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

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Installation, Operating and Service Instructions for
RSAH
Models:
• RSAH111E
• RSAH111E-T
• RSAH154E
• RSAH154E-T
Manual Contents
1.
General Information . . . . . . . . . . . . . . . . . . . . . .5
2.
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . .7
3. Water Piping and Trim . . . . . . . . . . . . . . . . . . . .10
4.
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
6.
OIl Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
7.
System Start-Up . . . . . . . . . . . . . . . . . . . . . . . .22
8.
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
10. Boiler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .34
11. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .37
12. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .42
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
110891-02 - 5/22
• Natural Draft
• Oil-Fired
• Water Boiler
• B20 Ready
Page

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Summary of Contents for U.S. Boiler Company RSAH Series

  • Page 1: Table Of Contents

    Installation, Operating and Service Instructions for RSAH • Natural Draft • Oil-Fired • Water Boiler Models: • B20 Ready • RSAH111E • RSAH111E-T • RSAH154E • RSAH154E-T Manual Contents Page General Information ..... .5 Pre-Installation .
  • Page 2 Installation & Service Manual RSAH IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumb- All boilers must be installed in accordance with National, State and Local Plumb- ing, Heating and Electrical Codes and the regulations of the serving utilities. These ing, Heating and Electrical Codes and the regulations of the serving utilities.
  • Page 3 Installation & Service Manual RSAH 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.
  • Page 4 Installation & Service Manual RSAH 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 5: General Information

    Installation & Service Manual RSAH General Information Figure 1-1: RSAH Series Boiler Dimensional Data Table 1-2: Dimensional D (See Figure 1-1) Dimension Water Capacity Approx. Boiler Model Number ‘A’ (gallons) Shipping Weight (lb.) RSAH111E(-T) 34-9/16 10.1 RSAH154E(-T) 41 in. 15.4 Note: Maximum Working Pressure: Water 30 PSI shipped standard.
  • Page 6 Installation & Service Manual RSAH General Information (continued) Table 1-3: Rating Data Burner Capacity DOE Heating AHRI NET Minimum Chimney Requirements Boiler Model Capacity - Ratings AFUE % - MBH Round In. Rectangle Height Ft. Dia. In. x In. RSAH111E(-T) 0.75 86.2 8 x 8...

  • Page 7: Pre-Installation

    Page 9 for additional details. A Combustible Floor Shield can also Figure 2-1: Minimum Clearances to Combustible Materials NOTE 2: RSAH Series boilers can be installed in rooms with clearances from combustible material as listed above. Chimney...
  • Page 8 Installation & Service Manual RSAH Pre-Installation (continued) C. REMOVE CRATE 5. For boiler located in a confined space or an unconfined space in a building of unusually 1. Remove all fasteners at crate skid. tight construction, provide outdoor air with the 2.
  • Page 9 (continued) INSTALLATION INSTRUCTIONS FOR OPTIONAL SHIELD REQUIRED FOR COMBUSTIBLE FLOOR This shield for combustible floors is intended for use only with the following U.S. Boiler Company oil-fired boilers: Use Part Number 6183504 for the following models: RSAH111E(-T) RSAH154E(-T) ADDS 4-3/16” TO BOILER HEIGHT 1.

  • Page 10: Water Piping And Trim

    Domestic Water Heater, install the Indirect- connected to correct boiler pipe. Fired Domestic Water Heater as a separate U.S. Boiler Company recommends sizing the heating zone. Refer to the Indirect-Fired system circulator to supply sufficient flow (GPM) Domestic Water Heater Installation, to allow a 20°F temperature differential in the...
  • Page 11 Installation & Service Manual RSAH Water Piping and Trim (continued) d. Use a system bypass if the boiler is to be D. INSTALL DRAIN VALVE in return piping. See operated in a system which has a large Figures 3-3 and 3-4. volume or excessive radiation where low E.
  • Page 12 Installation & Service Manual RSAH Water Piping and Trim (continued) 110891-02 - 5/22...
  • Page 13 Installation & Service Manual RSAH Water Piping and Trim (continued) 110891-02 -5/22...
  • Page 14 Installation & Service Manual RSAH Water Piping and Trim (continued) THE FOLLOWING GUIDELINES SHOULD BE dishwashers and automatic washers is FOLLOWED WHEN PIPING THE TANKLESS HEATER: possible by piping the hot water from the heater prior to entering the mixing valve. The 1.

  • Page 15: Venting

    The combination 2. The RSAH Series is designed to be vented into of a large uninsulated chimney, reduced a fireclay tile-lined masonry chimney or...
  • Page 16 Installation & Service Manual RSAH Venting (continued) Figure 4-1: Recommended Smokepipe Arrangement and Chimney Requirements Figure 4-2: Draft Regulator Locations 110891-02 - 5/22...

