Burnham V8 User Manual

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As an ENERGY

Partner,

STAR Burnham Hydronics has determined that the V83S, V83WM, V84S, V84WM, V85S, V85WM, V86S, V86WM and V87 meet the ENERGY STAR guidelines for Energy

efciency established by the

United States Environmental Protection Agency (EPA).

8142824R10.5-4/07

Price - $3.00

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. In all cases, reference should be made to the following Standards:

USA BOILERS A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations.

CANADIAN BOILERS A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment", for recommended Installation Practices. B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or Local Regulations.

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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TABLE OF CONTENTS

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TABLE OF CONTENTS

I. Pre-Installation .........................................10

II. Knockdown Boiler Assembly ....................12

III. Packaged Boiler Assembly .........................26

IV. Water Boiler Piping & Trim ......................31

V. Steam Boiler Piping & Trim ......................36

VI. Tankless & Indirect Water Heater Piping ..38

VII. Venting & Air Intake Piping .....................41

VIII. Electrical ...................................................44

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IX. Oil Piping .................................................63

X. System Start-Up ........................................65

XI. Maintenance & Service Instruction ...........74

XII. Boiler Cleaning .........................................78

XIII. Trouble Shooting ......................................80

XIV. Repair Parts ...............................................81

XV Appendix

Low Water Cut Oﬀ ....................................97

TABLE 1A: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1D)

Boiler

Model No.

Dimensions

See Figures 1A - 1D

Water Content - Gallons

Heat Transfer

Surface Area

- Sq. Ft.

Approximate

Shipping Weight

(LB.)

"A"

"B"

"C"

Steam

Boiler

Water Boiler

Steam Boiler

V82

12-1/8"

6-5/8"

10.0

450

V83

17-1/8"

9-1/8"

10.3

12.8

15.88

542

V84

22-1/8"

11-5/8"

12.4

15.7

22.92

634

V85

27-1/8"

14-1/8"

14.6

18.5

29.96

726

V86

32-1/8"

16-5/8"

16.7

21.4

37.00

818

V87

37-1/8"

19-1/8"

18.8

24.2

44.04

910

V88

42-1/8"

21-5/8"

20.9

27.1

51.08

1002

V89

47-1/8"

24-1/8"

23.0

30.0

58.12

1094

NOTE: 1

The V82 Boiler is available as a packaged water boiler only.

22Maximum working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped From Factory (Std.),

40 PSI Optional, 50 PSI Optional

Boiler

Model No.

Burner Capacity

I=B=R NET Ratings

Minimum Chmney

Requirements

AFUE %

GPH

MBH

DOE Heating

Capacity MBH

Water

MBH

Steam

MBH

Steam Sq. Ft.

Round

In. Dia.

Rectangle

In. x In.

Height

Ft.

Steam

Water

V82W

0.60

8 x 8

82.1

V83W

1.05

147

123

107

8 x 8

82.6

V83S

V83WM

0.75

105

283

8 x 8

85.1

86.0

V84W

1.35

189

159

138

8 x 8

83.2

V84S

V84WM

1.05

147

127

110

396

8 x 8

85.3

86.1

V85W

1.65

231

196

170

8 x 8

83.9

V85S

V85WM

1.35

189

164

143

123

512

8 x 8

85.4

86.2

V86W

1.90

266

227

197

8 x 8

84.6

V86S

V86WM

1.65

231

201

175

151

629

8 x 8

85.7

86.3

V87S

V87W

2.10

294

252

219

189

787

8 x 8

84.7

85.0

V88S

2.35

329

266

200

833

8 x 12

V88W

2.35

329

275

239

8 x 12

V89S

2.60

364

298

224

933

8 x 12

V89W

2.60

364

299

260

8 x 12

Boiler Model Sufﬁ x: S=Steam at standard rate, W=Water, WM=Water at minimum rate

Dimensions

Boiler

Model No.

V82 V83 V84 V85 V86 V87 V88 V89

NOTE: 1

See Figures 1A - 1D

"A"

12-1/8" 17-1/8" 22-1/8" 27-1/8" 32-1/8" 37-1/8" 42-1/8"

47-1/8" The V82 Boiler is available as a packaged water boiler only. Maximum working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped From Factory (Std.),

40 PSI Optional, 50 PSI Optional

"B"

6-5/8"

9-1/8" 11-5/8" 14-1/8" 16-5/8" 19-1/8" 21-5/8" 24-1/8"

"C"

5" 6" 6" 7" 7" 8" 8" 8"

Water Content - Gallons

Steam

Boiler

10.3

12.4

14.6

16.7

18.8

20.9

23.0

Water Boiler

10.0

12.8

15.7

18.5

21.4

24.2

27.1

30.0

Heat Transfer

Surface Area

- Sq. Ft.

Steam Boiler

15.88

22.92

29.96

37.00

44.04

51.08

58.12

Approximate

Shipping Weight

(LB.)

450 542 634 726 818

910 1002 1094

TABLE 1B: RATING DATA

Minimum Chmney

Burner Capacity

Boiler

Model No.

V82W

V83W

V83S

V83WM

V84W

V84S

V84WM

V85W

V85S

V85WM

V86W

V86S

V86WM

V87S

V87W

V88S

V88W

V89S

V89W

Boiler Model Sufﬁ x: S=Steam at standard rate, W=Water, WM=Water at minimum rate

GPH

0.608484

1.05

0.75

1.35

1.05

1.65

1.35

1.90

1.65

2.10

2.35

2.60

MBH

147 105

189 147 231 189 266 231

294 329

329 364 364

DOE Heating

Capacity MBH

123

159 127 196 164 227 201

252 266

275 298 299

I=B=R NET Ratings

Water

MBH

107

138 110 170 143 197 175

219

239

260

Steam

MBH

123

151

189 200

224

Steam Sq. Ft.

283

396

512

629

787 833

933

Requirements

Round

In. Dia.

6 6

6 7 6 7 7 8 7

8 8

8 9 9

Rectangle

In. x In.

8 x 8 8 x 8

8 x 8 8 x 8 8 x 8 8 x 8 8 x 8 8 x 8 8 x 8

8 x 8

8 x 12 8 x 12 8 x 12 8 x 12

Height

Ft. 15 15

15 15 15 15 15 15 15

15 15

15 15 15

AFUE %

Steam

85.1

85.3

85.4

85.7

84.7

Water

82.1

82.6

86.0

83.2

86.1

83.9

86.2

84.6

86.3

85.0

Figure 1A: V82 thru V89 Water Boiler without Tankless Heater

Figure 1B: V83 thru V89 Water Boiler with Front Tankless Heater

Figure 1C: V83 thru V89 Water Boiler with Rear Tankless Heater

Figure 1D: V83 thru V89 Steam Boiler with or without Tankless Heater

SECTION I: PRE-INSTALLATION

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.

2. Any claims for damage or shortage in shipment must be ﬁ led immediately against the carrier by the consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after receipt of goods.

B. LOCATE BOILER in front of ﬁ nal position before

removing crate. See Figures 1A thru 1D.

1. LOCATE so that vent pipe connection to chimney will be short and direct.

2. BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR. Boiler cannot be installed on carpeting.

3. FOR BASEMENT INSTALLATION, provide a solid elevated base, such as concrete, if ﬂ oor is

not level, or if water may be encountered on ﬂ oor around boiler.

4. PROVIDE SERVICE CLEARANCE of at least 24” clearance from front jacket panel for servicing and removal of front tankless heater (increase to 30" for #A54 heater). If boiler is equipped with a rear tankless heater, provide at least 24" service clearance on the right side of the boiler. Boiler ﬂ ueways may be cleaned either from the top or from the right side. Provide at least 24" clearance from either the right side of the boiler or the top of the boiler for cleaning ﬂ ueways.

5. For minimum clearances to combustible materials. See Figure 2.

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Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)

NOTES:

1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.

2. V8 Series boilers can be installed in rooms with clearances from combustible material as listed

above. Listed clearances cannot be reduced for alcove or closet installations.

3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31 standard.

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and should

be referenced.

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1. Determine volume of space (boiler room). Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the space.

Volume(ft3) = Length(ft) x Width(ft) x Height(ft)

2. Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round

the result to the nearest 1000 BTU per hour.

3. Determine type of space. Divide Volume by total input of all appliances in space. If the result is greater than or equal to 50 ft3/1000 BTU per hour, then it is considered an unconﬁ ned space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a conﬁ ned space.

4. For boiler located in an unconﬁ ned space of a conventionally constructed building, the fresh air inﬁ ltration through cracks around windows and doors normally provides adequate air for combustion and ventilation.

5. For boiler located in a conﬁ ned space or an unconﬁ ned space in a building of unusually tight construction, provide outdoor air.

a. Outdoor air for combustion may be provided

with an optional Burnham V8 Inlet Air Accessory Kit, Part Number 611280031 (ONLY AVAILABLE WITH BECKETT BURNER). See Section VII for installation details.

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b. Outdoor air may be provided with the use of two

permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Size each opening per following:

i. Direct communication with outdoors.

Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space.

ii. Vertical ducts. Minimum free area of 1

square inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

iii. Horizontal ducts. Minimum free area of 1

square inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

Alternate method for boiler located within

conﬁ ned space. Use indoor air if two

permanent openings communicate directly with additional space(s) of sufﬁ cient volume such that combined volume of all spaces meet criteria for unconﬁ ned space. Size each opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches.

6. Louvers and Grilles of Ventilation Ducts a. All outside openings should be screened and

louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow.

b. Free area requirements need to consider the

blocking effect of louvers, grilles, or screens protecting the openings. If the free area of the louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area.

c. Louvers and grilles must be ﬁ xed in the open

position, or interlocked with the equipment to open automatically during equipment operation.

SECTION II: KNOCKDOWN BOILER ASSEMBLY

A. REMOVAL OF BARE BOILER FROM SKID

1. Boiler is secured to skid with 4 bolts, 2 in front and 2 in rear of shipping skid, see Figure 3. Remove all bolts.

Figure 3: Knockdown Boiler Removal from Skid

2. Tilt boiler to right and to rear. Using right rear leg as pivot, rotate boiler 90° in a clockwise direction, and lower left side of boiler to ﬂ oor. Tilt boiler and remove skid.

B. MOVE BOILER TO PERMANENT POSITION

by sliding or walking.

C. TEST BOILER FOR LEAKS before installing

controls, trim, and jacket, and before connecting to heating system.

