinducingfaninseverecases.

3. Forthesamereasonsasin(2.)above,heatextractorsmountedintothebreechingarenotrecommended.

H. INSTALLELECTRICWIRINGinaccordancewithNationalElectricalCodeandlocalregulations.Aseparateelectricalcircuitmustberunfromthemainelectricalservicewithanover-currentdevice/disconnectinthecircuit.Aserviceswitchisrecommendedandmayberequiredbysomelocaljurisdictions.WiringshouldconformtoFigure11or12.

I. FUELUNITSANDOILLINES SINGLE-PIPEOILLINESStandardburnersare

providedwithsingle-stage3450rpmfuelunitswiththeby-passplugremovedforsingle-pipeinstallations.

Thesingle-stagefuelunitmaybeinstalledsingle-pipewithgravityfeedorlift.Maximumallowableliftis8feet.SeeFigure9.

TNATROPMIyletulosbaebtsumsnoitallatsniepip-elgniS.tluseryamemirpfossolroskaelrothgitria

.yletelpmoctinuleufdnaenildeelB

TWO-PIPEOILLINESFortwo-pipesystemswheremoreliftisrequired,thetwo-stagefuelunitisrecommended.Table4(single-stage)andTable5(two-stage)showallowableliftandlengthsof3/8-inchand1/2-inchODtubingforbothsuctionandreturnlines.RefertoFigure10.

Besurethatalloillineconnectionsareabsolutelyairtight.Checkallconnectionsandjoints.Flaredfittings are recommended. Do not use compression fittings or PTFE ("Teflon®") tape.

Opentheair-bleedvalveandstarttheburner.Forcleanbleed,slipa3/16"IDhoseovertheendofthebleedvalveandbleedintoacontainer.Continuetobleedfor15secondsafteroilisfreeofairbubbles.Stopburnerandclosevalve.

13

TAbLe �: TWo-sTAge uniTs (34�0 RPm) - TWo-PiPe sysTems

TAbLe 4: singLe-sTAge uniTs (34�0 RPm) - TWo-PiPe sysTems

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gnibuTfohtgneLmumixaM)52erugiFeeS("R"+"H"

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DO"2/1)HPG3(gnibuT

'0 '39 '001

'2 '58 '001

'4 '77 '001

'6 '96 '001

'8 '06 '001

'01 '25 '001

'21 '44 '001

'41 '63 '001

'61 '72 '001

'81 --- '67

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'0 '48 '001

'1 '87 '001

'2 '37 '001

'3 '86 '001

'4 '36 '001

'5 '75 '001

'6 '25 '001

'7 '74 '001

'8 '24 '001

'9 '63 '001

'01 '13 '001

'11 '62 '001

'21 '12 '38

'31 --- '26

'41 --- '14

14

Figure 11: Wiring Diagram without Tankless Heater seQuenCe oF oPeRATion

A call for heat by the thermostat energizes the L7248C control which in turn energizes the R7184B primary control. The burner will initiate ignition after com-pleting a 10 second pre-purge cycle. If burner ignites within approximately 45 seconds and the cad cell sees flame, the burner will continue to operate until the call for heat is satisfied or the setting of the high limit is reached. The circulator will operate as long as the thermostat is calling for heat. If the thermostat is not satisfied and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high limit is closed by a drop in boiler water temperature.

Figure 12: Wiring Diagram with Tankless HeaterseQuenCe oF oPeRATion

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

1�

SECTION III: OPERATING AND SERvICE INSTRUCTIONS

C. CHECKCONTROLS,WIRINGANDBURNERtobesurethatallconnectionsaretightandburnerisrigid,thatallelectricalconnectionshavebeencompletedandfuses installed, and that oil tank is filled and oil lines havebeentested.

D. LUBRICATION—Followinstructiononburnerandcirculatorlabeltolubricate,ifoillubricated.Mostmotorscurrentlyusedonresidentialtypeburnersemploypermanentlylubricatedbearingsandthusdonot require any field lubrication. Water lubricated circulators do not need field lubrication.

Donotover-lubricate.Thiscancauseasmuchtroubleasnolubricationatall.

E. ADjUST CONTROL SETTINGSwithburnerserviceswitchturned“ON”androomthermostatset10°below roomtemperature.

1. Adjustment and display modesoftheL7248/L7224OilElectronicAquastatController.

a. OntheL7248/L7224,theoverallrangeoftheHighLimitisfrom180°Fto240°F(82°Cto116°C).

b. SettheHighLimit(designatedHL)ontheL7248/L7224AquastatControlat180°F.Thistemperaturesettingmaybevariedtosuitrequirements of installation. Differential is fixed at15°F.i. Adjusting Settings: Todiscourageunauthorizedchangingof

Aquastatsettings,aproceduretoentertheadjustmentmodeisrequired.Toentertheadjustmentmode,presstheUP,DOWN,andIbuttons(seeFigureS1)simultaneouslyforthree(3)seconds.Pressthe‘I’buttonuntilthefeaturerequiringadjustmentisdisplayed(pressthe“I”buttonagainandwilldisplayLL(LowLimitonL7224):

· HighLimit

·°F--°C(Toggle) ThenpresstheUPand/orDOWNbuttons

tomovethesetpointtothedesiredvalue.After60secondswithoutanybuttoninputs,thecontrolwillautomaticallyreturntotheREADmode.

