Leisure Line WL110 Operator's manual

Leisure Line WL110 Boiler

Operations & Maintenance Manual

And

Safety Instructions

SAFETY NOTICE

PLEASE READ ENTIRE MANUAL BEFORE INSTALLING

YOUR NEW BOILER. FAILURE TO FOLLOW THESE

INSTRUCTIONS MAY RESULT IN PROPERTY DAMAGE,

BODILY INJURY, OR EVEN DEATH

CONTACT YOU LOCAL BUILDING AND FIRE OFFICIALS

ABOUT RESTRICTIONS AND PERMIT/INSPECTION

REQUIREMENTS IN YOUR AREA

Black Rock Manufacturing

DBA

Leisure Line Stove Company

Rear 620 Broad Street

Berwick, PA 18603

http://www.leisurelinestoves.com

[email protected]

570-752-1811

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

Table of Contents

Important Warning Statements........................................................................................... 2

Important Warning Statements (contd.).............................................................................. 3

Boiler Concept of Operation and General Information ...................................................... 3

Unpack and Installation instructions................................................................................... 5

Boiler Plumbing Instructions.............................................................................................. 6

Boiler Pre-Operation Instruction ........................................................................................ 6

Lighting the Boiler for Coal Operation............................................................................... 7

In Season Maintenance....................................................................................................... 8

Resolution of Common Problems....................................................................................... 9

Boiler Shut Down and End of Season Maintenance......................................................... 10

Recommended Spare Parts ............................................................................................... 10

Specifications.................................................................................................................... 11

APPENDIX A, Boiler Parts List....................................................................................... 12

APPENDIX B, Coal/Oil Set up instructions Leisure Line WL 110................................. 13

APPENDIX C, Control Schematic for the Leisure Line WL 110.................................... 15

APPENDIX D, Manufacturers Labels.............................................................................. 16

APPENDIX D, Manufacturers Labels (contd.)................................................................ 17

Appendix E: Installation and Maintenance Record......................................................... 18

Important Warning Statements

Your Boiler comes with one Carbon Monoxide Detector, It is recommended that there be one outside each sleeping area and at least one per

floor, read your CO manual completely before lighting boiler

IMPORTANT: This carbon monoxide alarm is designed to detect carbon monoxide from ANY source of combustion. It is NOT designed to

detect smoke, fire, or any other gas. WARNING: Carbon monoxide alarms are not smoke alarms. This

carbon monoxide alarm is not a substitute for installing and maintaining an appropriate number of smoke alarms in your home. This

carbon monoxide alarm will not sense smoke, fire, or any poisonous gas other than carbon monoxide even though carbon monoxide can be

generated by fire. For this reason you must

install smoke alarms to provide early warning of fire and to protect you and your family from fire and its related hazards. CAUTION: This

alarm will only indicate the presence of carbon monoxide at the sensor. Carbon monoxide may be present in

other areas.

General Carbon Monoxide Information

Carbon monoxide is a colorless, odorless and tasteless poison gas that can be fatal when inhaled. CO inhibits the blood’s capacity to carry oxygen.

Periodically review this alarm manual and discuss your CO alarm emergency procedure with all the members of your family. Never ignore a CO

alarm. A true alarm is an indication of potentially dangerous levels of CO. CO alarms are designed to alert you to the presence of CO before

an emergency –before most people would experience symptoms of CO poisoning, giving you time to resolve the problem calmly. Determine if

anyone in the household is experiencing symptoms of CO poisoning. Many cases of reported CO poisoning indicate that while victims are aware they

are not well, they become so disoriented they are

unable to save themselves by either exiting the building or calling for assistance. Also, young children and household pets may be the first affected.

You should take extra precautions to protect high-risk persons from CO exposure because they may experience ill effects from CO at levels that

would not ordinarily affect a healthy adult.

Symptoms of CO Poisoning

The following common symptoms are related to CO poisoning and

should be discussed with ALL members of the household.

Mild Exposure:

Slight headache, nausea, vomiting, fatigue (often described as

“flu-like” symptoms).

Medium Exposure:

Severe throbbing headache, drowsiness, confusion, fast heart rate.

Extreme Exposure:

Unconsciousness, convulsions, cardio-respiratory failure, death.