  • Page 17: Electrical

    Installation & Service Manual RSAH 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 •...
  • Page 18 Installation & Service Manual RSAH Electrical (continued) 110891-02 - 5/22...
  • Page 19 Installation & Service Manual RSAH Electrical (continued) Figure 5-2: Schematic Wiring Diagram 110891-02 -5/22...

  • Page 20: Oil Piping

    Installation & Service Manual RSAH Oil Piping NOTICE: The National Oilheat Research Alliance 3. Use Flared fittings only. DO NOT use (NORA) recommends single pipe oil systems and compression fittings. high-quality filtration for all fuel types. This should 4. Use of a high efficiency micron filter (Garber or include at least a 10-micron Spin-on filter.
  • Page 21 Installation & Service Manual RSAH Oil Piping (continued) Table 6-2: Single Stage Units (3450 RPM) Table 6-3: Two-Stage Units (3450 RPM) Two Pipe Systems Two Pipe Systems Maximum Length of Tubing Maximum Length of Tubing "H" + "R" (See Figure) "H"...

  • Page 22: System Start-Up

    Installation & Service Manual RSAH System Start-Up A. ALWAYS INSPECT INSTALLATION BEFORE i. Close purge valve, continue filling the STARTING BURNER. system until the pressure gauge reads 12 psi. Close shut-off valve in cold water 1. Verify that the venting, water piping, oil piping, supply piping.
  • Page 23 Installation & Service Manual RSAH System Start-Up (continued) 4. WATER BOILERS WITH TANKLESS HEATERS: 2. BECKETT AFG BURNERS The Warm Start Boiler Control is factory This Beckett AFG burner is equipped with a programmed with a High Limit setpoint of non-adjustable Fixed “F”...
  • Page 24 Installation & Service Manual RSAH System Start-Up (continued) G. START OIL BURNER. WARNING 1. Open vent fitting on fuel pump. DO NOT loosen or remove any oil line fittings 2. TURN ‘ON’ BURNER service switch and while burner is operating. allow burner to run until oil flows from vent fitting in a SOLID stream without air bubbles for approximately 10 seconds.
  • Page 25 Installation & Service Manual RSAH System Start-Up (continued) mounted on the bottom of the electronic ignitor. See Figure 7-4. To service cad cell or to replace the plug in portion, swing open the ignitor. After service is complete, be sure to fasten down the ignitor.
  • Page 26 Installation & Service Manual RSAH System Start-Up (continued) iii. Limited Recycle: This feature limits the 3. CHECK OIL PRIMARY CONTROL number of recycle trials (for each call CAUTION for heat) to a maximum of three trials. If the flame is lost three times and does Due to the potential hazard of line voltage, not successfully satisfy a call for heat, only a trained, experienced service technician...
  • Page 27 Installation & Service Manual RSAH System Start-Up (continued) • Failure occurs, device enters Recycle Mode. • Device tries to restart system after approximately 60 seconds. • After third Recycle Mode trial, safety switch locks out within safety switch timing indicated on label and control enters Restricted Mode.

  • Page 28: Operating

    Installation & Service Manual RSAH Operating A. Setting the High Limit: The high limit is factory set will supply latent heat that may remain at 190oF. To adjust, turn the HI TEMP Dial A until in the boiler from a previous run cycle the desired setting is displayed.
  • Page 29 Installation & Service Manual RSAH Operating (continued) BOILER HAS FULLY COOLED. Standard Immersion Well) To activate Manual Reset LWCO mode When used to replace older temperature- 1. Turn the LO TEMP dial to access the only controls, the HyrdroStat can be installed Program Mode - indicated in the display as on the existing well.
  • Page 30 Installation & Service Manual RSAH Operating (continued) Default Dial Setting Feature Options Description Setting Purge Inactive Thermal Pre-Pruge Purge Active Degrees Fahrenheit Fahrenheit or Celsius Degree Celcius LWCO Manual or Automatic Reset Automatic Reset Manual Reset Circulator operation on TT call only Circulator Options Circulator operation on ZC/ZR call only Circulator operation on call from either...
  • Page 31 Installation & Service Manual RSAH Operating (continued) LWCO TEST LCO WARNING The red Low Water light should illuminate and the burner circuit (B1 and B2) should de-energize. Allow the boiler to fully cool before adding water. NOTE: The control must be installed with a Hydrolevel Electro-Well for low water cut-off functionality.