A. ALWAYSINSPECTINSTALLATIONBEFORESTARTINGBURNER.

B. FILLHEATINGSYSTEMWITHWATER. NOTE:Itisimportanttoproperlyremovetheoiland

dirtfromthesystem.Failuretocleanthesystemcanresultinerraticwaterlinesandsurging.1. CLEANHEATINGSYSTEMIFboilerwateror

condensatereturnwaterisdirtyoriferraticwaterlinesorsurgingexistafterafewdaysofboileroperation.

Refertostep"N"forpropercleaninginstructionsforsteamandwaterboilers.

2. FILLENTIREHEATINGSYSTEMwithwaterandventairfromsystem.Usethefollowingprocedureonaseriesloopormulti-zonedsysteminstalledasperFigure3,toremoveairfromsystemwhenfilling:a. Closeisolationvalveinboilersupplypiping.b. Isolateallcircuitsbyclosingzonevalvesor

balancingvalves.c. Attachahosetohosebiblocatedjustbelow

isolationvalveinboilersupplypiping. (Note - Terminate hose in five gallon bucket at a

suitable floor drain or outdoor area).d. Startingwithonecircuit,openzonevalve.e. Openhosebib.f. Open fill valve (make-up water line should be

locateddirectlyaboveisolationvalveinboilersupplypiping).

g. Allow water to overflow from bucket until dischargefromhoseisbubblefreefor30seconds.

h. Openzonevalvetothesecondzonetobepurged, then close the first. Repeat this step until allzoneshavebeenpurged,butalwayshaveonezoneopen.Atcompletion,openallzonevalves.

i. Close hose bib, continue filling the system until the pressure gauge reads 12 psi. Close fill valve.

(Note-Ifmake-upwaterlineisequippedwithpressurereducingvalve,systemwillautomatically fill to 12 psi. Leave globe valve open).

j. Openisolationvalveinboilersupplypiping.k. Removehosefromhosebib.

GNINRAWerevesesuacnachcihwdrazahlaitnetopaevahroodgniwsrenrubhtiwdeppiuqesreliobllA

ffonrut,roodgniwsgninepoerofeB.derongifiefilfossolroyrujnilanosrep,egamadytreporp.rebmahcnoitsubmocehtedistuorenrubfogniriflatnediccatneverpotreliobothctiwsecivres

.detelpmocsiecivresnehwyletelpmocrenetsafroodgniwsnethgitoteruseB

16

Figure s1: L7248 Circuit board Layout -Horizontal mount

ii. Display: IntheRUNmode,theAquastatwill

flash “bt” (boiler temp.) followed by the temperature(i.e.,220),followedby°For°C.

Toreadboilersettings,pressthe‘I’keytoreadtheparameterofinterest.Forexample,pressI(HL)HighLimitisdisplayed,followedbyathree-digitnumber,i.e.,220,followedby°For°C.

SeeFigureS2forDisplayReadoutDefinitions.

Afterapproximately60secondswithoutanykeypressed,thedisplaywillenteradimdisplaymode.Toreturntothebrightdisplaymode,simplypressanykey.

2. Control Operating Characteristics TheL7248/L7224canbeinanythree(3)

operationalstates:Normal,High-LimitandError.ThecontrollermovesbackandforthfromHigh-LimittoNormalstateaspartofnormaloperation.

ThecontrollerwillentertheErrorstatewhenthereisanabnormalcondition.Theoperatingstatesare:a. Normal:Boilertemperaturehasgonebelowthe

highlimitsetting(minusthedifferential)andhasnotexceededthehighlimitsetting.

b. High-Limit:Boilertemperaturehasgoneabovethehighlimitsettingandhasnotdroppedbelowthehighlimitsetting(minusthedifferential).

Figure S2: Display Readout Definitions

Display Text Description Shows bt BoilerTemperature HL HighLimit err ErrorCode f DegreesFahrenheit c DegreesCelsius LL LowLimit

TAbLe s1: LeD eRRoR CoDes

rorrEedoC

noitcA/esuaC

1rrE .rosneskcehc;tluafrosneS

2rrE .gniriw™MOCarivnEkcehc;tluafMOCE

3rrE .lortnocecalper;tluaferawdraH

TAbLe s2: L7248/L7224 ConTRoLLeR oPeRATing seQuenCe

noitcA esnopseRmetsyS

tatsomrehTrofsllac

taeh

.stratsrotalucriCrenruB.dekcehcsierutarepmetrelioBsierutarepmetretawehtnehwstratser

.gnittestimilhgihwoleb

relioBehtsdeecxe

timilhgih

nehwstratserrenruB.ffodenrutsirenruBehtwolebsporderutarepmetretaweht.laitnereffidehtsunimgnittestimilhgih

tatsomrehTdeifsitassi

.ffonrutrenrubdnarotalucriC

rorrEnoitidnoc

stuptuolla,detcetedsinoitidnocrorrenafIlortnoC.ffosirenruB.nwodtuhsera

nehwstratserdnanoitcnufotseunitnoc.detcerrocsirorre

eht,ecneuqeskcehcrorreehtgniruDdnarosnesehtnitfirdrofskcehcmetsys

.snoitcennocehtninoisorroc

e. TheoperatingsequenceforL7248/L7224isdescribedbelowandshowninTableS2.