If you experience even mild symptoms of CO poisoning, consult your

doctor immediately!

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

Important Warning Statements (contd.)

WARNING

Improper installation, adjustments, alterations, service, or maintenance of your Leisure Line Boiler or

Power Venter can cause property damage, personal injury or loss of life. Installation and service must be

performed by a qualified installer or service agency. Proper permits and inspections should always be

obtained.

If applicable, please make sure you notify your insurance company before placing your boiler into

service. Boiler must be placed on a non-combustible surface.

UL ratings on all Leisure Line boilers and Power Venters are dependent on sufficient clearance as

defined on the label on the rear of your boiler and in this manual. All boilers must utilize a Barometric

Draft Control such as the Field Controls Type RC Barometric Damper, the weights should be adjusted to

obtain a -.03” to -.05” water column negative pressure in the flue pipe at the boiler outlet. Do not operate

with a flue draft exceeding .07” (17.4Pa) water column. Do not store fuel or other combustible material

within marked installation clearances. Inspect and clean flues and chimney regularly.

CAUTION

Hot Surfaces. Keep children away. Do not touch during operation.

Ashes should be placed in a metal container with a tight fitting lid. The closed container of ashes should

be placed on a noncombustible floor or on the ground, well away from all combustible materials, pending

final disposal. If the ashes are disposed of by burial in soil or otherwise locally dispersed, they should be

retained in the closed container until all cinders have thoroughly cooled. Any activities that involve

touching or working around boiler heated surfaces should be accomplished using welding gloves or other

suitable protection for the hands. Additionally safety glasses should be worn when handling ash or

during cleaning and maintenance operations involving fly ash removal.

Boiler Concept of Operation and General Information

1. The Axeman Anderson WL110 pressure Vessel holds 12 gallons of water which makes it very

responsive during the coal fired mode, this small amount of water requires the use of a dump zone high

limit control. The L6006 Aquastat provided with your boiler contains both close on rise and open on

rise contacts, the common terminal R is connected to the power in from the circuit breaker panel/fused

switch, terminal B will be connected to the Red wire in the Coal/Oil switch box to provide power to the

boiler. This circuit will open at the set point of the Aquastat removing power from the boiler. Terminal

W will be connected directly to the circulator that will dump heat from the boiler in the event the unit is

over the set point, typically this works very well on radiant heat zones or fan coil units located outside

the living space such as a garage or basement.

2. The L7224 triple Aquastat provides control of normal boiler high and low limits and can be used to run

one circulator pump. The output of the burner circuit provides full power to the stoker motor and

combustion fan and bypasses the idle circuit designed to keep the boiler running. For this reason it is

important to set the full burn adjustment using the screw adjuster on the feeder prior to setting up the

idle circuit. A full explanation of how this control works is found in the Honeywell instruction manual

found with the documentation envelope or on our website.

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

3. The relay box with two rheostats on top provides an asymmetrical cycle timer and speed control of the

stoker motor and combustion fan to keep the boiler running between burn cycles. The factory setting for

the timer is 4 minutes off (this is the first cycle) and 2 minutes on, the combustion fan rheostat is set for

full speed and the stoker rheostat is set for half speed. When the burner circuit is de-energized two

relays isolate the stoker and combustion fan from the L7224 triple aquastat and allow direct control by

the timer and rheostats.

4. The combustion fan mounted under the feeder motor is run at full speed all the time when the L7224

triple aquastat calls for heat and runs by the rheostat and timer when it is not calling for heat.

5. The feeder motor is run at full speed all the time when the L7224 triple aquastat calls for heat and runs

by the rheostat and timer when it is not calling for heat. The coal feed is adjusted by way of a

adjustment screw on the back of the feeder. This adjustment must be accomplished prior to setting the

idle fire settings using the rheostat and timer.

6. The DWYER Air Meter 460 draft gauge supplied with the boiler is designed to monitor draft in the base

and ensure that the fly ash accumulation in the fire tubes is not excessive so as to effect efficiency and

proper operation.

7. The oil gun is designed to hang on a bracket during coal operation and is either unplugged from power

or disabled by a limit switch when in the stowed position.

