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Price - $5.00
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Table of Contents
Related Manuals for U.S. Boiler Company LE DV Series
Summary of Contents for U.S. Boiler Company LE DV Series
- Page 1 ® 9700609 104428-03 - 8/14 Price - $5.00...
- Page 2 IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made.
- Page 3 DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
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Page 4: Table Of Contents
WARNING This boiler contains very hot water under 12 - 15 PSI pressure. DO NOT unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. -
Page 7: General Information
I. GENERAL INFORmATION (continued) TABLE 1: RATING DATA Burner Capacity Direct Vent System AHRI NET Boiler Model Heating AFUE % Ratings - Capacity - Vent Pipe Maximum Vent Dia. - Inches Length - Feet LEDV1 0.60 86.7 TABLE 2: GENERAL INFORmATION Water Capacity Approximate Shipping Weight Boiler Model No. -
Page 8: Pre-Installation
II. PRE-INSTALLATION 2. Boiler is suitable for installation on combustible INSPECT SHIPMENT carefully for any signs of damage. floor. DO NOT install boiler on carpeting. 1. All equipment is carefully manufactured, inspected 3. For basement installation, provide a solid elevated and packed. - Page 9 II. PRE-INSTALLATION (continued) REMOVE CRATE 3. Determine type of space. Divide Volume by total input of all appliances in space. If the result is greater than 1. Remove all fasteners at crate skid. or equal to 50 ft /1000 BTU per hour, then it is 2.
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Page 10: Packaged Boiler Assembly - Trim & Controls
III. PACKAGED BOILER ASSEmBLy - TRIm AND CONTROLS 7. Replace door assembly. Hinge brackets attached to CHANGE HINGE POSITION door must rest on top of hinge brackets attached to 1. Look at the area where boiler will be installed. If Tubesheet. - Page 11 III. PACKAGED BOILER ASSEmBLy - TRIm AND CONTROLS (continued) 2. Riello BF Burner: INSTALL BOILER CONTROL, refer to Figure 5A or Step a. Locate the L7248L Boiler Control/ Transformer - Relay Control Center/Harness 1. Beckett AFII Burner: Assembly in the carton secured to shipping skid. Step a.
- Page 12 III. PACKAGED BOILER ASSEmBLy - TRIm AND CONTROLS (continued) Figure 5B: Relief Valve and Boiler Control Assembly Details - Riello BF Burner Figure 6: Limit Sensor Insertion...
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Page 13: Water Piping And Trim
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler Company’s Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water. - Page 16 IV. WATER PIPING AND TRIm (continued) gravity circulation of boiler water during the INSTALL DRAIN VALVE in return piping. See operation of the cooling system. Figures 8A and 8B. d. If boiler is used with an Indirect-Fired Domestic . OIL, GREASE, AND OTHER FOREIGN Water Heater, install the Indirect-Fired Domestic MATERIALS which accumulate in new hot water and a Water Heater as a separate heating zone.
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Page 17: Venting
V. VENTING 5. Locate the vent terminal so vent pipe is short and General Guidelines direct, and at a place on the exterior wall that 1. Vent system installation must be in accordance with complies with the minimum distances as specified in these instructions and applicable provisions of local Figure 9 and listed below. - Page 18 V. VENTING (continued) 6. Intake Terminal Location (Direct Vent only) - Locate DANGER Air Intake Terminal not less than 12 inches to the left, right, or bottom of the vent terminal. Do not Vent pipe may not be spliced. Do not drill through locate air intake terminal above vent terminal.
- Page 19 V. VENTING (continued) Figure 11: Vent Installation Figure 12: Vent Connector, Un-Assembled...
- Page 20 V. VENTING (continued) Figure 13: Vent Connector, Assembled Figure 14: Air Intake Installation...
- Page 21 V. VENTING (continued) e. Secure the inside trim plate to inside wall. Air Intake Installation (Direct Vent only) See Figure 14. f. Tighten the gear clamp to the terminal pipe. g. Seal all external joints with a weatherproof WARNING caulk. 2.
- Page 22 V. VENTING (continued) 3. Discard the Vacuum Relief Valve. WARNING Alternate to 1., 2. and 3.: Keep the black plastic inlet cover in place and Do not locate air intake where petroleum discard the Air Intake Terminal and the Vacuum distillates, CFC's, detergents, volatile vapors or Relief Valve.
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Page 23: Electrical
VI. ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. - Page 26 VI. ELECTRICAL (continued) NOTE: APPLy THIS BURNER SCHEMATIC TO APPROPRIATE 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...