1. Loosen nuts on tie rods until only ﬁ nger tight.

2. Install pressure gauge (at least 50 PSI capacity), a hose to the city water and a valve in the supply tapping. Plug remainder of tappings.

3. Fill boiler with water and apply a pressure of at least 10 PSI but no more than 50 PSI gauge pressure.

G. INSTALL AND SECURE CANOPY with gasket

and hardware provided to ensure gas tight seal — see Figure 4.

Figure 4: Boiler Canopy Installation

1. Cut two (2) strips 13 ¾” long from the roll of gasket insulation. Place one (1) strip across the top of the front section and the other across the rear section as shown in Figure 4.

2. Cut the remainder of the roll into two (2) equal pieces. Place each piece along the sides, allowing the ends to overlap the front and rear pieces.

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4. Examine boiler carefully inside and outside for leaks or damage due to shipment or handling.

D. DRAIN WATER FROM BOILER. Remove gauge,

valve and plugs from those tappings to be used. Leave other tappings plugged or bushed according to Figure 5.

E. INSPECT JOINTS BETWEEN SECTIONS. All

joints are factory sealed. If there are any spaces due to shipment or handling, seal them with boiler putty.

F. INSPECT FLUE COVER PLATES for tightness.

If loose, retighten mounting hardware. If ﬂ ue plate or sealing rope is damaged, repair or replace as needed.

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3. Position canopy body within the retaining bar which borders the ﬂ ueway openings on top of the bare boiler block assembly.

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4. Secure canopy to boiler with two (2) 1/4" - 20 x 3" long carriage bolts, 1/4" ﬂ at washers and 1/4" - 20 wing nuts provided.

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B"¼

C"¾

C-C"¾

D"½

F"¾

G"½1

H"½1

J"½1

K"2

L"2

M"¾

P"¾

R"¾

Figure 5: Boiler Tapping Locations and Usage (Knockdown Boilers Only)

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Figure 6: Knockdown Boiler Jacket Assembly

H. INST ALL TRIM. The following steam or water trim

will be concealed or inaccessible after boiler jacket is installed, see Figure 5 for boiler tapping locations and usage.

1. STEAM BOILER — Top tappings: a. Tapping "L" — Install 2" NPT plug in rear

section top supply tapping on boiler sizes V83 thru V85, if only one supply riser is used.

b. Tapping “M” — Install ¾” NPT coupling and

¾” NPT x 8” long nipple into ¾” NPT tapping located next to front section top supply tapping — all boiler sizes.

2. WATER BOILER — Top tappings: a. Tapping “L” — Install 2” NPT plug in rear

section top supply tapping — all boiler sizes.

b. Tapping “M” —Install ¾” NPT x 8” long nipple

into ¾” NPT tapping located next to front section top supply tapping — all boiler sizes.

I. INSTALL BOILER JACKET. (See Figure 6).

1. Remove burner swing door and hinge assembly. Remove one (1) 5/16"-18 ﬂ ange nut and washer from right side latching stud and one (1) 5/16"- 18 x 3½" cap screw on left side used for securing burner swing door to the boiler section. Swing door open and remove 5/16" hairpin cotter from rear hinge pin. While holding swing door remove hinge pin and set door aside. Remove two (2) 5/16" - 18 x ¾" long cap screws securing the hinge bracket to the boiler section.

2. Install jacket rear panel support bracket. (See Figure 6, Item 2A). Align bracket with two (2) 5/16" - 18 tapped holes in rear section and secure with two (2) 5/16" - 18 x 1/2" long cap screws.

3. Install jacket rear panel. (See Figure 6, Item 2B). Align holes in jacket rear panel and support bracket. Secure with two (2) #8 x 1/2" long sheet metal screws.

4. Jacket Front Panel a. Install black plastic collar extension to jacket

front panels for 7-13/16" diameter tankless heater opening. (See Figure 6, Items 2C and 2D). Engage two (2) of the collar retaining tabs over raw edge of jacket opening. Provide support behind the panel with one hand while applying pressure on collar to snap each tab over edge of opening until all eight (8) tabs are securing collar.

b. Install jacket front panel. Locate two (2) 11/32"

diameter holes, one round, one obround, on front panel approximately 16” up from the bottom of the panel. Align these holes with the similarly located 5/16" - 18 tappings on the front section. Secure with two (2) 5/16" - 18 x 1/2" long cap screws.

5. Install jacket left side panel. (See Figure 6, Item 2E). Fold panel at perforation keeping insulation inward. Align left side panel mounting holes with the front and rear panel holes. Secure with #8 x ½” long sheet metal screws.

Figure 7: Oil Burner Installation (Beckett Burner Shown)

6. Install jacket top panel. (See Figure 6, Item 2F). Place jacket top panel on boiler and secure to front, rear and left side panels with #8 x ½” long sheet metal screws.

7. Install jacket right side access panel. (See Figure 6, Item 2G). Align right side panel mounting holes with front and rear panel holes. Secure with #8 x ½” long sheet metal screws.

8. Attach the labels shipped in the instruction envelope as follows:

a. Locate both the Rating Label and Combination

Warning Label (P/N 8142803). Remove paper backing from the labels and apply to the jacket top panel in approximate locations shown in (Figure 6, Item 2F).

b. On steam boilers only; locate Lowest Permissible

Water Level Plate (Form No. 1204 shipped in Steam Trim Carton). Align plate with two 1/8" diameter holes located near the front edge; in line with the lower sight glass tapping, of the jacket right side access panel. Attach plate with two (2) #8 x 1/2" long sheet metal screws. (See Figure 6, Item 2G).

J. INSTALL BECKETT OIL BURNER. (See Figure

7).

1. Check target wall and combustion chamber blanket. If any damage or movement occurred during shipment, replace as needed.

2. Locate burner swing door and hinge assembly removed in Paragraph I, No. 1. Check the burner swing door insulation and rope gasket for damage and adhesion. If damaged, replace insulation or gasket. If insulation or gasket is loose, reattach to swing door with RTV 732 or 736 silicone caulk.

3. Install burner swing door in reverse order from Paragraph I, No. 1.

4. Use the following procedure to properly close and secure the burner swing door after it has been removed and re-installed for Field Assembly (Knockdown Boiler) or opened for inspection, cleaning or ﬁ eld service (refer to Figures 11A and 11B):

Step 1. Lift the door up unto the built-in cast ramp/

door rest (protruding from the bottom of the front section casting - see Figure 11A), while rotating the articulated hinge and door to the right and engaging the slot (on right side of door) unto the 5/16" stud protruding from the front section.

Step 2. Use one hand to help hold door in position

by applying pressure directly to the door while re-installing the securing hardware with your opposite hand. Always install right side

latching hardware (5/16" ﬂ ange nut and ﬂ at washer) ﬁ rst, then install left side hinge

hardware (5/16" x 3-1/2" lg. hex head ﬂ ange bolt) second. Apply additional pressure while

hand tightening the hardware as far as possible, then release the pressure.

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Step 3. Use a hand wrench to tighten door hardware

and always start with the right side ﬂ ange nut ﬁ rst (see ﬁ gure 11B). Use an alternating tightening method from right side ﬂ ange nut to left side ﬂ ange bolt to tighten door equally until sealed without applying excessive torque. Never tighten left side ﬂ ange bolt ﬁ rst or tighten either piece of hardware 100% without using the alternating tightening method described above.

5. Place oil burner gasket on burner and align holes.

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6. Insert oil burner into the opening of the burner swing door. Align holes and install four (4) 5/16”

- 18 x ¾” long cap screws. Level burner and fully tighten all four (4) screws.

7. Install oil nozzle in burner, inspect electrodes and head setting.

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e. Remove nozzle line electrode assembly. f. Remove Beckett MD(V1) or MB(L1) Head. g. Remove plug from nozzle adapter and install

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K. INSTALL CARLIN 102CRD OIL BURNER. (See

the proper nozzle. Refer to Table 6 for proper nozzle. The nozzle must be securely installed to assure leak free joints between the nozzle and adapter. When installing the nozzle, be careful not to bump or move the burner electrodes.

h. Inspect and measure burner electrodes. Refer

to Figure 27A for the proper electrode setting. Readjust electrode setting to the proper

dimensions if necessary. i. Reinstall Beckett MD(V1) or MB(L1) Head. j. Reinstall nozzle line electrode assembly. k. Connect copper connector tube. l. Inspect Beckett head setting on left side of

burner by insuring the blue line MD(V1) or the

line on the label MB(L1) are aligned, readjust if

necessary. m. Tighten knurled nut. n. Swing igniter closed, rotate tabs and tighten two

(2) igniter screws. o. Replace burner cover and tighten burner cover

knobs.

Figure 7). Follow instructions in Paragraph J, Steps 1 through 6.

7. Install oil nozzle in burner, inspect electrodes and head setting.

REGNAD

a. Select the proper oil nozzle for the installation.

Two (2) oil nozzles are supplied loose with each knockdown V83 - V86 boiler. Either nozzle may be used with water boilers. Steam boilers must use the lower input nozzle. The lower input nozzle will provide greater boiler efﬁ ciency and for steam boilers, reduce boiler corrosion. However, boiler output will be reduced. Refer to Table 1B for ratings. The nozzle input is stamped on the hex ﬂ at of the nozzle.

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b. Loosen burner cover knobs and remove cover. c. Loosen two (2) igniter latching screws, rotate

tabs and swing open igniter about hinge.

d. Loosen knurled nut and disconnect copper

connector tube.

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Steam Boilers Only

Knockdown V87 - V89 boilers are provided with

one nozzle, installed in the burner, that provides the same ﬁ ring rate as the water boiler of the same size.

a. Installation/Removal of Drawer Assembly

i. Loosen screws, rotate latches and swing

open the transformer.

Disconnect the ﬂ ared ﬁ tting to the oil line

and remove the aluminum thumb-nut from the nozzle line. Remove the combustion head assembly from the air tube. Rotating the assembly upside down will ease removal. Inspect the nozzle for size and type, refer to Table 6 of this manual.

ii. To change a nozzle, loosen the clamp screw

on the retention ring assembly and slide the retention ring off the adaptor.