8. There is a glass view port which covers the hole left open when the oil gun is removed, this glass is held

in by a plate and the three screws that mount the oil gun.

NOTE: Outside combustion air may be necessary if: The solid-fuel-fired appliance does not draw steadily, smell, experiences

smoke roll-out, burns poorly, or back-drafts whether or not there is combustion present. Any of the above symptoms are alleviated

by opening a window slightly on a calm day. The house is equipped with a well-sealed vapor barrier and tight fitting windows

and/or has any powered devices which exhaust house air.

There is excessive condensation on windows in the winter. A ventilation system is installed in the house.

Idle Fire Relay

Box

Oil/Coal Switch

Coal Hopper

Oil Burner

Bracket

Base with ash

door

Supply Lines

Domestic Hot

Water Coil

Triple Aquastat

Return Line with

Circulator Pump

Oil Burner

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

Unpack and Installation instructions

To ensure safe installation, it is recommended that this boiler be installed by a qualified installer

1. Record Data in Appendix E and remove plastic and un-band boiler from pallet

2. Remove the two screws that hold the wood shipping base to the pallet

3. Remove the ash pan and fire brick from the bottom of the boiler/pallet

4. Inventory all parts and ensure that all items in Appendix A are present. Immediately notify your dealer

of any missing items.

5. Carefully remove the boiler from the pallet using a fork lift or hand truck

6. Move boiler to installation location

7. Remove the two screws that hold the boiler base to the wood shipping base

CAUTION: ALL PLACARDED CLEARANCES SHALL TO BE ADHERED TO AND MAINTAINED.

UNIT MUST SIT ON A NON-COMBUSTABLE FLOOR WHICH EXTENDS TO LISTED CLEARANCES.

8. Carefully slide the boiler off the wood shipping base and slide the boiler in its final resting place and

connect flue pipe and barometric damper to chimney or Power Vent (refer to Power Vent Instruction

manual for mounting and safety switch installation). All Stove pipe must be 6” black or blued steel 24

gauge pipe. DO NOT USE GALVANISED OR ALUMINUM PIPE! Unless using a Powervent, no

more than 10 feet of stove pipe should be used, including two or less 90* elbows. All horizontal runs

should have a minimum ¼” rise per foot.

9. Verify clearances to combustibles

Per the diagram on right

Ash Door Side

10. Chimney should be Terra Cotta, 316 grade Stainless Steel Liner or Brick lined and in good condition,

height requirement for minimum draft is 15 feet. If a liner is placed in a masonry chimney fill or wrap

insulation around the liner is required to ensure proper draft. If a metal chimney is used it must be Type

HT (Class A) double lined and constructed from Stainless Steel. An excellent Source of supply for this

is Olympia Chimney Supply, 600 Sanders Street, Scranton, PA18505-2495, Phone: 570-496-8890, Fax:

570-496-8894, Website: http://www.olympiachimney.com/ .

NOTE: ALWAYS CHECK WITH LOCAL CODES FOR PROPER INSTALLATION

11. Using the torpedo or carpenters short level check the bottom edges of the boiler to ensure it is level, if

not shim under the appropriate side using non-combustible material.

12. Connect piping and 120 volt power (use a switch with 15 amp fuse in a single gang box and mount on

boiler above switch box) and make connections to the L6006 high limit per the schematic in Appendix

13. Refer to Appendix B in the back of this manual for configuration for Oil or Coal, for coal operation the

Axeman Anderson, Beckett, Honeywell, Carlin and other documentation should be reviewed first.

14. Install spring handle on door by sliding and twisting the spring over the steel handle.

TIP: IF THE COMBUSTION FAN VIBRATES OR MAKES EXCESSIVE NOISE IT CAN BE QUIETED DOWN BY PLACING SOME FIBERGLASS BOILER GASKET

ON THE MOUNTING SURFACE BETWEEN THE BOILER BODY AND FAN FLANGE.

TIP: USE Permatex 81343 ANTI SEIZE COMPOUND ON ALL THREADED FASTENERS FOR EASIER REMOVAL AT A LATER TIME.

Boiler

& Base

4”

19”

18”

48”

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

Boiler Plumbing Instructions

1. Read the Axeman Anderson boiler manual, Becket Oil Gun Manual (or Carlin Gas Gun Manual), the

Honeywell L7224C manual found in the envelope that is shipped in the ash pan.