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Page 27: Oil Piping
VII. OIL PIPING SINGLE-PIPE OIL LINES GENERAL 1. Standard burners are provided with single-stage 1. Use flexible oil line(s) so that burner can be re- 3450 rpm fuel units with the bypass plug removed moved without disconnecting the oil supply. for single-pipe installations. - Page 28 VII. OIL PIPING (continued) TABLE 4: SINGLE-STAGE UNITS (3450 RPm) - TABLE 5: TWO-STAGE UNITS (3450 RPm) - TWO PIPE SySTEmS TWO PIPE SySTEmS Maximum Length of Tubing Maximum Length of Tubing "H" + "R" (See Figure) "H" + "R" (See Figure) Lift "H"...
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Page 29: System Start-Up
VIII. SySTEm START-UP WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. - Page 30 VIII. SySTEm START-UP (continued) 2. PRESS RED RESET BUTTON on burner primary b. Check electrodes to comply with dimensions control, hold for one second and release to reset the shown in Figure 19 for Beckett burner or Figure control. 20 for Riello Burner. For adjustment, loosen the electrode clamp screw and slide/rotate electrodes 3.
- Page 31 VIII. SySTEm START-UP (continued) Figure 19: Electrode Tip Gap & Spacing Figure 20: Riello Electrode Setting Figure 21: Riello Turbulator Setting 4. Close vent fitting and burner flame should start WARNING immediately after prepurge is completed. Prepurge prevents burner flame until 15 seconds has elapsed Very hot flue gases come out of sight hole when after initial power is applied to burner.
- Page 32 VIII. SySTEm START-UP (continued) 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 combustion chamber is very hot.
- Page 33 VIII. SySTEm START-UP (continued) cycling the burner operation about 5 to 10 times will ii. Pump Priming Cycle: To facilitate purging rid oil line of this air. air from the oil lines and filters, the 7505 can be placed in a purge routine by: 2.
- Page 34 VIII. SySTEm START-UP (continued) perimeter of ignitor lid for proper seal. If vii. Cad Cell Resistance Check: For proper operation it is important that the cad gasket is missing or damaged, replace gasket. cell resistance is below 1600 ohms. During Room light can effect cad cell resistance.
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Page 35: Operating
IX. OPERATING WATER BOILERS SEQUENCE OF OPERATION Water Boilers Without Tankless Heaters (Cold Start), Sequence Of Operation: a. The LEDV Boiler is equipped with an Intelligent Oil Boiler Control (cold start boiler control). The boiler control replaces the traditional electronic aquastat and circulator relays and adds energy saving thermal purge features. - Page 36 IX. OPERATING (continued) “I” Press and release the key on the Boiler Control Cold Start Boiler Control to change from one parameter to the next. Each Adjustment mode Options setting will alternately flash between the relevant 140-240°F Adjust High Limit Setting display code and its corresponding value.
- Page 37 IX. OPERATING (continued) TABLE 9: CIRCULATOR PRE-PURGE TImE EXAmPLE, TABLE 10: DOmESTIC HOT WATER DEmAND, PARAmETER PP_= 2 mINUTES (PARAmETER ZC_= DH) ZC and ZR Call for Heat Circulator Status Call for Terminal Boiler Boiler Status, Priority System Heat Function Temp.
- Page 38 IX. OPERATING (continued) TABLE 11: ZONE REqUEST, PARAmETER ZC_= ZR TABLE 12: EXTERNAL LOW LImIT, PARAmETER ZC_= ELL Call for Heat Circulator Status Call for Heat Circulator Status Input Input Output Output Input Input Output Output ii. When ZC_ is set equal to Zone Request (ZR) iii.
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Page 39: Maintenance And Service Instructions
X. mAINTENANCE AND SERVICE INSTRUCTIONS After boiler and system have been cleaned and WATER BOILERS: refilled as previously described, test the pH of the 1. Filling of boiler and system. water in the system. This can easily be done by GENERAL —... - Page 40 X. mAINTENANCE AND SERVICE INSTRUCTIONS (continued) 3. Always keep the manual fuel supply valve shut off ATTENTION TO BOILER WHILE NOT IN if the burner is shut down for an extended period of OPERATION time. NOTICE 4. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions If boiler is not used during winter time, it must be outlined in Section VIII, System Start-Up,...