TheswitchingactionintheL7248/L7224controlhasonesetting,thehighlimit,seeFigureS3.Theswitchingrelayiscontrolledbythelowvoltageroomthermostat.Onacallforheat,therelaycontactsmaketocompletethelinevoltagecirculatorcircuitandalsotheburnercircuitiftheboilerwatertemperatureisbelowthehighlimitsetting.Thehighlimitswitchshutsofftheburnerifboilerwatertemperatureexceedsthehighlimitsetting.Thecirculatorwillcontinuetooperateaslongasthethermostatiscallingforheat.Thehighlimitautomaticallyresetsafterthewatertemperaturedropspastthesetpointandthroughthedifferential.

c. Error:Thecontrollerhasdetectedanerrorcondition(e.g.,opensensor)andhasshutdowntheburneroutput.Thecontrollercontinuestomonitorthesystemandautomaticallyrestartsiftheerrorconditionclears.SeeTableS1.

d. Low-Limit:Boilertemperaturehasgonebelowthelowlimitsetting(minusthelowlimitdifferential)andhasnotgoneabovethelowlimitsetting.

17

4. REMOVEGAUGEPORTPLUGfromfuelpumpandinstallpressuregaugecapableofreadingatleast150PSI.

5. OPENFLAMEOBSERVATIONDOORonfrontofboiler.

H. STARTOILBURNER.1. Open vent fitting on fuel pump.2. TURN‘ON’BURNERserviceswitchandallow

burner to run until oil flows from vent fitting inaSOLIDstreamwithoutairbubblesforapproximately10seconds.

3. Close vent fitting and burner flame should start immediatelyafterpre-purgeiscomplete.Pre-purgeprevents burner flame until 10 seconds has elapsed afterinitialpowerisappliedtoburner.Duringpre-purge,themotorandignitorwilloperatebuttheoilvalvewillremainclosed.RefertoOilPrimaryControlInstructionsformoredetails.

I. ADJUSTOILPRESSURE.1. Locateoilpressureadjustingscrewandturnscrew

toobtain140PSIpressure.2. DONOTREMOVEPRESSUREGAUGEuntil

later.j. OTHERADJUSTMENTS

1. ADJUSTTHEAIRBANDAND/ORAIRSHUTTER.

Adjustairsupplybylooseninglockscrewsandmovingtheairshutterandifnecessarytheairband.RefertoTable6forpreliminarysettings.

2. ADJUSTDRAFTREGULATORforadraft of — .02” (water gauge) over the fire after chimney

hasreachedoperatingtemperatureandwhileburnerisrunning.

3. READJUSTAIRBANDSonburnerforalightorange colored flame while the draft over the fire is —.02”. Use a smoke tester and adjust air forminimumsmoke(nottoexceed#1)withaminimum of excess air. Make final check using suitableinstrumentationtoobtainaCO2of11.5to12.5% with draft of —.02” (water gauge) in fire box. These settings will assure a safe and efficient operating condition. If the flame appears stringy instead of a solid fire, try another nozzle of the same type.Flameshouldbesolidandcompact.Afteralladjustmentsaremaderecheckforadraftof—.02”over the fire.

4. TURN“OFF”BURNERandremovepressuregauge.Installgaugeportplugandtighten.Startburneragain.

5. CADCELLLOCATIONANDSERVICE The burner is supplied with a cadmium sulfide flame

detectormountedatthefactory,mountedonthebottomoftheignitor.SeeFigure14.Toservicecad

GFAttekceB

relioB gniriFetaRHPG

daeH citatScsiD

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4C 02.1 3F "8/3-3 01 0 A°08x00.1

ISP041:erusserPpmuPliOelffabetargnirifwolaseziliturelioB3C*

TAbLe 6: buRneR sPeCiFiCATions

F. REMOVEGUNASSEMBLY1. Itemstobecheckedarenozzlesize,type,andangle;

headsize;gunsetting;andpositioningofelectrodes.ThisinformationsisshowninFigure13andTable6.

2. Reinstallgunassembly.

Figure 13: "F" Head electrode Positioning and gun setting (beckett AFg)

Figure s3: L7248/L7224 setpoint and Differential switching Action

G. ADJUSTOILBURNERBEFORESTARTING.1. SETBURNERAIRBANDANDAIRSHUTTER,

seeTable6.2. OPENALLOILLINEVALVES.3. Attach a plastic hose to fuel pump vent fitting and

provideapantocatchtheoil.

18

cell or to replace the plug in portion, swing open the ignitor. After service is complete, be sure to fasten down the ignitor.

6. FLAME FAILURE The C3 & C4 Series boiler controls operate the

burner automatically. If for unknown reasons the burner ceases to fire and the reset button on the primary control has tripped, the burner has experienced ignition failure. Before pressing the reset button call your serviceman immediately.