2. Connect all plumbing in accordance with local codes and requirements. SEE FIGURE BELOW FOR

ADDITIONAL INFORMATION ON BOILER CONNECTIONS:

3. Since the WL110 has a water capacity of 12 gallons, it is important that the plumbing connection

method controls the return temperature to ensure a boiler differential temperature of around 25*F. This

can be accomplished by using a primary/secondary connection or by running the circulator continuously

to maintain the temperature of the heating loops.

NOTE: IT IS IMPORTANT FOR THE DUMP ZONE TO BE CONNECTED AND FUNCTIONAL BEFORE LIGHTING

THE BOILER TO PREVENT AN OVERTEMP CONDITION.

Boiler Pre-Operation Instruction

1. Refer to Appendix B for converting unit from oil to coal operation and vice versa.

2. Read the Axeman Anderson boiler manual, Becket Oil Gun Manual (or Carlin Gas Gun Manual), the

Honeywell L7224C manuals AGAIN!

3. Verify that all piping has been pressure tested and that the cold water supply is turned on and the fill

valve is operating properly (there should be around 12 PSI registering on the Tridicator located on the

DHW coil.

4. Verify that all control wiring has been installed and verify that the thermostat (s) is hooked up to the

L7224 triple aquastat.

5. Verify that the L6006 high limit aquastat terminals R to B are in series with the power feeding the

boiler, verify that terminals R to W are feeding the dump zone circulator pump.

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

6. Using a level ensure that the barometric damper pivot is level and that the weight is located appropriate

to the flue pipe orientation and is lined up with the 4 on the sliding scale. If your barometric damper

does not have a value on the scale you must use a draft gauge to adjust the weight for proper draft.

7. Verify the 8 fire bricks are properly placed so as to surround the feeder.

8. Verify that the chimney has been inspected by a professional and is clean and free of damage.

9. Drill a 5/16”hole in the base near the bracket that holds the oil gun and verify that the Dwyer Air Meter

460 is installed so that is is monitoring the draft in the base at all times, a piece of wire can be used to

hang it so that it hangs plumb/level.

10. Turn on the boiler and verify there is power to the L7224 Triple Aquastat and that the coal feed adjuster

is backed all the way off to prevent coal from being fed before it is needed.

11. Familiarize yourself with the menus and settings on the L7224 Triple Aquastat by going through each

to see how the display responds to input.

12. Place the fire stop ring on the grate and fill the hopper with coal after all familiarization activities are

complete.

Lighting the Boiler for Coal Operation

1. Two of the fire bricks can be removed or remove the access cover on the front of the boiler for lighting,

to accomplish this remove the four 9/16” brass nuts and pull the cover straight out. If the over is not

removed, two of the fire brick can be moved during the initial lighting and fire adjustment phase and

replaced when complete.

2. Verify the fire starter ring is in place if there is no ash on the grate from a previous fire, verify there is

sufficient coal in the hopper. If the unit has been fired before push some fresh coal down to leave just 2”

of ash by manually pushing the adjustment screw in and out which will move the feeder carpet. Place a

fire starter bag on the grate and move the coal aside so it contacts the air holes, cover it partially with

coal.

3. If boiler is vented by a power vent, switch the unit on and adjust the rheostat until the barometric damper

is opening slightly.

4. Verify boiler power is on at the switch and that the coal oil switch is placed in the “Coal” position.

5. Adjust feed screw to all the way out (minimum coal feed). Light the starter bag and push the cover

straight back over the studs, leave the nuts off, after four minutes, if there is exposed starter bag visible

throw a handful of coal onto the flames using a small steel shovel.

NOTE: DURING THIS PHASE IT WILL BE NECESSARY TO RUN AT LEAST ONE ZONE TO TAKE THE HEAT BEING

GENERATED, THE BOILER WILL COME UP TO 180*F WITHIN 20 MINUTES WITH NO LOAD.

6. After ash is visible at the end of the grate remove the starter ring by knocking it into the ash pan with the

shovel (when the ash bucket is emptied, remember to remove the fire stop ring for future use).