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Page 41: Boiler Cleaning
XI. BOILER CLEANING WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. - Page 42 XI. BOILER CLEANING (continued) Figure 28: Cleaning of LEDV Boiler Firetubes / Combustion Chamber 3. Terminal and wall thimbles (if used) must be 4. Clean and inspect the electrodes for damage, weather-tight. replacing any that are cracked or chipped. 4. Pipe must be full round shape, and show no damage 5.
- Page 43 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
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Page 44: Troubleshooting
XII. TROUBLESHOOTING 6. WATER — Water in the fuel in large amounts will COMBUSTION stall the fuel pump. Water in the fuel in smaller 1. NOZZLES — Although the nozzle is a relatively amounts will cause excessive wear on the pump, but inexpensive device, its function is critical to the more importantly water doesn’t burn. - Page 45 XII. TROUBLESHOOTING (continued) f. CAD cell defective. OIL PRIMARy CONTROL (Oil Primary) 1. Burner (Oil Primary) will not come on. g. Oil valve stuck open or closed. a. No power to Oil Primary. Note: The Safety Monitoring Circuit (SMC) is designed to provide lockout in the event of a b.
- Page 46 XII. TROUBLESHOOTING (continued) b. If the Boiler Control detects an error it will flash "Err" (boiler control error) followed by a number. Use this text and number to identify the boiler problem and corrective action in Table 14 below. TABLE 14: BOILER CONTROL ERROR NUmBERS Display Status Recommended Corrective Actions...
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Page 47: Repair Parts
DV Series Repair Parts may be obtained through your local U.S. Boiler 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... - Page 49 XIII. REPAIR PARTS (continued) LEDV Bare Boiler Assembly Item Description Qty. Part Number Shell Assembly 6303301 Combustion Chamber Liner 8203305 Turbulator 7116039 Front Swing Door (Painted) 7303312 Front Door Outer Insulation 8203302 Front Door Outer Rope Gasket 7203301 Front Door Inner Insulation 8203301 Front Door and Furnace Rope Gasket 7203305...
- Page 50 XIII. REPAIR PARTS (continued) Figure 30: LEDV Boiler Jacket & Insulation...
- Page 51 XIII. REPAIR PARTS (continued) Figure 31: LEDV Boiler Trim & Controls Item Description Qty. Part Number Honeywell L7248L1080 High Limit & Circulator Relay 103852-01 (Includes Temperature Sensor Listed Below) Limit Rated Temperature Sensor Only, 12" Length 103195-01 Honeywell R8239A1052 Control Center Transformer / Relay 80160235 Shown (Required on Riello Burner Applications Only)
- Page 53 XIII. REPAIR PARTS (continued) BECKETT AFII BURNER REPLACEmENT PARTS LEDV1 Part Description Beckett Part Number Complete Burner (without Primary Control) BCB5406 Air Tube Combination HLX50HD Air Tube Screws 4352 Blower Wheel 21439 Coupling (Motor to Pump) 21437 Electrodes (Replacement Kit) 51484U Escutcheon Plate 31623...
- Page 54 XIII. REPAIR PARTS (continued) RIELLO BF OIL BURNER PART NUmBERS FOR LEDV SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Model BF3 Installation Manual, Riello BF Series Residential Oil Burners (C6505027) for an exploded view of the burner and a list of spare parts.
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Page 56: Appendix A - Low Water Cut Off
APPENDIX A: LOW WATER CUT OFF (LWCO) ON HOT WATER BOILERS WARNING DO NOT ATTEmPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When minimum connection must have a... -
Page 57: Appendix B: Figures
APPENDIX A: LOW WATER CUT OFF (LWCO) ON HOT WATER BOILERS (continued) How to Test A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler. Shut off fuel supply. Lower water level until water However, a 24 VAC LWCO can only be used if the level is BELOW the LWCO. - Page 58 APPENDIX B: FIGURES (continued) Figure Page Description Number Number Section VII - Oil Piping Figure 17 Single-Pipe Installation Figure 18 Two-Pipe Installation Section VIII - System Start-Up Figure 19 Electrode Tip Gap & Spacing Figure 20 Riello Electrode Setting Figure 21 Riello Turbulator Setting Figure 22 Checking / Adjusting Fuel Pump Pressure...
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Page 59: Appendix C: Tables
APPENDIX C: TABLES Table Page Description Number Number Section I - General Information Table 1 Rating Data Table 2 General Information Section V - Venting Table 3 Vent Pipe Part Numbers Section VII - Oil Piping Table 4 Single-Stage Units (3450 RPM) - Two Pipe Systems Table 5 Two-Stage Units (3450 RPM) - Two Pipe Systems Section VIII - System Start-Up... - Page 60 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...