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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
LE™ SERIES
OIL - FIRED BOILER
®
As an ENERGY STAR Partner, U.S. Boiler Co., Inc. has determined that the LE1 fired at the
0.60 GPH rate meets the ENERGY STAR guidelines for Energy efficiency established by the
United States Environmental Protection Agency (EPA).
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.
Boiler Ser
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IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY 1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS MANUAL. 2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CAN NOT BE INSTALLED ON CARPETING. 3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY DIFFER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION
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IMPORTANT Before starting to install this oil boiler, read these instructions carefully. Keep instructions in legible condition and posted near oil boiler for reference by owner and service technician. TAbLE OF CONTENTS I. General Information .................................. 3 IV. Boiler Cleaning ........................................ 20 II. Installation Instructions ............................ 5 V. Repair Par ts ............................................. 21 III. Op
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D. For boiler located in an unconfined space of a conventionally constructed building, the fresh air infiltration through cracks around windows and doors normally provides adequate air for combus- tion and ventilation. E. For boiler located in a confined space or an uncon- fined space in a building of unusually tight con- struction, provide outdoor air with the use of two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communica
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II. Installation Instructions D. Remove 2 (two) 5/16" - 18 x 3" long hex head cap 1. REMOVE CRATE screws and flatwashers from right side of door. A. Remove all fasteners at crate skid. Remove 2 hairpin cotter pins and 2 hinge pins from B. Lift outside container and remove all other inside hinges on left side of door and remove Door protective spacers and bracing. Remove container Assembly from boiler. Inspect Front and Rear containing Safety Relief Valve, Boiler Drain Valve Door Insu
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Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems Figure : Recommended Water Piping for Circulator Zoned Heating Systems
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4. INSTALL BOILER CONTROL. A. Pull bulb and capillary tube out of hole in back of control. Insert bulb in immersion well on top of boiler and secure control with set screw in control. B. Secure flexible conduit to Jacket Wrapper side with conduit clamp and sheet metal screw. Conduit must be on same side of boiler as Swing Door hinges. 5. MOVE BOILER TO PERMANENT POSITION by sliding or walking. 6. INSPECT FRONT AND REAR DOOR INSULATION PIECES AND COMBUSTION CHAMBER LINER A. OPEN SWING DO
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a home without insulation or storm windows. With 8. INSTALL SMOKEPIPE — The LE should be vented increasing fuel prices that home probably has been into a fireclay tile-lined masonry chimney or a chimney insulated and fitted with storm windows so that the constructed from Type L Vent or a factory built heat loss of the home has been reduced. This chimney that complies with the Type HT requirement, requires less fuel to be burned and sends less heat of UL103. The chimney and vent pipe sha
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TABLE 2: SINGLE-STAGE UNITS (3450 RPM) TWO-PIPE SYSTEMS Maximum Length of Tubing "H" + "R" Lift "H" 3/8" OD 1/2" OD Tubing (3 GPH) Tubing (3 GPH) 0' 84' 100' 1' 78' 100' 2' 73' 100' 3' 68' 100' Figure 4' 63' 100' IMPORTANT 5' 57' 100' 6' 52' 100' Single-pipe installations must be absolutely airtight or leaks or loss of prime may result. 7' 47' 100' Bleed line and fuel unit completely. 8' 42' 100' TWO-PIPE OIL LINES - For two-pipe systems where 9' 36' 100' more lift is required, the two-stage
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Figure 11A: Wiring Diagram for LE Boilers with Beckett AFG Burner and Split Controls 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 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 or the setting of the high limit is reached
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Figure 11C: Wiring Diagram for LE Boilers with Riello Burner 11
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III. Operating and Service Instructions 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 and disconnect two halves of Burner Swing Door Interlock wiring harness to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely and reconnect two halves of Burner Swing Door
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setting and has not gone below the Low Limit setting (minus the Differential). (2) High Limit: Boiler temperature went above the High Limit setting and has not dropped below the High Limit setting (minus the Differential). TABLE 4: LED ERROR CODES Error Cause / Action Code Err1 Sensor fault; check sensor. Err2 ECOM fault; check EnviraCOM™ wiring. Err3 Hardware fault; replace control. Err4 B1 fault; check B1 wiring/voltage. Err5 Low Line; check L1-L2, 110 Vac. Figure 1: L48 Circuit Board
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the burner output. The ZC output is energized. G. HIGH LIMIT CONTROLLER The controller continues to monitor the system The High Limit opens and turns off the burner when and automatically restarts if the error condition the water temperature reaches the setpoint. The clears. Refer to Table 4. High Limit automatically resets after the water The operating sequence for the L7248 is shown in temperature drops past the setpoint and through the Table 5. Differential. The L7248 models h
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TABLE : BECkETT AFG BURNER Nozzle Settings Firing Boiler Static Pump Rate Head Air Air Model Disc Manufacturer GPH Angle Type Head Pressure (GPH) Shutter Band (PSIG) LE1 0.60 * 0.50 70° B 5 0 N/A 140 Hago or MB(L1) 3-3/8U Delavan LE2 1.00 0.85 60° B 10 0 N/A 140 LE3 1.25 + MD(V1) 2-3/4U Delavan 1.10 45° B 10 1.5 0 140 Settings are approximate and must be verified by Smoke and Carbon Dioxide measurement. Readjust where necessary. See Text of the Manual. * Install low firing rate baffle f
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(1) Safe Start i. Jumper the yellow cad cell leads. ii. Follow procedure to turn on burner. Burner must not start, indictor light turns on and control remains in Idle Mode. (2) Simulate Flame Failure. i. Follow procedure to turn on burner. ii. Close hand valve in oil supply line. iii. Device enters recycle mode. iv. Device tries to restart system after approximately 60 seconds. v. Safety switch locks out approximately in Figure 1: Cad Cell safety switch timing indicated on label. Befo
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B. Boiling Out of Boiler and System. The oil and grease shorten the life of the boiler. Entrained in make-up which accumulate in a new hot water boiler can be water are dissolved minerals and oxygen. When the washed out in the following manner. fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen (1) Remove Safety Relief Valve using extreme care escapes as a gas. Both can result in reduced boiler to avoid damaging it. life. The accumulation of
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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 about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health. A
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(4) Tank connection leaks. H. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower poor combustion or There are various test kits available to trace air delayed ignition may result. Cold oil is harder to leaks, such as electronic sight glasses. Follow the atomize at the nozzle. Thus, the spray droplets get manufacturers' instructions to find air leaks. larger and the flame shape gets longer. An outside The following actions can eliminate air leaks: fuel tank
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IV. 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. Be sure to tighten swing door fastener completely when service is completed. 1. CLEAN THE FIRETUBES 4. CLOSE BOILER