  • Page 32: Maintenance & Service Instructions

    Installation & Service Manual RSAH Maintenance & Service Instructions A. WATER BOILERS: supply house or through your local druggist. 1. Filling of boiler and system. The pH should be higher than 7 but lower than 11. Add some of the washout chemical GENERAL —...
  • Page 33 Installation & Service Manual RSAH Maintenance & Service Instructions (continued) 3. With steam boilers, at end of season add sufficient water to fill boiler to top of water WARNING column and leave it that way until fall when This boiler contains controls which may cause water should be drained again to proper level.

  • Page 34: Boiler Cleaning

    Installation & Service Manual RSAH Boiler Cleaning NOTICE: BURNER SHUTDOWN: Open Service b. For access to the firetubes, pull top jacket Switch to turn off burner. panel off. Remove brass nuts, that hold canopy down. Without taking off carriage Manual Oil Supply Valve should be closed and bolts, pull canopy off.
  • Page 35 Installation & Service Manual RSAH Boiler Cleaning (continued) Table 10-2 Boiler Model Dimension “X” RSAH111E(-T) 13 3/8 RSAH154E(-T) 19 7/8 Figure 10-1: Cleaning of RSAH Boiler 110891-02 -5/22...
  • Page 36 Installation & Service Manual RSAH Boiler Cleaning (continued) Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.

  • Page 37: Troubleshooting

    Installation & Service Manual RSAH Troubleshooting A. COMBUSTION system can clog the nozzle or nozzle strainer 1. NOZZLES — Although the nozzle is a and produce a poor spray pattern from the relatively inexpensive device, its function is nozzle. The smaller the firing rate, the smaller critical to the successful operation of the oil the slots become in the nozzle and the more burner.
  • Page 38 Installation & Service Manual RSAH Troubleshooting (continued) e. Excessive back pressure causing flame to NOTICE: CHECK TEST PROCEDURE. A very be erratic. good test for isolating fuel side problems is to disconnect the fuel system and with a 24” length 3.
  • Page 39 Installation & Service Manual RSAH Troubleshooting (continued) Burner Will Not Fire See Flow Chart 1 Burner Will Not Shut See Flow Chart 2 Down Temperature Display Under normal operation, boiler temperature will continue to rise after the control shuts off the burner. Exceeds High Limit This condition, known as “thermal stacking”...
  • Page 40 Installation & Service Manual RSAH Troubleshooting Flow Chart 1 – Burner Will Not Fire Troubleshooting (continued) Troubleshooting Flow Chart 1 - Burner Will Not Fire The Control is The Thermal Pre-Purge feature holds off the burner until the Does the Purging Latent control determines if the latent heat in the boiler can satisfy Display Read...
  • Page 41 Installation & Service Manual RSAH Troubleshooting (continued) Troubleshooting Flow Chart 2 – Burner Will Not Shut Down Troubleshooting Flow Chart 1 - Burner Will Not Shut Down Is the The Control is Red LED (LOW Sensing WATER) On? Low Water. WARNING! TURN OFF POWER TO BURNER IMMEDIATELY! CAUTION –...

  • Page 42: Service Parts

    RSAH Service Parts All RSAH Series Boiler Service 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 service parts, please contact U.S.
  • Page 43 Installation & Service Manual RSAH Service Parts (continued) RSAH Bare Boiler Item No. Description Part Number RSAH111E(-T) RSAH154E(-T) S-101 110840-01 BBA Assembly Includes: Shell Assembly, Base, and Canopy S-301 110841-01 Base Assembly 110842-01 Canopy Includes: Cerafelt Strips and Hardware 110843-01 110844-01 S-101 111600-01...
  • Page 44 Installation & Service Manual RSAH Service Parts (continued) Figure 12-2: Service Parts Jacket and Trim NOTE: When ordering parts always give the serial number and model number shown on the boiler. Also provide the name of the part(s) shown below: 110891-02 - 5/22...
  • Page 45 Installation & Service Manual RSAH Service Parts (continued) RSAH Trim Item No. Descrption Part Number RSAH111E(-T) RSAH154E(-T) Complete Jacket Carton S-101 110889-01 Includes: Labels and S-301 110890-01 Hardware Observation Port Cover 110848-01 Temperature/ Pressure Gauge 105894-01 Non Heater 110849-01 Limit, Hydrolevel HydroStat 3250 Plus Heater 110850-01...
  • Page 46 Installation & Service Manual RSAH SERVICE RECORD DATE SERVICE PERFORMED 110891-02 - 5/22...
  • Page 47 Installation & Service Manual RSAH SERVICE RECORD DATE SERVICE PERFORMED 110891-02 -5/22...
  • Page 48 Installation & Service Manual RSAH U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 110891-02 - 5/22...

This manual is also suitable for:

Rsah111eRsah111e-tRsah154eRsah154e-t

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