NOITUAC

nehwrenrubehttratsottpmettatonoDsitinuehtnehw,detalumuccasahliossecxe

noitsubmocehtnehwro,ropavfolluf.tohyrevsirebmahc

K. 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.

2. IF NOZZLE CONTINUES TO DRIP, repeat step K.1. If this does not stop the dripping, remove cutoff 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.

L. TEST CONTROLS.

GNINRAWsireliobehtfonoitallatsnierofeB

ehtfonoitarepoeht,etelpmocderedisnoc,dekcehcebdluohsslortnocreliob

hgihdnalortnocyramirpehtylralucitrap.lortnoctimil

1. CHECK THERMOSTAT OPERATION. Raise and

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:

GNINRAWebdluohsreliobsihtfonoecivreS

delliksdnadeniartybylnonekatrednu.ycnegaecivresdeifilauqamorflennosrep

a. Check wiring connections. Close line switch. Check power at control.

PRIMARY RELAY TESTb. Disconnect cad cell leads from the underside of

the Primary Control. Reset safety switch.c. Set controller to call for heat. Burner should

start.d. Jumper the two (2) quick connect terminals on

the underside of the Primary Control within 15 to 30 seconds. Burner should run.

e. Remove Jumper. Burner shuts down in approximately 15 to 60 seconds.

f. If burner operates as described, relay is good. If not, install new relay.

CAD CELL TESTg. Open line switch. Clean cell face and see that

cell is securely in socket. Reconnect leads. Reset safety switch.

h. Close line switch. If burner starts and runs beyond safety switch cut-out time, cell is good. If not, install new cell.

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.

4. Check operating control. With burner off, draw hot water until burner starts, then turn off hot water and check burner shut-down.

IF CONTROLS DO NOT MEET REQUIREMENTS OUTLINED IN PARAGRAPH L., REPLACE CONTROL AND REPEAT CHECK-OUT PROCEDURES.

M. BOILER AND SYSTEM CLEANING INSTRUCTIONS FOR TROUBLE FREE OPERATION.1. Filling of Boiler and System — General —-In a hot

Figure 14: Cad Cell Location

1�

1. FillingofBoilerandSystem—General—-Inahotwaterheatingsystem,theboilerandentiresystem(otherthantheexpansiontank)mustbefullofwaterforsatisfactoryoperation.Watershouldbeaddedtothesystemuntiltheboilerpressuregaugeregisters12psi.Toinsurethatthesystemisfull,watershouldcomeoutofallairventswhenopened.

2. BoilingOutofBoilerandSystem.Theoilandgreasewhichaccumulateinanewhotwaterboilercanbewashedoutinthefollowingmanner.a. Removesafetyreliefvalveusingextremecareto

avoiddamagingit.b. Addanappropriateamountofrecommendedboil

outcompound.

ECITONlacoltlusnocroseitirohtualacolhtiwkcehC

elbatpeccarofsecivrestnemtaertretaw.sdnuopmocgninaelclacimehc

c. Replacesafetyreliefvalve.d. Filltheentiresystemwithwater.e. Start firing the boiler.f. Circulatethewaterthroughtheentiresystem.g. Ventthesystem,includingtheradiation.h. Allowboilerwatertoreachoperating

temperature,ifpossible.i. Continuetocirculatethewaterforafewhours.j. Stop firing the boiler.k. Drainthesysteminamannerandtoalocation

thathotwatercanbedischargedwithsafety.l. Removeplugsfromallavailablereturnsand

washthewatersideoftheboilerasthoroughlyaspossible,usingahigh-pressurewaterstream.

m.Refill the system with fresh water.3. Addappropriateboilerwatertreatmentcompounds

as recommended by your qualified water treatment company.

4. MakepHorAlkalinityTest. Afterboilerandsystemhavebeencleanedand

refilled as previously described, test the pH of the waterinthesystem.Thiscaneasilybedonebydrawingasmallsampleofboilerwaterandtestingwithhydrionpaperwhichisusedinthesamemanner as litmus paper, except it gives specific readings.AcolorchartonthesideofthesmallhydriondispensergivesthereadingpH.Hydrionpaperisinexpensiveandobtainablefromanychemicalsupplyhouseorthruyourlocaldruggist.ThepHshouldbehigherthan7butlowerthan11.Addappropriatewatertreatmentchemicals,if necessary, to bring the pH within the specified range.Withthislowerlevelofprotection,caremust

beexercisedtoeliminateallofthefreeoxygeninthesystem.

5. Boilerisnowreadytobeputintoservice.N. HINTSONCOMBUSTION

1. NOZZLES—Althoughthenozzleisarelativelyinexpensivedevice,itsfunctioniscriticaltothesuccessfuloperationoftheoilburner.TheselectionofthenozzlesuppliedwiththeC3&C4Seriesboileristheresultofextensivetestingtoobtainthebest flame shape and efficient combustion. Other brandsofthesamesprayangleandspraypatternmaybeusedbutmaynotperformattheexpectedlevelofCO2andsmoke.Nozzlesaredelicateandshouldbeprotectedfromdirtandabuse.Nozzlesaremass-producedandcanvaryfromsampletosample.Forallofthosereasonsasparenozzleisadesirableitemforaservicemantohave.