Install and tighten the proper nozzle in

the adaptor. See Table 6 of this manual. Be careful not to damage the electrode insulators or to bend the wires.

iii. Replace the retention ring assembly, slipping

one of the riveted arms through the 1/8-inch gap between the electrode tips. This arm should be straight up. Also, be sure that the

retention ring clamp is tight against the shoulder on the adaptor. Then tighten the

clamping screw.

iv. Check the electrode settings speciﬁ ed as

follows and shown in Figure 27B. 1/8-inch gap, 1/4-inch above the nozzle centerline, and 3/16-inch ahead of the nozzle tip.

v. Re-install the combustion head assembly

into the air tube. It may be necessary to turn nozzle line assembly upside down to ease insertion into the air tube. Then the threaded adapter on the end of the nozzle line is passed through the opening in the left side of the housing.

vi. Run the aluminum (knurled) thumb-nut onto

the nozzle line and tighten hand-tight.

vii. Connect the ﬂ ared ﬁ tting on the copper oil

line to the nozzle line and tighten.

viii. Swing the transformer to the closed position,

rotate latches and tighten screws.

b. Combustion Head Setting/Adjustment

i. Verify combustion head setting, refer to

Table 6 of this supplement. Read the scale embossed in the housing, which is calibrated in 1/16-inch divisions (dimension ‘A’) the position of the ﬂ ame retention ring in relation to the air cone can be determined at a glance. Refer to Figure X.

ii. By moving the electrode and combustion

head assembly forward or backward, the location of the ﬂ ame retention ring relative to the throttle ring can be controlled. Refer to Figure 7A.

By loosening the locking screw and thumb-

nut and turning the adjusting screw using a 5/32-inch allen wrench, the assembly can be

Figure 7A: Combustion Head Adjustment

moved to the required position.

Turn the adjusting crew clockwise to move

the combustion head forward, increasing the ‘A’ dimension, counterclockwise will pull the head back, decreasing the ‘A dimension. To lock in place, ﬁ rst tighten the thumb-nut and then the locking screw.

c. Initial Air Shutter/Band Setting

i. The air shutter has a pointer which indicated

the percent of opening against a calibrated scale (9 = 90%, fully open = 100%). The setting is locked in place by a screw just above the fuel unit.

ii. The air band is adjusted by loosening the

screw, rotating the air band and then locked in place after ﬁ nal adjustment. Refer to Table 6 of this manual for initial settings.

iii. The burner is now set at the approximate

air band setting for the gallonage indicated. During ﬁ nal adjustment, using combustion testing equipment, the air band may need minor adjustment to achieve the desired efﬁ ciency.

Water Boilers Only

Knockdown V87 - V89 boilers are provided

with one nozzle, installed in the burner, that provides the same ﬁ ring rate as the steam boiler of the same size.

Inspect the installed nozzle and assure that

the nozzle is the correct size and type as speciﬁ ed in Table 6 of this manual. The nozzle input is stamped on the hex ﬂ at of the nozzle.

Refer to Paragraph K, 7, a for burner drawer

assembly removal.

L. INSTALL CARLIN ELITE EZ OIL BURNER.

(See Figure 7). Follow instructions in Paragraph J, Steps 1 through 6.

7. Inspect oil nozzle, electrodes and head setting/ change ﬁ ring rate.

REGNAD

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Steam Boilers Only

Steam boilers must use the lower input nozzle.

The lower input nozzle will provide greater boiler efﬁ ciency and for steam boilers, reduce boiler corrosion. However, boiler output will be reduced.

Burners for knockdown V83 - V86 steam boilers

are shipped with the lower (standard) ﬁ ring rate nozzle installed. Knockdown V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same ﬁ ring rate as the water boiler of the same size.

a. Installation/Removal of Drawer Assembly

i. Loosen screws, rotate latches and swing

open the transformer.

ii. The combustion head assembly can be

removed with the blower wheel access cover in place or removed. If the access cover is removed, the head assembly will not have to be rotated.

Disconnect the ﬂ ared ﬁ tting to the oil line

and remove the aluminum thumb-nut from the nozzle line. Remove the combustion head assembly from the air tube. Rotating the assembly upside down will ease removal.

iii. Loosen the clamp screw on the retention

ring assembly and slide the retention ring off the adaptor.

Install and tighten the proper nozzle in

the adaptor. See Table 6 of this manual. Be careful not to damage the electrode insulators or to bend the wires.

iv. Replace the retention ring assembly, slipping

one of the riveted arms through the 1/8-inch gap between the electrode tips. This arm should be straight up. Also, be sure that the retention ring clamp is tight against the shoulder on the adaptor. Then tighten the clamping screw.

v. Check the electrode settings speciﬁ ed as

follows and shown in Figure 27C. 1/8-inch gap, 1/4 to 5/16-inch above the nozzle centerline, and ﬂ ush to 1/16-inch ahead of

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b. Combustion Head Positioning Bars

the nozzle tip.

vi. Re-install the combustion head assembly

holding it upside down while inserting into the housing. The ﬂ ame retention ring end of the assembly must be lifted and guided through the throttle cone (a reduced diameter) in the end of the air tube. DO NOT FORCE IT.

vii. After attaching the proper positioning bar,

refer to Paragraph 7,b, run the thumb-nut onto the nozzle line and tighten it lightly. Connect the ﬂ ared ﬁ tting on the copper oil line to the nozzle line and tighten.

i. The Elite EZ-1HP and EZ-2HP burners are

supplied with the proper positioning bar installed onto the housing that matches the high (standard) input oil nozzle installed in the burner. A second positioning bar and nozzle for the lower (minimum) ﬁ ring rate is shipped loose for the V83-V86 models, attached the burner.

Verify that the installed positioning bar

matches the high input oil nozzle installed in the burner or replace them both with the nozzle and positioning bar that matches the lower ﬁ ring rate, refer to Table 6 of this manual.

The remaining bar(s) should be placed in

the rear of the housing or junction box for future use in the event the ﬁ ring rate must be changed.

In the case of the EZ-1HP, the proper head

positioning bar is still matched by the size of the nozzle, not the input. For example, if nozzle size is 0.75 GPH, input @ 150 psi is approximately 0.90 GPH and the proper bar is 0.75 GPH.

ii. Model EZ-1HP Positioning Bars: 0.50

GPH, 0.60-0.65 GPH, 0.75 GPH, 0.85-1.00 GPH, 1.10-1.25 GPH, 1.35-1.50 GPH, 1.65 GPH.

iii. Model EZ-2HP Positioning Bars: 1.50

GPH, 1.65-1.75 GPH, 2.00 GPH, 2.25 GPH.

c. Initial Air Band Setting

i. The nozzle size in GPH INPUT is printed

directly on the air band. Loosen the locking screw, move the air band until the pointer on the air shutter and housing lines up with the appropriate GPH INPUT. Tighten the locking screws.

ii. The Elite burners use calibrated air bands

marked in nozzle sizes. Models EZ-1HP and EZ-2HP have air bands calibrated to deliver the proper amount of air for their speciﬁ c pump pressure. The air bands on H.P. models are designed to be set by the rating stamped on the nozzle.

iii. The burner is now set at the approximate

air band setting for the gallonage indicated. During ﬁ nal adjustment, using combustion testing equipment, the air band may need minor adjustment to achieve the desired efﬁ ciency.

Water Boilers Only Select the proper oil nozzle for the installation.

Burners for knockdown V8 water boilers are shipped with the high (standard) input oil nozzle installed in the burner.

A second oil nozzle for the lower (minimum)

ﬁ ring rate is shipped loose for the V83 - V86 models, attached to the burner. Either nozzle may be used with water boilers. The lower (minimum) input nozzle will provide greater boiler efﬁ ciency. However, boiler output will be reduced. Refer to Table 1B for ﬁ ring rates. If the higher rate is desired, inspect the installed nozzle and assure that the nozzle is the correct size and type as speciﬁ ed in Table 6 of this manual. The nozzle input is stamped on the hex ﬂ at of the nozzle.

If the lower (minimum) input is desired, remove

the nozzle which was factory installed. Locate the lower (minimum) ﬁ ring rate nozzle that is supplied loose. Conﬁ rm the nozzle is the proper size and type for the lower ﬁ ring rate as speciﬁ ed in Table 6 of this manual. Install the proper nozzle in the burner nozzle adaptor.

Refer to Step 7a for burner drawer assembly

removal.

M. INSTALL RIELLO OIL BURNER. (See Figure 7). Follow instructions in Paragraph J, Steps 1 through 6.

7. Install oil nozzle in burner, inspect electrodes and head setting.

REGNAD

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Steam Boilers Only

Steam boilers must use the lower input

nozzle. The lower input nozzle will provide greater boiler efﬁ ciency and for steam boilers, reduce boiler corrosion. However, boiler output will be reduced.

Burners for knockdown V83 - V86 steam

boilers are shipped with the lower (standard) ﬁ ring rate nozzle installed. Knockdown V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same ﬁ ring rate as the water boiler of the same size.

a. Installation/Removal of Drawer assembly, refer

to Figure 7B.

Figure 7B: Installation/Removal of Drawer Assembly

i. Removal:

• Disconnect oil delivery tube nut from pump.

• Loosen SCREW (3), and then unplug PRIMARY CONTROL (1) by carefully pulling it back and then up.

• Remove the AIR TUBE COVER PLATE (5) by loosening the retaining SCREW (4) (Two SCREWS-Model F5).

• Loosen SCREW (2), and then slide the complete drawer assembly out of the combustion head as shown.

ii. Installation: To insert drawer assembly, reverse the

procedure in Step i above.

b. Nozzle Replacement, refer to Figure 7C.

Figure 7C: Nozzle Replacement

i. Remove the nozzle adapter (2) from the

drawer assembly by loosening the screw (1).

ii. Remove existing nozzle from nozzle

adapter.

iii. Insert the proper nozzle into nozzle adapter

and tighten securely (Do not over tighten).

iv. Replace adapter, with nozzle installed, into

drawer assembly and secure with screw (1).

c. Inspect and measure burner electrodes. Refer to

Figure 27D for the proper electrode settings.

d. Re-install Drawer Assembly into Comustion

Head per Step 7c above.

e. Insertion Depth, verify the distance between

the tip of the end cone is equal to the distance speciﬁ ed in Table 6 of this manual.

f. Turbulator Setting, refer to Figure 7D.

i. Conﬁ rm the turbulator setting is correct

for standard higher (maximum) input oil nozzle installed in the burner. If the lower (minimum) input is desired, readjust turbulator setting to index mark speciﬁ ed in Table 6 of this manual.

ii. Loosen nut (1) and turn screw (2) until the

index marker (3) is aligned with the correct index number in the Burner Setup Chart (Table 6).