7. When the middle of the fire is looking dull it is time to start adjusting the feed rate for max burn by

screwing in the feeder adjustment screw in a clockwise direction. When there is around ½” of ash at the

end of the fire, allow the boiler to run at this feed rate for at least a half hour to verify the setting, mark

the feed adjustment screw with a permanent marker for future reference.

8. Allow the boiler to run with the burner circuit disabled for at least an hour and adjust the asymmetrical

timer and rheostats to obtain a 1/2” fire all the way across the grate. Verify the setting by allowing the

boiler to run at least ½ hour after the last adjustment. Refer to the idle circuit detail on the next page for

more information.

9. Remove power from the boiler and re-install the burner circuit wire inside the L7224 triple aquastat and

take note of the timer and rheostat settings, retain information for later use.

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

10. The boiler should be tested to verify the high limit and dump zone is working properly, simply adjust the

high limit until the boiler shuts off and verify that the dump zone operates and that the boiler comes

back on within 5 degrees of the set point (there is a small white wheel under the terminals that should be

set on 5 to accomplish this).

In Season Maintenance

1. Check Elbows and horizontal pipe runs for fly ash build up every ton of coal used, clean as needed.

2. Clean under the feed carpet every two or three months.

3. Clean combustion fan.

4. Oil fan motor every two months or so with 1 drop of 30W5 synthetic oil.

5. Burn oiled coal if possible, this will reduce coal dust in the boiler area and therefore reduce

maintenance.

6. Power off boiler and clean combustion fan squirrel cage fins every two months, depending on level of

dust in area of boiler, may be required more frequently.

7. Refer to Power Vent manual for cleaning and maintenance instructions.

Standard Sheet Metal

cover and Insulation

Optional Flue Clean Out

and Sheet Metal Cover

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

8. Check Draft gauge to ensure boiler base has at least -,005 to -.01” WC, clean fire tubes per the following

procedure if draft is too low or there is evidence of moisture in the hopper lid/slight sulpher smell in

hopper.

CAUTION: THE FOLLOWING STEPS INVOLVE WORKING WITH HEATED METAL SURFACES. APPROPRIATE

WELDING GLOVES OR OTHER HIGH HEAT HAND PROTECTION AND SAFETY GLASSES SHALL BE USED. A DUST

MASK IS OPTIONAL IF THE PERSON PERFORMING THE TASK IS SENSITIVE TO DUST.

9. If the boiler is equipped with the optional cleanout (refer to photo above to aid in identification), shut the

unit off, remove the sheet metal cover using gloves and open the clean out door, vacuum the tubes out

from the top and close the door, restore power and re-install the sheet metal cover.

10. If not equipped with the optional flue clean out remove four sheetmetal screws that hold top jacket on

boiler

11. Shut off boiler power and quickly remove flue pipe and remove sheet metal and insulation from top of

boiler. Re-connect flue pipe and power boiler back on for the following two steps.

12. Tools needed for next steps include: a shop vacuum with HEPA filter, 9/16” deep socket on ¼” drive

ratchet or cordless drill motor, bright flashlight or drop light.

13. Remove the four 9/16” brass nuts from boiler flue pipe adapter cover,.

14. Make sure shop vac and light source are plugged in and ready to go.

15. Shut off boiler power and remove flue pipe and set to the side, vacuum each tube and then move

economizer up and down so as to loosen any remaining fly ash and re-vacuum that tube, inspect each

tube with the light and verify free of obstructions and clear of most of the fly ash.

16. Replace cover and flue pipe, re-apply boiler power and re-install the four 9/16” nuts.

17. Shut off boiler power and quickly remove flue pipe and install sheet metal and insulation to top of

boiler. Re-connect flue pipe and power boiler back on

Resolution of Common Problems

1. If there is black dust evident on the horizontal surfaces in the home, shut down the fans and try adding

the coal to the hopper more slowly, or get oiled coal. Check your coal supply, if there are many small

broken pieces and dust mixed in, try an alternate source to see if cleaner coal is available.