2. FLAMESHAPE—Lookingintothecombustionchamber through the observation door, the flame shouldappearstraightwithnosparklersrollinguptoward the crown of the chamber. If the flame drags totherightorleft,sendssparklersupwardormakeswetspotsonthetargetwall,thenozzleshouldbereplaced.Iftheconditionpersistslookforfuelleaks,airleaks,waterordirtinthefuelasdescribedabove.

3. FUELLEAKS—Anyfuelleakbetweenthepumpandthenozzlewillbedetrimentaltogoodcombustionresults.Lookforwetsurfacesintheairtube,undertheignitor,andaroundtheairinlet.Anysuchleaksshouldberepairedastheymaycauseerraticburningofthefuelandintheextremecasemay become a fire hazard.

4. AIRLEAKS—Anysuchleaksshouldberepaired,astheymaycauseerraticburningofthefuelandinextreme cases may become a fire hazard.

5. GASKET LEAKS — If 11.5 to 12.5% CO2witha#1smokecannotbeobtainedinthebreeching,lookforairleaksaroundtheburnermountinggasket,observationdoor,andcanopygasket.SuchairleakswillcausealowerCO2readinginthebreeching.Thesmaller the firing rate the greater effect an air leak canhaveonCO2readings.

6. DIRT — A fuel filter is a good investment. Accidentalaccumulationofdirtinthefuelsystemcanclogthenozzleornozzlestrainerandproduceapoorspraypatternfromthenozzle.Thesmallerthefiring rate, the smaller the slots become in the nozzle andthemorepronetopluggingitbecomeswiththesameamountofdirt.

7. WATER—Waterinthefuelinlargeamountswillstallthefuelpump.Waterinthefuelinsmalleramountswillcauseexcessivewearonthepump,butmoreimportantlywaterdoesn’tburn.Itchillsthe flame and causes smoke and unburned fuel to passoutofthecombustionchamberandclogtheflueways of the boiler.

20

8. COLDOIL—Iftheoiltemperatureapproachingthefuelpumpis40°Forlowerpoorcombustionordelayedignitionmayresult.Coldoilishardertoatomizeatthenozzle.Thus,thespraydropletsgetlarger and the flame shape gets longer. An outside fueltankthatisabovegradeorhasfuellinesinashallowburyisagoodcandidateforcoldoil.Thebestsolutionistoburythetankandlinesdeepenoughtokeeptheoilabove40°F.

9. HIGHALTITUDEINSTALLATIONS Airopeningsmustbeincreasedathigheraltitudes.

Use instruments and set for 11.5 to 12.5% CO2.10.START-UPNOISE—Lateignitionisthecauseof

start-upnoises.Ifitoccursrecheckforelectrodesettings, flame shape, air or water in the fuel lines.

TNATROPMITIREVETAHW-SKAELENILNOITCUS

.RIAFOEERFEBTSUMLIOEHT,SEKATebtsumtitub,melborphguotaebnacsihT

ahguorhtpmupehtgnideelbyrT.devloser.elbisivhtorfonebtsumerehT.ebutraelc

otelbaliavastiktsetsuoiraveraerehTraelchguorhtlioehttakoolotuoyelbane

ehttaenilylppusehtotdetpadagnibutehtnoerasrotanimileriA.gnittifpmup

cinortcele,oslA.laitnetopevahtahttekramdooghtiwdesugnieberasessalgthgis

nurebtsumgnibutwen,semittA.sseccustsuJ.notupsgnittifwenroknatehtotuoyerofebtuoriaehtteguoyerusekam

.evaelnaesuaclliwenilleufehtniskaelriaynA

deyaledesuacyamdnaemalfelbatsnuehtnisgnittiferalfylnoesU.sesionnoitingi

.senilleuf

TNATROPMIdoogyrevA.ERUDECORPTSETKCEHCotsismelborpedisleufgnitalosiroftset'2ahtiwdnametsysleufehttcennocsid

evifyrailixuanafotuoerif,gnibutfohtgnelmorflio2#mraw,hserf,naelcfoliapnollag

snurrenrubehtfI.ecruosrehtonaehtfotuogniwardnehwyllufsseccus

otdetalosisimelborpehtnehtliapyrailixuaehtnodesugniebsenilleufroleufeht

.etisboj

11. SHUT DOWN NOISE — If the flame runs out of airbeforeitrunsoutoffuel,anafterburnwithnoisemayoccur.Thatmaybetheresultofafaultycut-offvalveinthefuelpump,oritmaybeairtrappedin

the nozzle line. It may take several firing cycles for thatairtobefullyventedthroughthenozzle.Waterin the fuel or poor flame shape can also cause shut downnoises.

O. ATTENTIONTOBOILERWHILENOTINOPERATION.1. IMPORTANT IFBOILERISNOTUSEDDURINGWINTER

TIME,ITMUSTBEFULLYDRAINEDTOPREVENTFREEZEDAMAGE.

2. Sprayinsidesurfaceswithlightlubricatingorcrankcaseoilusinggunwithextendedstemsoastoreachallcorners.

3. Alwayskeepthemanualfuelsupplyvalveshutoffiftheburnerisshutdownforanextendedperiodoftime.

4. Toreconditiontheheatingsysteminthefallseasonafteraprolongedshutdown,followtheinstructionsoutlinedinSectionIII,ItemsAthroughL.