Figure 7D: Turbulator Setting

iii. Retighten the retaining nut (1).

MODEL F3 NOTE: Zero and three are scale

indicators only. From left to right the ﬁ rst line is 3 and the last line 0.

MODEL F5: Same as above, except, scale

indicators are 0 and 4.

MODEL F10: Same as above, except, scale

indicators are 0 and 5. i. Pump Connections and Port Identiﬁ cation,

refer to Figure 7E.

This burner is shipped with the oil pump

set to operate on a single line system. To operate on a two-line system the bypass plug must be installed.

WARNING: Do not operate a single line system

with the by-pass plug installed. Operating a single line system with the by-pass plug installed will result in damage to the pump shaft seal.

NOTE: Pump pressure was factory pre-set but

must be checked at time of burner start-up. A pressure gauge is attached to the PRESSURE/ BLEEDER PORT (7) for pressure readings. Two PIPE CONNECTORS (4) are supplied with the burner for connection to either a single or twoline system. Also supplied are two ADAPTORS (3), two female ¼” NPT to adapt oil lines to burner pipe connectors. All pump port threads are British Parallel Thread design. Direct connection of NPT threads to the pump will damage the pump body.

Figure 7E: Pump Connections and Port Identiﬁ cation

Riello manometers and vacuum gauges do not

require any adapters, and can be safely connected to the pump ports. An NPT x metric adapter must be used when connecting other gauge models.

g. Replace Burner Cover and Tighten Burner Cover

Screws.

Water Boilers Only

Select the proper oil nozzle for the installation.

Burners for knockdown V8 water boilers are shipped with the high (standard) input oil nozzle installed in the burner.

A second oil nozzle for the lower (minimum)

If the lower (minimum) input is desired, remove

Proceed to Step c for burner drawer assembly

removal.

N. INSTALL TRIM AND CONTROLS WITH

BECKETT BURNER. - Steam Boiler Only (see

Figures 1D & 5).

1. Thread the pressure gauge into the ¼” NPT tapping "B", of the front section. Tighten with wrench applied to the square shank of the gauge.

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2. Thread 1½” NPT x ¾” NPT bushing and a ¾” NPT drain valve into the 1½” NPT tapping located in the lower right corner of the front section. Tighten with wrench.

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3. Thread safety valve, as shown in Figure 1D, into ¾" NPT coupling and ¾” NPT x 8” nipple previously installed in Paragraph H, No. 1, step b. Tighten with wrench. Pipe discharge as shown in Figure

14. Installation of the safety (relief) valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

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4. Install probe type Low Water Cut-Off (LWCO) if so equipped.

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a. Thread probe into ¾” NPT tapping "C" located

on the front section, down and to the right of the pressure gauge. Slip the low water cut-off (LWCO) control over the probe and clamp in place. Connect the wire(s) between the probe and control per the manufacturer’s instructions.

b. Install the gauge glass using the two ½” NPT

tappings to the right of the probe LWCO.

5. Install ﬂ oat-type LWCO, if so equipped.

See Figure 8.

a. Install nipples and unions in "D" Tappings. b. Mount hardware to low water cut-off body.

Install assembly.

c. Install water gage glass on low water cut-off

assembly's tee ﬁ ttings.

6. Install Pressure Limit Control.

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a. Float LWCO only: Remove ¼" NPT plug from

top of Low Water Cut-Off. Install Syphon and Limit into this tapping. See Figure 8.

b. Probe LWCO only: Install Limit in Tapping "A"

using ¾" NPT x 3" long nipple, ¾" NPT elbow, ¾" NPT x ¼" NPT bushing, and syphon. See Figure 9.

c. Do not tighten the limit by holding the case;

apply a wrench to the brass hex below the case.

d. Level an L404A pressure limit by carefully

bending the syphon until the limit's leveling indicator hangs freely with its pointer directly over the index mark inside the back of the case.

Figure 8: Float-Type Low Water Cut-Off and

Pressure Limit Installation

Figure 9: Pressure Limit Installation for Probe

LWCO Equipped Boilers

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e. An L404F pressure limit does not require

leveling.

7. On units with a heater opening, install the aquastat controller well in the ½" NPT or ¾” NPT tapping in tankless heater plate or cover plate. Slip the bulb of the aquastat into the well and secure the control in place with the set screw.

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8. Connect the ﬁ eld wiring to the pressure limit, the LWCO, the R8239A Control Center/J-box and the burner J-box or burner disconnect J-box.

If equipped with tankless heater, connect ﬁ eld

wiring from the aquastat control to the R8239A Control Center transformer terminals or oil burner primary control's "T-T" terminals.

Make the wiring connections as shown in Figures

19, 20 and 21.

NOTE:

• The R7184P Primary Control has pre-installed

"T-T" jumper resistor. To activate "T-T" terminals, "T-T" jumper must be removed. To remove, use side cutting pliers to cut jumper (see Figure 28).

• Do not remove (cut) "T-T" jumper unless

wiring diagram indicates a direct connection from thermostat and/or tankless heater aquastat control to the oil burner primary control's "T-T" terminals.

Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

O. INSTALL TRIM AND CONTROLS WITH

BECKETT BURNER. - Water Boilers Only (See

Figures 1A, 1B, 1C and 5).

1. Thread ½” NPT pipe plugs into gauge glass tappings in the upper right side of front section.

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2. Thread ¾” NPT pipe plug in probe low water cut off tapping (just left of gauge glass tappings).

3. Thread combination pressure/temperature gauge into ¼” NPT tapping. Tighten with wrench applied to the square shank of the gauge.

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4. Screw drain valve into ¾" NPT side outlet of the 1½” NPT x 90° elbow (note - lower front section tapping “G” is used for standard return on water boilers).

5. If circulator (not supplied with boiler) is to be mounted directly to 1½" NPT boiler return tapping "G", use the piping arrangements outlined in steps a. thru e. as follows: (see Figures 13A, 13B and 13C)

a. Thread 1½” NPT x 3” long nipple and 1½” NPT x 90° elbow with ¾" NPT side outlet

into the return tapping and tighten with a pipe wrench.

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b. Thread 1½” NPT x 15” long nipple into the 1½"

NPT x 90° elbow and tighten with a pipe wrench.

c. Thread one of the circulator ﬂ ange onto the

nipple and tighten with a pipe wrench. Position ﬂ ange so that the bolt slots are parallel to the boiler front.

d. Place a circular ﬂ ange gasket in the ﬂ ange

groove on the circulator and mount the circulator on the ﬂ ange. Note that this is the return piping and the ﬂ ow arrow on the circulator should point down Ð. Fasten circulator with 7/16” - 14 x 1½" long cap screws and 7/16" - 14 nuts.

e. Fasten the second circulator ﬂ ange and gasket to

the circulator.

6. Install relief valve, as shown in Figure 1A, 1B, and 1C, onto ¾” NPT x 8” nipple previously installed in Paragraph H, No. 2, step b. Tighten with wrench. Pipe discharge as shown in Figures 13A, 13B and 13C. Installation of the relief valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

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7. On units without a heater opening, install the well into the ¾” NPT tapping "A" located on the front of the boiler in the upper left corner. See Figures 1A and 5. Tighten the well and insert the control’s bulb into the well. Secure control to well with set screw.

GNINRAW

NOTE:

• Do not remove (cut) "T-T" jumper on R7184P Primary Control for application 9a or 9b above.

c. Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

P. INSTALL TRIM AND CONTROLS WITH

CARLIN 102CRD BURNER.

Follow instructions in Paragraph N, Steps 1 through 7.

Steam Boilers Only (see Figures 1D and 5).

8. Connect Field Wiring a. Steam Boiler with Hydrolevel CG450 LWCO,

Carlin Burner.

Connect the ﬁ eld wiring to the pressure limit, the

LWCO, R8239C Control Center and the burner disconnect J-box or directly to burner J-box on burners less disconnect harness (power cord). If equipped with tankless heater, connect ﬁ eld wiring from the aquastat control to the R8239C Control Center’s “R-G” terminals. Make the wiring connections as shown in Figure 19A.

b. Steam Boiler with McDonnell & Miller PS-801 or McDonnell & Miller 67 LWCO,

Carlin Burner.

Connect the ﬁ eld wiring to the LWCO, the

pressure limit and the burner disconnect J-box. If equipped with tankless heater, connect ﬁ eld wiring from the aquastat control to the oil burner primary control’s “T-T” Terminals. Make the wiring connections as shown in Figures 20A, and 21A.

c. Refer to Paragraph S for details on use of burner

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8. On units with a heater opening, install the well in the ½" NPT or ¾” NPT tapping on the tankless heater plate or cover plate. See Figures 1B, 1C and

5. Tighten the well and insert the control’s bulb into the well. Secure control to well with set screw.

9. Connect Field Wiring. a. Water boilers without tankless heater and with

front tankless heater. Connect the ﬁ eld wiring from the circulator to the aquastat control and from the control to the burner disconnect J-box or directly to the burner J-box. Make the wiring connections as shown on Figures 22, 23A and 23D.

b. Water boilers with rear tankless heater. Connect

the ﬁ eld wiring from a standard junction box or burner disconnect J-box to the circulator, aquastat control and burner. Make the wiring connections as shown on Figure 23B.

Water boilers Only (see Figures 1A, 1B, 1C and 5). Follow instructions in Paragraph O, Steps 1 through 7

9. Connect Field Wiring a. Water boilers without tankless heater and with

front tankless heater. Connect the ﬁ eld wiring from the circulator to the aquastat control and from the control to the burner disconnect J-box or directly to oil burner primary control on burners less disconnect harness (power cord). Make the wiring connections as shown on Figures 22A and 23B .

b. Water boilers with rear tankless heater. Connect

the ﬁ eld wiring from a standard junction box or burner disconnect J-box to the circulator, aquastat control and burner. Make the wiring connections as shown on Figure 23E.

c. Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

Q. INSTALL TRIM AND CONTROLS WITH

CARLIN ELITE EZ BURNER.

Follow instructions in Paragraph N, Steps 1 through 7. Steam Boilers Only (see Figures 1D and 5).

8. Connect Field Wiring a. Steam Boiler with Hydrolevel CG450 LWCO,

Carlin Burner.

Connect the ﬁ eld wiring to the pressure limit, the

b. Steam Boiler with McDonnell & Miller PS-801 or McDonnell & Miller 67 LWCO,

Carlin Burner.