2. A moist hopper lid indicates a draft issue that must be resolved immediately. Make sure all flue pipes

are clean, ensure that the barometric damper is adjusted properly and is not stuck open, ensure that the

coal is not dripping wet when added to the hopper, check that the chimney is not restricted if the

preceding items do not correct the issue. If the boiler is on a power vent ensure that the unit has been

maintained per the manual and is spinning fast enough to provide sufficient draft.

3. A coal fire that is burning toward the back of the grate is indication of insufficient or too much draft and

must be resolved immediately. Check all items in paragraph 2, if all those items are not the source of

the issue, shut the boiler down and check the fiberglass gasket that is between the back edge of the grate

and feeder body. This gasket will often fall out when the grate is removed and must be replaced if

missing.

4. If the combustion fan or feeder motor stop operating, plug the motor directly into a power outlet to

verify that the issue is not with the boiler wiring or controls. Often a motor will stop operating after the

boiler is shut down even after a power outage, cleaning the motor and oiling the bearings will often

solve the issue.

CAUTION: EXCESSIVE CORROSION WILL REULST FROM BOILER SHUT DOWN FOR MORE THAN A WEEK

WITHOUT PROPERLY CLEANING AND PROTECTING THE SURFACE EXPOSED TO COAL ASH. THE RESULTING

CORROSION WILL VOID THE WARRANTY ON THE PRESURE VESSEL.

WARNING –RISK OF FIRE –DO NOT OPERATE WITH A FLUE DRAFT EXCEEDING -.07”wc,

OPERATING AT A DRAFT ABOVE -.07”wc CAN CAUSE UNIT TO BURN BACK INTO THE HOPPER

DO NOT OPERATE WITH ASH REMOVAL DOOR OPEN

DO NOT STORE FUEL OR OTHER COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES

CAUTION –BURN RICE OR BUCKWHEAT SIZED ANTHRACITE COAL ONLY

DANGER - Risk of Fire or Explosion - Do not burn garbage, gasoline, drain oil or other flammable liquids.

CAUTION –HOT SURFACES –KEEP CHILDREN AWAY –DO NOT TOUCH APPLIANCE DURING OPERATION

DO NOT CONNECT THIS UNIT TO A CHIMNEY SERVING ANOTHER APPLIANCE

PLEASE SAVE THESE INSTRUCTIONS

Boiler Shut Down and End of Season Maintenance

1. It is recommended that the boiler be run and kept at operating temperatures year round. If a shut down

of the unit is required for any reason the following steps should be taken. After the boiler is cool

remove all unburned coal from the hopper, and remove the ash pan from the boiler. Remove all ash off

the grate and vacuum the inside of the boiler using a shop vac fitted with a HEPA filter to minimize

dust. Remove the diffuser and economizers. Brush down all interior surfaces with a stiff nylon brush

and vacuum up all loose ash. A wipe down of all boiler surfaces using a baking soda and water mixture

at the rate of two gallons water to one box baking soda, this will help neutralize the acidic nature of the

coal ash.

2. Remove all flue pipes from the boiler and chimney/power venter. Take pipes and ash pans outside and

wash down thoroughly and dry in ths sun.

3. Spray all surfaces with metal protector such as LPS 3 or CRC SP 350/SP400.

4. Cover the opening to the chimney and block air from entering the house. If a power vent is used remove

the motor and block the opening.

5. If the boiler is located in a damp location, a drop cord with a 40 watt bulb makes an excellent heat

source to keep the boiler dry and rust free.

Recommended Spare Parts

1. Generally speaking the motors on your boiler are the first items to fail, the feeder motor is the most

common failure point and should be purchased as a spare item. Next on the list is the combustion fan

which runs 24-7 and is located in one of the dirtiest places on the boiler. The next item to keep as a

spare would be the timer/relays/rheostats although these items generally last more than 5 years with no

issues.

2. The diffuser is a wear item that will last at least 5 years but could be spared as it nears the end of it’s

useful life.

3. Purchase of these parts can be accomplished through your local dealer. If you do not have a dealer

nearby or your dealer does not stock the parts you can purchase them directly from the factory at

suggested retail plus shipping and handling. Warranty items will be credited at the time the old part is

received and warranty coverage is verified.

4. Spare item listing for the Oil Burner are located in the Beckett Manual provided in the document

envelope (this also applies to the Carlin Gas Burner).

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