NOITUACyamhcihwslortnocsniatnocreliobsihT

tondnanwodtuhsotreliobehtesuacoteudegamadfI.ecivrestuohtiwtratser

gnitaeheht,ytilibissopasisepipnezorfnidednettanutfelebtondluohsmetsyssdraugefasetairporpparo;rehtaewdloc

ehtnodellatsniebdluohssmraladnaehtfiegamadtneverpotmetsysgnitaeh

.evitareponisireliob

P. FREQUENTWATERADDITION

Aleakysystemwillincreasethevolumeofmake-upwater supplied to the boiler which can significantly shortenthelifeoftheboiler.Entrainedinmake-upwateraredissolvedmineralsandoxygen.Whenthefresh,coolmake-upwaterisheatedintheboilerthemineralsfalloutassedimentandtheoxygenescapesasagas.Bothcanresultinreducedboilerlife.Theaccumulationofsedimentcaneventuallyisolatethewaterfromcontactingthecastiron.Whenthishappensthecastironinthatareagetsextremelyhotandeventuallycracks.Thepresenceoffreeoxygenintheboilercreatesacorrosiveatmospherewhich,iftheconcentrationbecomeshighenough,cancorrodethecastironthroughfromtheinside.Sinceneitherofthesefailuretypesaretheresultofacastingdefectthewarrantydoesnotapply.Clearlyitisineveryone’sbestinteresttopreventthistypeoffailure.Themaintenanceofsystemintegrityisthebestmethodtoachievethis.

21

SECTION Iv: BOILER CLEANING

GNINRAWdeppiuqesrelioB.ffodenruthctiwsecivresrenrubhtiwdetelpmocebtsumgninaelcreliobllA

,egamadytreporperevesesuacnachcihwdrazahlaitnetopaevahroodgniwsrenrubhtiwothctiwsecivresffonrut,roodgniwsgninepoerofeB.derongifiefilfossolroyrujnilanosrep

nethgitoteruseB.rebmahcnoitsubmocehtedistuorenrubfogniriflatnediccatneverpotreliob.detelpmocsiecivresnehwyletelpmocrenetsafroodgniws

Figure 1�: Cleaning of boiler Flueways

A. CLEANTHEFLUEWAYS(SeeFigure15).1. Priortocleaningboiler,layaprotectiveclothor

plasticovercombustionchamberblankettocollectdebris falling from flueways.

2. For access to firebox Onboilerswith burner swing door and flexible

fuelline(s),removefastenersecuringdoorandswing door open. For full access to firebox, remove burnerandswingdoorfrommountingplateby

pullinghairpincotterfrombottomofhingepinandremovingpinfromhinge.Setburneraside.Removeswingdoormountingplate,seeFigure2.

ECITONehtmorfdenaelcebyamsyaweulfrelioB

snoitceridhtobmorfro,edisehtmorfropot.gninaelchguorohttsomehtrof

22

3. Forcleaningfromtheside:a. Liftthejacket'supperrightsideaccesspaneloff

to expose the flue cleanout plates.b. Loosen nuts securing the flue cleanout plates

andremovetheplates.Theinsulationshouldberemovedwiththeplatestakingcarenottodamagetheinsulation.

4. Forcleaningfromthetop:a. Liftthejacket'supperrightsideaccesspaneloff

toallowremovalofthejackettoppanel.b. Removeasmuchsmokepipeasnecessaryto

allowremovalofthejackettoppanelandcanopy(smokebox).

c. Removethejackettoppanel.d. Removethecanopy,beingcarefulnottodamage

the ceramic fiber gasket.5. Using a 1¼” diameter wire or fibre bristle brush

(30” handle) clean the flueways. Brush from the top and/orsideusinghorizontalanddiagonalstrokesforbestresults.DONOTallowbrushtostrikethetargetwallorlinerinthechamber.

B. CLEANTOPOFBOILERSECTIONS(ifcleaningfromthetop).

Brushandvacuumthetopsoftheboilersections.C. CLEANTHEFIREBOX. Using wire or fibre bristle brush, clean crown of boiler

andinsideofwaterlegs.DONOTallowbrushtostriketargetwallorblanketinthecombustionchamber.

D. AFTERCLEANING,removeprotectiveclothwithdebrisandvacuumasnecessary,butbecarefulnottodamageblanket.Inspecttargetwall,combustionchamberblanket,burnermountingplateinsulationandburnerswingdoorinsulationforsignsofdamage.Ifdamaged,replaceasneeded.

E. REASSEMBLEBOILER. CAUTION: Donotstarttheburnerunlesscanopy,

smokepipe,burnermountingplate,burnerswingdoorand all flue plates are secured in place.1. Installthecanopytakingcaretoalignthegaskets

without blocking the flueways. If gasket is damaged, replaceasneeded.