Connect the ﬁ eld wiring to the pressure limit,

the R8239C Control Center, the LWCO and the burner disconnect J-box. If equipped with tankless heater, connect ﬁ eld wiring from the aquastat control to the oil burner primary control’s “T-T” Terminals. Make the wiring connections as shown in Figures 20 and 21.

c. Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

Water boilers Only (see Figures 1A, 1B, 1C and 5). Follow instructions in Paragraph O, Steps 1 through 7.

9. Connect Field Wiring a. Water boilers without tankless heater and with

b. Water boilers with rear tankless heater. Connect

the ﬁ eld wiring from a standard junction box or burner disconnect J-box to the circulator, aquastat control and burner. Make the wiring connections as shown on Figure 23B.

c. Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

R. INSTALL TRIM AND CONTROLS WITH

RIELLO BURNER.

Follow instructions in Paragraph N, Steps 1 through 7.

Steam Boilers Only (see Figures 1D and 5).

8. Connect Field Wiring a. Steam boiler with Hydrolevel CG450 or

McDonnell & Miller 67 LWCO, Riello Burner.

Connect the ﬁ eld wiring to the pressure limit,

the LWCO, R8239C Control Center and the burner disconnect J-box or directly to oil burner primary control on burners less disconnect harness (power cord). If equipped with tankless heater, connect ﬁ eld wiring from the aquastat control to the R8239C Control Center’s “R-G” terminals. Make the wiring connections as shown in Figures 19 and 21.

b. Steam boiler with McDonnell & Miller PS-801

LWCO, Riello Burner.

Connect the ﬁ led wiring to the pressure limit,

the R8239C Control Center, the LWCO and the burner J-box. If equipped with tankless heater, connect ﬁ eld wiring from the aquastat control to the R8239C Control Center’s “R-G” terminals. Make the wiring connections as shown in Figure

20.

c. Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

Water Boilers Only (see Figures 1A, 1B, 1C and 5). Follow instructions in Paragraph O, Steps 1 through 7.

9. Connect Field Wiring

a. Water boilers without tankless heater and with

b. Water boilers with rear tankless heater. Connect the

ﬁ eld wiring from a standard junction box or burner disconnect J-box to the circulator, aquastat control and burner. Make the wiring connections as shown on Figure 23B.

c. Refer to Paragraph S for details on use of burner

disconnect junction box provided with all knockdown boiler builds.

S. BURNERS SUPPLIED BY BURNHAM utilize

a burner disconnect harness that is pre-wired into the burner junction box and primary control. Packed in the canopy carton is the mating burner disconnect junction assembly and mounting hardware for use with these burners.

If you are using a burner with the disconnect harness,

complete the following assembly instructions for mounting the mating burner disconnect junction box, see Figure 10.

1. Remove (2) #6 x 1/2" lg. machine screws and J-box cover from junction box.

2. Secure 2" x 4" junction box to jacket front panel with (2) #8 x 3/8" lg. sheet metal screws using prepunched holes below tridicator or pressure gauge tapping.

3. Complete the ﬁ eld wiring phase of Paragraphs N & O (Beckett), P (Carlin 102CRD), Q (Carlin Elite EZ) or R (Riello) Install end of harness from low water cut-off (LWCO), R8239A Control Center or Aquastat Control into appropriate knockout of burner disconnect junction box according to source, refer to Figures 1A thru 1D.

4. Use wire nuts to connect wires from control or power source to (3) pigtail wires connected to spade terminals on rear of power outlet receptacle. Make the connections as shown in appropriate wiring diagram based on boiler conﬁ guration, refer to Figures 19 thru 23F.

5. Secure J-box cover to junction box with (2) #6 x ½" lg. machine screws.

6. Insert mating end of burner disconnect harness (power cord) into power outlet receptacle on J-box.

7. Install snap bushing into 7/16" diameter hole in upper right corner of burner enclosure back plate on all Beckett burners, see Figure 10. On certain builds, 18/2 wire from L4006A Aquastat Control mounted in rear heater will pass through this snap bushing and connect to "T-T" terminals on primary control, refer to Figures 20 and 21.

IMPORTANT: Remove (cut) jumper resistor on

R7184P Primary Control to activate "T-T" terminals when making a direct connection from thermostat and/or tankless heater aquastat control.

Figure 10: Burner Disconnect Junction Box with Power Outlet Receptacle

(Mated to Burners with Disconnect Harness)

SECTION III: PACKAGED BOILER ASSEMBLY

A. REMOVE CRATE.

1. Remove all fasteners at crate skid.

2. Lift outside container and remove all other inside protective spacers and bracing. Remove draft regulator box and miscellaneous trim bag containing safety or relief valve, and pipe ﬁ ttings.

B. REMOVE BOILER FROM SKID.

1. Boiler is secured to base with 4 bolts, 2 in front and 2 in rear of shipping skid, see Figure 11. Remove all bolts.

Figure 11: Packaged Boiler Removal from Skid

2. Tilt boiler to right and to rear. Using right rear leg as pivot, rotate boiler 90° in a clockwise direction, and lower left side of boiler to ﬂ oor. Tilt boiler and remove crate skid. Care should be exercised to prevent damage to jacket or burner.

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C. MOVE BOILER TO PERMANENT POSITION

by sliding or walking.

D. PROCEDURE TO OPEN, CLOSE AND SECURE

BURNER SWING DOOR with articulated hinge.

Throughout this manual you will be instructed to open and close the burner swing door for various reasons. There is a proper and improper method to closing and securing the burner swing door after it has been removed and re-installed for Field Assembly (Knockdown Boiler) or opened for inspection, cleaning or ﬁ eld service.

1. TO OPEN BURNER SWING DOOR (see Figures

11A and 11B).

Step 1. Loosen and remove right side latching

hardware (5/16" ﬂ ange nut and washer).

Step 2. Loosen and remove left side hinge hardware

(5/16" x 3-1/2" lg. hex head ﬂ ange bolt).

Step 3. The duel pivot articulated hinge allows right

side of door to be pulled outward and rotated to the left all in one motion. To do so, place your right hand under burner air tube and lift up slightly to help carry the weight of the door and burner. Use your left hand to grasp the door's left side hinge ﬂ ange, pull outward to rotate the hinge, this motion will move the door outward and to the left approximately 3" (see Figure 11B, Position 2).

Figure 11A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured

Figure 11B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)

Step 4. From this position the door can be swung

clear of the vertical circulator return piping to provide full access to the combustion chamber and burner head (see Figure 11B, Position 3).

2. Perform routine inspection, service or cleaning as necessary.

3. To close Burner Swing Door (see Figures 11A and

11B):

Step 1. From the fully open position, rotate Burner

Swing Door toward the closed position. Make

sure that the articulated hinge is rotated to the extreme left position to allow the door to clear the vertical circulator return piping as shown in Figure 11B, Position 2.

Step 2. Grasp the door's left side hinge ﬂ ange

in your left hand and place your right hand under the burner air tube to lift upward. Lift the door up unto the built-in cast ramp/door

rest (protruding from the bottom of the front

section casting - see Figure 11A), while rotating the articulated hinge and door to the right and engaging the slot (on right side of door) unto the

5/16" stud protruding from the front section.

Step 3. Use one hand to help hold door in position

by lifting up on rear burner housing or applying pressure directly to the door while re-installing the securing hardware with your opposite hand.

Always install right side latching hardware

(5/16" ﬂ ange nut and ﬂ at washer) ﬁ rst, then install left side hinge hardware (5/16" x 31/2" lg. hex head ﬂ ange bolt) second. Apply

additional pressure while hand tightening the hardware as far as possible, then release the pressure.

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Step 4. Use a hand wrench to tighten door hardware

and always start with the right side ﬂ ange nut ﬁ rst. Use an alternating tightening method from right side ﬂ ange nut to left side ﬂ ange bolt to tighten door equally until sealed without applying excessive torque. Never tighten left side ﬂ ange bolt ﬁ rst or tighten either piece of hardware 100% without using the alternating tightening method described above.

Failure to follow the prescribed procedure could

cause thread damage to casting or a leak in the door seal. If left side ﬂ ange bolt is tightened before right side ﬂ ange nut, right side of door can not be drawn-in to provide an air tight seal, as shown in Figure 11C. Applying excessive torque will only cause thread damage.

Figure 11C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed

E. INSPECT COMBUSTION CHAMBER TARGET

WALL AND LINER, AND SWING DOOR GASKET.

1. Open burner swing door using procedure previously outlined in Paragraph D of this section.

2. Using a ﬂ ashlight, inspect the rear target wall and liner. The target wall should be rigidly secured to the rear boiler section. The combustion chamber liner should be evenly distributed in the boiler chamber. If either is damaged, they must be replaced.

3. Inspect ceramic rope located on the swing door. The rope must be evenly distributed around the

perimeter of the door groove and cannot bunch or overhang. There must not be a gap where the two ends of the rope meet. Repair or replace if the rope is damaged or if there is a gap between the ends.

F. INSPECT NOZZLE AND ELECTRODES /

CHANGE FIRING RATE FOR BECKETT BURNERS. Refer to Section II, Paragraph J, No. 7,

steps b through o for nozzle installation, electrode and head setting inspection.

Steam Boilers Only

Packaged V83 - V86 steam boilers are shipped with

the lower (standard) ﬁ ring rate nozzle installed.

Packaged V87 - V89 boilers are provided with one

nozzle, installed in the burner, that provides the same ﬁ ring rate as the water boiler of the same size.

Inspect the installed nozzle and assure that the

nozzle is the correct size and type as speciﬁ ed in

Table 6 of this manual.

Inspect and measure burner electrodes. Refer to

Figure 27 of this manual for the proper electrode settings.

Close the burner swing door and securely seal the

door to the boiler front section by reinstalling the hardware and securing the door using procedure previously outlined in Paragraph D of this section.

Water Boilers Only

Packaged V8 water boilers are shipped with the

higher input oil nozzle installed in the burner.

A second oil nozzle for the lower (minimum) ﬁ ring

Table 1B for ratings. If the higher rate is desired,

inspect the installed nozzle and assure that the nozzle is the correct size and type as speciﬁ ed in

Table 6 of this manual.

If the lower (minimum) input is desired, remove

G. INSPECT NOZZLE AND ELECTRODES

/ CHANGE FIRING RATE FOR CARLIN

102CRD BURNERS. Refer to Section II, Paragraph

K, No. 7, steps b through d for nozzle installation, electrode and head setting inspection.