2. Reinstall flue plates, making sure gasket on each plateisinplaceandformsgastightseal.Ifdamagedreplaceasneeded.

3. Reinstalljackettoppanelandsecurewithsheetmetalscrews.Replacejacketupperrightsideaccesspanel.

4. Reinstallsmokepipeoncanopyandsecuretocollarwithsheetmetalscrews.

5. Installswingdoormountingplatetofrontsectionwithfasteners,seeFigure2.

6. ReinstallburnerinreverseorderofdisassemblyoutlinedinparagraphA.2above.Fordetails,seeFigure2.

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23

Warning:

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

AVOID Breathing Fiber Particulates and Dust

Precautionary measures:

Do not remove or replace previously fired RCF (combustion chamber insulation, target walls, canopy gasket, flue cover gasket, etc.) or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing3. Gloves4. Eye Protection

• Take steps to assure adequate ventilation.• Wash all exposed body areas gently with soap and water after contact.• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes. • Discard used RCF components by sealing in an air tight plastic bag.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water. Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention.

24

SECTION vI: REPAIR PARTS

AllC3&C4SeriesRepairPartsmaybeobtainedthroughyourlocalBurnhamWholesaledistributor.Shouldyourequireas-sistanceinlocatingaBurnhamdistributorinyourarea,orhavequestionsregardingtheavailabilityofBurnhamproductsorrepairparts,pleasecontactBurnhamCustomerServiceat(717)481-8400orFax(717)481-8408.

2�

seRViCe ReCoRDDATE SERVICE PERFORMED

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beCKeTT oiL buRneR PART nos. FoR C3 &C4 seRies boiLeRs

NOTE:Whenorderingpartsalwaysgivetheserialandmodelnumbersshownonthe boilerandburner.Alsoprovidethenameofthepart(s)andpartnumberas listedbelow.

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ylbmessAebuTrotcennoC 6365

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ylbmessArotalusnIedortcelE 0875

ylbmessArecapSredipS 3055

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daeH 300063

swercSdaeH 1224

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)evlaVsedulcnI(pmuP 44812

etalPcitatS 4833

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rotingI 0447

wercSegniHrotingI 7124

wercSgnidloHrotingI 2924

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drauGeriW 15201

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34

A 24 VAC LWCO is used primarily for gas fired boilerswherea24voltcontrolcircuitexistswithintheboiler.However,a24VACLWCOcanonlybeusediftheboilermanufacturerhasprovidedpipingandwiringconnectionsandinstructionstoallowforthisapplication.

How to Test

Shutofffuelsupply.LowerwaterleveluntilwaterlevelisBELOWtheLWCO.Generateaboilerdemandbyturningupthermostat.Boilershouldnotattempttooperate. Increase the water level by filling the system. TheboilershouldattempttooperateoncethewaterlevelisabovetheLWCO.

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.)OCWL(ffOtuCretaWwoLtekramretfanallatsniotseriwyrotcaftucotTPMETTATONOD.ffOtuCretaWwoLrofdeifitnediyllacificepssnoitcennocesuylnO

.snoitcurtsnis'rerutcafunam)OCWL(ffOtuCretaWwoLehtwollof,sesacllanI

vI. LOW WATER CUT OFF (LWCO)

Wiring of Typical LWCo

When Alowwatercutoffisrequiredtoprotectahotwater

boilerwhenanyconnectedheatdistributor(radiation)isinstalledbelowthetopofthehotwaterboiler(i.e.baseboard on the same floor level as the boiler). In addition,somejurisdictionsrequiretheuseofaLWCOwithahotwaterboiler.

Where TheuniversallocationforaLWCOonbothgasandoil

hotwaterboilersisabovetheboiler,ineitherthesupplyorreturnpiping.Theminimumsafewaterlevelofawaterboilerisattheuppermosttopoftheboiler;thatis,itmustbefullofwatertooperatesafely.

What Kind Typically,inresidentialapplications,aprobetype

LWCO is used instead of a float type, due to their relativecostsandthesimplicityofpipingforaprobeLWCO.

How to Pipe A“tee”iscommonlyusedtoconnecttheprobeLWCO

tothesupplyorreturnpiping,asshownbelow.

LWCo Location

drainingtheheatingsystem.ManyprobeLWCOmanufacturersrecommendanannualinspectionoftheprobe.

How to Wire LWCO’sareavailableineither120VACor24VAC

configurations. The 120 VAC configuration can be universallyappliedtobothgasandoilboilersbywiringitinthelinevoltageservicetotheboiler(aftertheserviceswitch,ifsoequipped).

ThepresenceofwaterinaproperlyinstalledLWCOwillcausethenormallyopencontactoftheLWCOtoclose,thusprovidingcontinuityofthe120VACservicetotheboiler.

ItisrecommendedtosupplypowertotheprobeLWCOwiththesamelinevoltageboilerserviceasshownbelow.

SelecttheappropriatesizeteeusingtheLWCOmanufacturer’sinstructions.Often,thebranchconnectionmusthavea minimumdiametertopreventbridgingbetweentheprobeandthetee.Also,therunoftheteemusthaveaminimumdiametertopreventtheendoftheprobefromtouchingorbeinglocatedtooclosetotheinsidewalloftherunofthetee.