Follow instructions in Paragraphs A through E.

Steam or Water Boilers

Packaged V87 - V89 steam boilers are provided

with one nozzle, installed in the burner, that provides the same ﬁ ring rate as the water boiler of the same size.

Inspect the installed nozzle and assure that the

nozzle is the correct size and type as speciﬁ ed in

Table 6 of this manual.

H. INSPECT NOZZLE AND ELECTRODES /

CHANGE FIRING RATE FOR CARLIN ELITE EZ BURNERS. Refer to Section II, Paragraph L, No.

7, steps a through c for nozzle installation, electrode

and head setting inspection.

Follow instructions in Section III, Paragraphs A through

Steam Boilers Only

Packaged V83 - V86 steam boilers are shipped with

the lower (standard) ﬁ ring rate nozzle installed. Packaged V87 - V89 boilers are provided with one

nozzle, installed in the burner, that provides the

same ﬁ ring rate as the water boiler of the same size.

Inspect the installed nozzle and assure that the

nozzle is the correct size and type as speciﬁ ed in

Table 6.

Water Boilers Only

Packaged V8 water boilers are shipped with the

higher input oil nozzle installed in the burner.

A second oil nozzle for the lower (minimum) ﬁ ring

rate is shipped loose for the V83 - V86 models,

attached to the burner. Select the proper oil

nozzle for the installation. The lower (minimum) input nozzle will provide greater boiler efﬁ ciency. However, boiler output will be reduced. Refer to Table 1B For ﬁ ring rates. If the higher rate is desired, inspect the installed nozzle and assure that the nozzle is the correct size and type as speciﬁ ed in Table 6.

If the lower (minimum) input is desired, remove

6. Install the proper nozzle in the burner nozzle adaptor.

I. INSPECT NOZZLE AND ELECTRODES

/ CHANGE FIRING RATE FOR RIELLO

BURNERS. Refer to Section II, Paragraph M, No. 7,

steps a through g for nozzle installation, electrode and head setting inspection.

Steam Boilers Only

Packaged V83 - V86 steam boilers are shipped with

the lower (standard) ﬁ ring rate nozzle installed. Packaged V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same ﬁ ring rate as the water boiler of the same size.

Inspect the installed nozzle and assure that the

nozzle is the correct size and type as speciﬁ ed in Table 6 of this supplement.

Water Boilers Only

Packaged V8 water boilers are shipped with the

higher input oil nozzle installed in the burner.

A second oil nozzle for the lower (minimum) ﬁ ring

rate is shipped loose for the V83 - V86 models, attached to the burner. Select the proper oil nozzle for the installation. The lower (minimum) input nozzle will provide greater boiler efﬁ ciency. However, boiler output will be reduced. Refer to Table 1B for ﬁ ring rates. If the higher rate is desired, inspect the installed nozzle and assure that the nozzle is the correct size and type as speciﬁ ed in Table 6.

If the lower (minimum) input is desired, remove

6. Install the proper nozzle in the burner nozzle adaptor.

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K. PACKAGED BOILERS WITH PROBE STYLE

LWCO. Install Limit in Tapping "A" using ¾" NPT x

2" nipple, ¾" NPT elbow, ¾" NPT x ¼" NPT bushing, and syphon included in trim bag. See Figure 9.

1. Do not tighten the limit by holding the case; apply a wrench to the brass hex below the case.

2. Connect wiring harness from Low Water Cut-Off to steam pressure limit.

3. Level an L404A pressure limit by carefully bending the syphon until the limit's leveling indicator hangs freely with its pointer directly over the index mark inside the back of the case.

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J. INSTALL SAFETY OR RELIEF VALVE IN

TAPPING "M".

Use ¾" NPT x 8" nipple and/or ¾" NPT coupling

included in trim bag. Safety or Relief Valve must be installed with spindle in vertical position. Pipe discharge as shown in Figures 13A, 13B, 13C and

14. Installation of the safety or relief valve must be consistent with ANSI/ASME Boiler and Pressure

Vessel Code, Section IV.

SECTION IV: WATER BOILER PIPING AND TRIM

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A. EVALUATE THE EXISTING WATER SYSTEM.

Design a piping system and install boiler which will

prevent oxygen contamination of boiler water and frequent water additions.

1. There are many possible causes of oxygen contamination such as:

a. Addition of excessive make-up water as a result

of system leaks. b. Absorption through open tanks and ﬁ ttings. c. Oxygen permeable materials in the distribution

system.

2. In order to insure long product life, oxygen sources must be eliminated. This can be accomplished by taking the following measures:

a. Repairing system leaks to eliminate the need for

addition of make-up water. b. Eliminating open tanks from the system. c. Eliminating and/or repairing ﬁ ttings which allow

oxygen absorption. d. Use of non-permeable materials in the

distribution system. e. Isolating the boiler from the system water by

installing a heat exchanger.

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B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO BOILER. See Figures 13A, 13B and

13C. Also, consult I=B=R Installation and Piping Guides.

1. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler. See Figure 12. Also, consult I=B=R Installation and Piping Guides.

2. If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be equipped with ﬂ ow control valves to prevent gravity circulation of boiler water during the operation of the cooling system.

3. If boiler is used with an Alliance™ Indirect-Fired Domestic Water Heater, install the Alliance™ as a separate heating zone. Refer to the Alliance™ Installation, Operating, and Service Instructions for additional information.

4. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.) The bypass should be the same size as the supply and return lines with valves located in the bypass and return line as illustrated in Figures 13A, 13B and 13C in order to regulate water ﬂ ow for maintenance of higher boiler water temperature.

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If a low water cut-off is required, it must be

mounted in the system piping above the boiler. The minimum safe water level of a hot water boiler is just above the highest water containing cavity of the boiler; that is, a hot water boiler must be full of water to operate safely.

5. If it is required to perform a long term pressure test of the hydronic system, the boiler should ﬁ rst be isolated to avoid a pressure loss due to the escape of air trapped must ﬁ rst be removed from the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must ﬁ rst be removed from the boiler.

A loss of pressure during such a test, with no

visible water leakage, is an indication that the boiler contained trapped air.

Figure 12: Recommended Piping for Combination Heating and Cooling (Refrigeration) System

Figure 13A: Recommended Water Piping for Circulator Zoned Heating System

Figure 13B: Recommended Water Piping for Zone Valve Zoned Heating System - Supply Side Circulator

Figure 13C: Recommended Water Piping for Zone Valve Zoned Heating System - Return Side Circulator

SECTION V: STEAM BOILER PIPING AND TRIM

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A. EVALUATE THE EXISTING STEAM SYSTEM. The single most important factor in determining the

expected life cycle of a steam boiler, is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler. These contaminants greatly accelerate corrosion of the cast iron boiler sections.

1. Assure that all system radiators, piping and vents are absolutely leak tight.

a. When a steam boiler is installed in an existing

system, ALL air vents should be replaced at the same time. This assures that the new boiler will not be compromised by existing system leaks.

b. If the system contains hidden supply or return

piping (hidden behind walls, buried in concrete, etc.) pressure test this piping to assure there are no leaks.

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2. Repair any leaks in the system.

3. Install accurate water meter on the fresh water supply to the boiler.

B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO BOILER. See Figure 14 for piping

details. Also consult I=B=R Installation and Piping Guides.

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ECITON

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ECITON

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Figure 14: V83 Thru V89 Recommended Boiler Piping For Gravity Return Steam Boiler

SECTION VI: TANKLESS AND INDIRECT WATER HEATER PIPING

A. CONNECT TANKLESS HEATER PIPING as

shown in Figure 15A. See Tables 2A and 2B for Tankless Heater Rating.

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THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER:

1. FLOW REGULATION — If ﬂ ow through the heater is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand. For this reason a ﬂ ow regulator matching the heater rating should be installed in the cold water line to the heater. The ﬂ ow regulator should preferably be located below the inlet to the heater and a minimum of 3’ away from the inlet so that the regulator is not subjected to excess temperatures that may occur during “off” periods when it is possible for heat to be conducted back through the supply line. The ﬂ ow regulator also limits the ﬂ ow of supply water regardless of inlet pressure variations in the range of 20 to 125 psi.

2. TEMPERING OF HOT WATER — Installation of an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents the possibility of scalding hot water at the ﬁ xtures. In addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking a water temperature. Higher temperature hot water

required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve. The mixing valve should be “trapped” by installing it below the cold water inlet to heater to prevent lime formation in the valve. Refer to Figure 15A.

3. FLUSHING OF HEATER — All water contains some sediment which settles on the inside of the coil. Consequently, the heater should be periodically

s'rerutcafunamehthtiwecnadroccanievlav

back washed. This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hose bib A, through the heater, and out hose bib B until the discharge is clear. The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop.

4. HARD WATER — A water analysis is necessary to determine the hardness of your potable water. This is applicable to some city water and particularly to well water. An appropriate water softener should be installed based on the analysis and dealer’s recommendation. This is not only beneﬁ cial to the tankless heater but to piping and ﬁ xtures plus the many other beneﬁ ts derived from soft water.

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Figure 15A: Schematic Tankless Heater Piping

TABLE 2A: TANKLESS HEATER DATA: Rear Mounted Heater on Steam and Water Boilers

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58V2-1V52.35.36.54.6

68V2-1V57.357.32.72.7

78V2-1V57.342.78

88V2-1V45.488.9

98V2-1V45.488.9

TABLE 2B: TANKLESS HEATER DATA: Front Mounted Heater on Water Boilers

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Figure 15B: Alliance™ Water Heater Piping with V8 Boiler

B. CONNECT ALLIANCE™ INDIRECT WATER

HEATER PIPING as shown in Figure 15B.

1. Refer to Alliance™ manual for additional information.

SECTION VII: VENTING AND AIR INTAKE PIPING

A. GENERAL VENTING GUIDELINES

1. Vent system installation must be in accordance with these instructions and applicable provisions of local building codes. Contact local building or ﬁ re ofﬁ cials about restrictions and installation inspection in your area.