Ideally,manualshutoffvalvesshouldbelocatedabovetheLWCOandtheboilertoallowforservicing.Thiswillallowproberemovalforinspectionwithout

3�

seRViCe ReCoRDDATE SERVICE PERFORMED

36 79

water boiler for its intended purposes and its maintenanceaccordance with U. S. Boiler Co., Inc. recommendations andhydronics industry standards. These warranties will be inapplicable ifthe residential grade water boiler is used or operated over its ratedcapacity, is subjected to unauthorized modification, or is damaged asa result of being otherwise improperly operated or serviced including,but not limited to, damage from any of the following: operation withinsufficient water, allowing the boiler to freeze, subjecting the boilerto flood conditions, and operation with unapproved water or fueladditives which cause deposits or corrosion.

5. Removal and Installation: These warranties do not cover expenses ofremoval or reinstallation. The owner is responsible for the cost ofremoving and reinstalling any defective part and its replacementsand all labor and material connected therewith.

6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach ofthese warranties is limited to the repair or replacement of its parts inaccordance with the terms and conditions of these warranties.

7. Limitation of Damages: Under no circumstances shall U.S. BoilerCo., Inc. be liable for incidental, indirect, special or consequentialdamages of any kind whatsoever under these warranties, including,but not limited to, injury or damage to persons or property anddamages for loss of use, inconvenience or loss of time. U.S. BoilerCo., Inc. liability under these warranties shall under no circumstancesexceed the purchase price paid by the owner for the residential gradewater boiler involved. Some states do not allow the exclusion orlimitation of incidental or consequential damages, so the abovelimitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entireobligation of U.S. Boiler Co., Inc. with respect to any defect in aresidential grade water boiler and U.S. Boiler Co., Inc. shall have noexpress obligations, responsibilities or liabilities of any kindwhatsoever other than those set forth herein. These warranties aregiven in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDINGANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATIONTO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIEDWARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER INA RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THEORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNERAT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DONO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTYLASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested tocomplete and mail the attached Warranty Card within ten days after theinstallation of the boiler, although failure to comply with this request willnot void the owner’s rights under these warranties.

Upon discovery of a condition believed to be related to a defect inmaterial or workmanship covered by these warranties, the owner shouldnotify the installer, who will in turn notify the distributor. If this action isnot possible or does not produce a prompt response, the owner shouldwrite to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079,Lancaster, PA 17604, giving full particulars in support of the claim.

The owner is required to make available for inspection by U.S. BoilerCo., Inc. or its representative the parts claimed to be defective and, ifrequested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S.Boiler Co., Inc. at the above address for inspection or repair. Inaddition, the owner agrees to make all reasonable efforts to settle anydisagreement arising in connection with a claim before resorting to legalremedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS ANDYOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATETO STATE.

Limited Warranty

FOR RESIDENTIAL CAST IRON WATER BOILERS

03/03

Subject to the terms and conditions set forth below, U.S. Boiler™Co., Inc. Lancaster, Pennsylvania hereby extends the following limitedwarranties to the original owner of a residential grade water boilermanufactured and shipped on or after July 1,1991:

ONE YEAR LIMITED WARRANTYON RESIDENTIAL GRADE WATER BOILERS

U.S. Boiler Co., Inc. warrants to the original owner that its residentialgrade water boilers comply at the time of manufacture with recognizedhydronic industry standards and requirements then in effect and will befree of defects in material and workmanship under normal usage for aperiod of one year from the date of original installation. If any part of awater boiler is found to be defective in material or workmanship duringthis one year period, U.S. Boiler Co., Inc. will, at its option, repair orreplace the defective part.

LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER

U.S. Boiler Co., Inc. warrants to the original owner that the heatexchanger of its residential grade water boilers will remain free fromdefects in material and workmanship under normal usage for the lifetimeof the original owner at the original place of installation. If a claim ismade under this warranty during the first ten years from the date oforiginal installation, U.S. Boiler Co., Inc. will, at its option, repair orreplace the heat exchanger. If a claim is made under this warranty afterthe expiration of ten years from the date of original installation, U.S.Boiler Co., Inc. will, at its option and upon payment of the pro-ratedservice charge set forth below, repair or replace the heat exchanger.The service charge applicable to a heat exchanger warranty claim isbased upon the number of years the heat exchanger has been inservice and will be determined as a percentage of the retail price of theheat exchanger model involved at the time the warranty claim is madeas follows:

NOTE: If the heat exchanger model involved is no longer available dueto product obsolescence or redesign, the value used to establish theretail price will be the published price as shown in the BurnhamHydronics Repair Parts Price Sheet where the heat exchanger lastappeared or the current retail price of the then nearest equivalent heatexchanger.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extendedonly to the original owner at the original place of installation within theUnited States and Canada. These warranties are applicable only towater boilers designated as residential grade by U.S. Boiler Co., Inc.and installed in a single or two-family residence and do not apply tosteam boilers of any kind or to commercial grade boilers.

2. Components Manufactured by Others: Upon expiration of the oneyear limited warranty on residential grade water boilers, all boilercomponents manufactured by others but furnished by U.S. BoilerCo., Inc. (such as oil burner, circulator and controls) will be subjectonly to the manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc.are conditioned upon the installation of the residential grade waterboiler in strict compliance with U.S. Boiler Co., Inc. installationinstructions. U. S. Boiler Co., Inc. specifically disclaims liability of anykind 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

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