2. The V8 is designed to be vented into a ﬁ reclay tile-lined masonry chimney or chimney constructed from type L vent or a factory built chimney that complies with the type HT requirements of UL103. The chimney and vent pipe shall have a sufﬁ cient draft at all times, to assure safe proper operation of the boiler. See Figure 16 for recommended installation.

a. Install a draft regulator (supplied with boiler)

following the instructions furnished with the regulator. See Figure 17 for alternate draft regulator locations.

b. For the V82W, V84W and V86W the minimum

recommended chimney size from Table 1B is one size larger than the smokebox outlet. For a vertical vent, place the increaser on the smokebox outlet collar. Otherwise, locate the increaser in the horizontal vent at the entrance to the chimney.

c. With any new or replacement installation the

chimney has to be considered. Chimneys that have a high heat loss may become less suitable as the heat loss of the home goes down and the efﬁ ciency of the boiler installed goes up. Most homes have a chimney appropriate for the fuel and the era in which the home was built. That may have been a coal ﬁ red or an inefﬁ cient oil ﬁ red boiler built into a home without insulation or storm windows. With increasing fuel prices that home probably has been insulated and ﬁ tted with storm windows so that the heat loss of the home has been reduced. This requires less fuel to be burned and sends less heat up the chimney.

A new boiler probably has a higher efﬁ ciency

than the boiler being replaced. That probably means that the stack temperature from the new boiler will be lower than that from the old boiler and with less room air being drawn up the chimney to dilute the stack gases. The combination of a large uninsulated chimney, reduced ﬁ ring rate, reduced ﬁ ring time, lower stack temperature and less dilution air can, in some cases, contribute to the condensing of small amounts of water vapor in the chimney. Such condensation, when it occurs, can cause chimney deterioration. In extreme cases, the chimney may have to be lined to insulate the chimney and

thus prevent the condensation. The addition of dilution air into the chimney may assist in drying the chimney interior surfaces.

A massive chimney on a cold, or exposed outside

wall may have produced adequate draft when it was ﬁ red with a higher input and greater volumes of heated gases. With reduced input and volume, the draft may be severely affected. In one instance our research showed a new chimney of adequate sizing produced only .035" W.C. after 30 minutes of continuous ﬁ ring at 13.0% CO Outside wall chimneys take longer to heat up and can have .00" W.C. draft at burner startup. You may have to consider a special alloy chimney ﬂ ue liner with insulation around it and a stabilizing draft cap or even a draft inducing fan in severe cases.

d. For the same reasons as in c. above, heat

extractors mounted into the breeching are not recommended.

3. For minimum clearances to combustible materials refer to Figure 2.

B. OPTIONAL AIR INTAKE PIPING

INSTALLATION - All air for combustion can be supplied directly to the burner from outdoors (ONLY AVAILABLE WITH BECKETT BURNER). See

Figure 18.

GNINRAW

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1. General a. Use 4 inch diameter, single wall galvanized

metal pipe and ﬁ ttings available at most heating distributors for air intake piping. Maximum allowable air intake length is 50 equivalent feet. Each elbow is equal to 6 equivalent feet.

GNINRAW

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b. Start at Burner. Work toward air intake terminal. c. Maintain minimum of ¼ inch per foot slope in

horizontal run to air intake terminal. Slope down toward air intake terminal.

d. Seal all joints gas-tight, using silicone caulk or

self-adhesive aluminum tape.

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Figure 16: Recommended Vent Pipe Arrangement and Chimney Requirements

Figure 17: Proper and Improper Locations

of Draft Regulator

2. After determining location, cut a hole in the wall to accept 4 inch air intake pipe. See Figure 18.

3. Remove the metal knockout in right side of burner cover. Install Burnham Inlet Air Accessory Kit, Part Number 611280031.

4. Mount the Vacuum Relief Valve Tee Assembly (Part Number 8116268 included with Kit) or 90° elbow into the burner inlet ring. See Figure 18.

a. Secure with at least three (3) sheet metal screws

evenly spaced around the burner inlet ring.

b. Assemble the vacuum relief valve balance

weight onto the gate. Refer to the vacuum relief valve manufacturer's instructions.

c. Mount the vacuum relief valve into the tee and

fasten with a screw and nut in collar tabs. To ensure proper operation, the gate must be level across the pivot point and plumb. Refer to vacuum relief valve manufacturer's instructions.

5. Install remainder of air intake, securing each joint with at least three (3) sheet metal screws evenly spaced.

6. Install air intake terminal. See Figure 18.

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7. Seal all external joints with weatherproof caulk.

GNINRAW

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Figure 18: Optional Air Intake Piping Installation - Only Available with Beckett Burner

SECTION VIII: ELECTRICAL

REGNAD

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A. GENERAL

1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFPA 70, and/or the CSA C22.1 Electric Code.

2. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.

3. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions.

4. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.

5. Use armored cable (BX) over all exposed line voltage wiring.

6. If an Alliance™ indirect water heater is used, use priority zoning. Do not use priority zoning for Hydro-Air Systems.

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7. If boiler is installed in Canada, a blocked vent safety switch must be installed. Refer to Blocked Vent Safety Switch Instruction Supplement provided with boiler (Canada only).

8. Wiring should conform to Figures 19 through 23F.

B. INSTALL A ROOM THERMOSTAT on an

inside wall about four feet above ﬂ oor. Never install thermostat on an outside wall or where it will be inﬂ uenced by drafts, hot or cold water pipes, lighting ﬁ xtures, television, rays of the sun or near a ﬁ replace. Keep large furniture away from thermostat so there will be free movement of room air around this control.

Heat Anticipator in Thermostat should be set to match

the requirements of the control to which it is connected. See Figures 19 thru 23F for desired system and heat anticipator setting. If system tends to overheat above the thermostat's temperature setting, reduce heat anticipator setting by .1 or .2 amps. If system tends to short cycle without reaching desired room temperature, increase heat anticipator setting by .1 or .2 amps.

Figure 19: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Beckett Burners

BOILER SEQUENCE OF OPERATION WITH PROBE LWCO

When the thermostat calls for heat, it energizes the R8239C Control Center relay which in turn energizes the cad cell primary control, bringing on the burner. The burner will operate in the following sequence: Prepurge for the ﬁ rst 10 seconds; ﬁ re until the thermostat is satisﬁ ed or the limit setting on the high limit is reached; post-purge for the last 10 seconds. When the high limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat.

The probe low water cut-off will shut down the burner after a 10-15 second delay, if the water level in the boiler drops below the probe level.

The Hydrolevel CG450 low water cut-off will shut down the burner for 90 seconds every 10 minutes of ﬁ ring time to allow water level to stabilize. If the water level is too low the burner will not be allowed to restart.

The probe low water cut-off will reset and restart the burner with a call for heat a few seconds after the water is returned to its normal level.

On burner start, if the cad cell does not see ﬂ ame within approximately 15 seconds, primary control will shut burner down and enter into a recycle mode, after 60 seconds burner will restart and repeat trial for ignition. If after three (3) trials for ignition, ﬂ ame is not detected, control will enter into restricted mode and must be reset manually before burner can be restarted.

When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected setting for proper operation of the domestic water heater, if equipped with optional tankless heater.

Figure 19A: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Carlin Burners

Figure 19B: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Riello Burners

Figure 20: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Beckett Burners

BOILER SEQUENCE OF OPERATION WITH PROBE LWCO

When the thermostat calls for heat, it energizes the cad cell primary control, bringing on the burner. The burner will operate in the following sequence: Prepurge for the ﬁ rst 10 seconds; ﬁ re until the thermostat is satisﬁ ed or the limit setting on the high limit is reached; post-purge for the last 10 seconds. When the high limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The probe low water cut-off will shut down the burner after a 10-15 second delay, if the water level in the boiler drops below the probe level.

The probe low water cut-off will reset and restart the burner with a call for heat a few seconds after the water is returned to its normal level.

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Figure 20A: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Carlin Burners

Figure 20B: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Riello Burners

Figure 21: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Beckett Burners

BOILER SEQUENCE OF OPERATION WITH FLOAT LWCO

When the thermostat calls for heat, it energizes the cad cell primary control, bringing on the burner. The burner will operate in the following sequence: Prepurge for the ﬁ rst 10 seconds; ﬁ re until the thermostat is satisﬁ ed or the limit setting on the high limit is reached; post-purge for the last 10 seconds. When the high limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The low water cut-off will shut down the burner if the water level in the boiler drops too low. The control resets and restarts the burner with a call for heat a few seconds after the water is returned to its normal level.

Figure 21A: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Carlin Burners

Figure 21B: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Riello Burners

Figure 22: Wiring Diagram, Water without Tankless Heater for Beckett Burners

BOILER SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L8148A control which in turn energizes the primary control to turn on the burner. The burner will operate in the following sequence: Prepurge for the ﬁ rst 10 seconds; ﬁ re until the thermo- stat is satisﬁ ed or the limit setting on the high limit is reached; post-purge for the last 10 seconds. The circulator will operate as long as the thermostat is calling for heat. If the thermostat is not satisﬁ ed 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 22A: Wiring Diagram, Water without Tankless Heater for Carlin Burners

Figure 22B: Wiring Diagram, Water without Tankless Heater for Riello Burners

Figure 23A: Wiring Diagram, Water with Front Tankless Heater for Beckett Burners

BOILER SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L8124C control which in turn energizes the primary control to turn on the burner. The burner will operate in the following sequence: Prepurge for the ﬁ rst 10 seconds; ﬁ re until the thermo- stat is satisﬁ ed or the limit setting on the high limit is reached; post-purge for the last 10 seconds. 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 L8124C 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.

If the thermostat is not satisﬁ ed when the high limit is reached the burner will stop but the circulator will continue to operate until the thermostat is satisﬁ ed. 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.

Figure 23B: Wiring Diagram, Water with Front Tankless Heater for Carlin Burners

Figure 23C: Wiring Diagram, Water with Front Tankless Heater for Riello Burners

Figure 23D: Wiring Diagram, Water with Rear Tankless Heater for Beckett Burners

BOILER SEQUENCE OF OPERATION

Figure 23D: Wiring Diagram, Water with Rear Tankless Heater for Carlin Burners

Figure 23E: Wiring Diagram, Water with Rear Tankless Heater for Carlin Burners

Figure 23F: Wiring Diagram, Water with Rear Tankless Heater for Riello Burners

SECTION IX: OIL PIPING

A. GENERAL

1. Use ﬂ exible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping.

2. A supply line fuel oil ﬁ lter is recommended as a minimum for all ﬁ ring rates but a pleated paper fuel oil ﬁ lter is recommended for the ﬁ ring rates below

1.0 gph to prevent nozzle fouling.

3. Use Flared ﬁ ttings only.

ECITON

4. Use of a high efﬁ ciency micron ﬁ lter (Garber or equivalent) in addition to a conventional ﬁ lter is highly recommended.

B. SINGLE PIPE OIL LINES

1. Standard burners are provided with single-stage 3450 rpm fuel units with the bypass plug removed for single-pipe installations.

2. The single-stage fuel unit may be installed singlepipe with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 24.

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Figure 24: Single Pipe Oil Line

C. TWO PIPE OIL LINES

1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 3 (two-stage) and Table 4 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 25.

TABLE 3: TWO-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMS

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'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

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TABLE 4: SINGLE-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMS

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'41---'14

Figure 25: Two Pipe Oil Lines

SECTION X: SYSTEM START-UP

GNINRAW

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A. ALWAYS INSPECT INSTALLATION

BEFORE STARTING BURNER.

1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to Installation Instructions contained in this manual.

2. Conﬁ rm all electrical, water and oil supplies are turned off at the source and that the vent is clear from obstructions.

GNINRAW

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B. FILL HEATING SYSTEM WITH WATER.

ECITON

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CLEAN HEATING SYSTEM if boiler water or

condensate return water is dirty or if erratic water lines or surging exist after a few days of boiler operation.

Refer to Maintenance and Service Instructions Section

of this manual for proper cleaning instructions for steam and water boilers.

1. STEAM BOILERS — Fill boiler to normal water line. Refer to Figure No. 1D.

2. HOT WATER BOILERS. Fill entire heating system with water and vent air from system. Use the following procedure on a series loop or multizoned system installed as per Figures 13A, 13B and 13C, to remove air from system when ﬁ lling: a. Close full port ball valve in boiler system piping.

b. Isolate all zones by closing zone valves or shut-

off valves in supply and return of each zone(s).

c. Attach a hose to vertical purge valve in boiler

system piping.

(Note - Terminate hose in ﬁ ve gallon bucket at a

suitable ﬂ oor drain or outdoor area).

d. Starting with one zone at a time, open zone valve

or shut-off valve in boiler supply and return piping.

e. Open purge valve. f. Open shut-off valve in cold water supply piping

located between the air scoop and expansion tank.

g. Allow water to overﬂ ow from bucket until

discharge from hose is bubble free for 30 seconds.

h. When zone valve is completely purged of air,

close zone valve or shut-off valve. Open zone valve to the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves.

i. Close purge valve, continue ﬁ lling the system

until the pressure gauge reads 12 psi. Close shutoff valve in cold water supply piping.

GNINRAW

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j. Open full port ball valve in boiler system piping. k. Remove hose from purge valve. l. Conﬁ rm that the boiler and system have no water

leaks.

C. CHECK CONTROLS, WIRING AND

BURNER to be sure that all connections are tight and

burner is rigid, that all electrical connections have been completed and fuses installed, and that oil tank is ﬁ lled and oil lines have been tested.

D. SET CONTROLS with burner service switch turned

“OFF”.

1. SET ROOM THERMOSTAT about 10° above room temperature.

2. PRESS RED RESET BUTTON on front of burner cover (or Primary Control for Carlin

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Burners), hold for one (1) second and release to reset primary control.

3. On STEAM BOILERS: a. With an L404A1354 - set cut-out pressure

(MAIN scale) on the pressure limit for (2) PSI and differential pressure (DIFF. scale) below (2) PSI. These pressures may be varied to suit individual requirements of the system.

b. With an L404A1651 or an L404F1367 - set cut-

out pressure (MAIN scale) on the pressure limit for (1) PSI and differential pressure (DIFF.) for .5 PSI. These pressures may be varied to suit individual requirements of the system.

4. On STEAM BOILERS WITH TANKLESS DOMESTIC WATER HEATERS, set boiler water temperature dial on L4006 operating control at 190°F (max.). Set differential at 10°.

5. On WATER BOILERS WITHOUT TANKLESS HEATERS, set high limit dial on L8148 at 180°F. This temperature may be varied to suit requirements of installation.

6. On WATER BOILERS WITH TANKLESS HEATERS, set operating control dial (low limit) on L8124 at 190°F and high limit dial at 210°F. Operating control (low limit) must be a minimum of 20° below high limit setting. Set differential at 25°.

proper nozzle size, air settings and fuel pump pressure setting based on desired ﬁ ring rate.

If the desired ﬁ ring rate is the lower GPH:

1) replace the loose or factory installed high ﬁ ring rate nozzle with the loose lower ﬁ ring rate nozzle,

2) change the factory air settings according to Table 6 and,

3) reduce the oil pump pressure on models V83 and V86 to the pressure setting speciﬁ ed in Table 6, refer to Paragraph F for details.

3. Carlin 102CRD Burners

a. Inspect Carlin head setting on left side of burner

by reading the scale embossed on the housing. Refer to Figure 7A and Table 6 of this manual.

b. OPEN ALL OIL LINE VALVES. c. Attach a plastic hose to fuel pump vent ﬁ tting

and provide a pan to catch the oil.

d. OPEN FLAME OBSERVATION PORT

COVER on burner swing door.

e. Carlin burners for packaged and knockdown

boiler models V87 thru V89 are provided with one nozzle, installed in the burner, that provides the same ﬁ ring rate for both the steam and water boiler builds.

4. Carlin Elite EZ Burners

E. ADJUST OIL BURNER BEFORE STARTING.

1. CHECK BURNER AIR BAND AND AIR SHUTTER, readjust if necessary, see Table 6 at rear of manual.

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2. Beckett Burners a. Inspect Beckett head setting on left side of

burner by insuring the blue line MD(V1) or the line on the label MB(L1) are aligned, readjust if

necessary. b. OPEN ALL OIL LINE VALVES. c. Attach a plastic hose to fuel pump vent ﬁ tting

and provide a pan to catch the oil. d. OPEN FLAME OBSERVATION PORT

COVER on burner swing door. e. Beckett burners for boiler models V83 thru V86

are factory equipped with (2) nozzles for dual

ﬁ ring rates. On packaged boiler models PV83W

thru PV86W, the higher ﬁ ring rate nozzle is

installed; on knockdown boiler models KV83W/

S thru KV86W/S both nozzles are shipped loose.

Refer to Table 6 at the rear of this manual for

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a. Inspect Carlin head setting on left side of burner

to ensure that the proper head positioning bar

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matches the nozzle that is installed in drawer

assembly. Replace bar if necessary. b. OPEN ALL OIL LINE VALVES. c. Attach a plastic hose to fuel pump vent ﬁ tting

and provide a pan to catch the oil. d. OPEN FLAME OBSERVATION PORT

COVER on burner swing door. e.. Carlin burners for boiler models V83 thru V86

are factory equipped with (2) nozzles for dual

ﬁ ring rates. On packaged boiler models PV83W

thru PV86W, the higher ﬁ ring rate nozzle is

installed; on knockdown boiler models KV83W/

S thru KV86W/S both nozzles are shipped loose.

Refer to Table 6 at the rear of this manual for

proper nozzle size, air settings and fuel pump

pressure setting based on desired ﬁ ring rate. If the desired ﬁ ring rate is the lower GPH:

1) replace the loose or factory installed high

ﬁ ring rate nozzle with the loose lower ﬁ ring rate nozzle,

2) change the factory air settings according to Table 6 and,

3) check the oil pump pressure and adjust if necessary to the setting speciﬁ ed in Table 6, refer to Paragraph F for details.

5. Riello Burners

a. OPEN ALL OIL LINE VALVES. b. Provide a pan to catch oil. c. Remove pressure port/bleeder plug from fuel

pump and install Riello Combination Pressure Gauge and Bleeder Valve Assembly.

d. OPEN FLAME OBSERVATION PORT COVER

on burner swing door.

F. START OIL BURNER.

1. Open vent ﬁ tting on fuel pump.

2. TURN ‘ON’ BURNER service switch and allow burner to run until oil ﬂ ows from vent ﬁ tting in a SOLID stream without air bubbles for approximately 10 seconds.

3. Close vent ﬁ tting and burner ﬂ ame should start immediately after prepurge is completed. Prepurge prevents burner ﬂ ame until 10 seconds has elapsed after initial power is applied to burner. During prepurge the motor and igniter will operate but the oil valve will remain closed. Refer to Oil Primary Control Instructions for more details.

4. Adjust oil pressure. a. When checking a fuel unit's operating pressure, a

reliable pressure gauge may be installed in either the bleeder port or the nozzle port. See Figure

26.

Figure 26: Adjusting Fuel Pump Pressure

b. Locate oil pressure adjusting screw and turn

screw to obtain proper pump pressure, refer to Table 6 at rear of manual.

c. To check the cutoff pressure, deadhead a reliable

pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure should drop and hold.

d. Remove the gauge and install bleeder port and/or

reconnect the nozzle port line.

G. ADJUST OIL BURNER WHILE OPERATING.

(ﬂ ame present)

1. ADJUST DRAFT REGULATOR for a draft of — .02” (water gauge) over the ﬁ re after chimney has reached operating temperature and while burner is running.

2. READJUST THE AIR BAND on burner for a light orange colored ﬂ ame while the draft over the ﬁ re is —.02”. Use a smoke tester and adjust air for minimum smoke (not to exceed #1) with a minimum of excess air. Make ﬁ nal check using suitable instrumentation to obtain a CO

of 11.5 to

12.5% with draft of —.02” (water gauge) in ﬁ re box. These settings will assure a safe and efﬁ cient operating condition. If the ﬂ ame appears stringy instead of a solid ﬁ re, try another nozzle of the same type. Flame should be solid and compact. After all adjustments are made recheck for a draft of —.02” over the ﬁ re.

3. READJUST THE HEAD SETTING only if necessary.

Beckett Burners

a. V82 & V83: Beckett MB(L1) Head burners have a ﬁ xed head

which are non-adjustable.

b. V84 thru V89: Beckett MD(V1) (variable) Head burners have

the ability to control air by moving the head. It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO2 readings. See Figure 27A.

Carlin 102CRD Burners

a. V87 through V89 The Carlin 102 CRD-3 Burner has the ability

to control air by moving the head. It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO2 readings.

b. If the ﬁ re is a little too rich, move the

combustion head slightly forward by increasing dimension “A”. Refer to Figure 27B.

Figure 27A: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)

Figure 27B: "L1" and "V1" Head Electrode

Positioning and Gun Setting (Beckett AFG)

Figure 27D: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)

Figure 27C: "L1" and "V1" Head Electrode

Positioning and Gun Setting (Beckett AFG)

Carlin Elite EZ Burners

a. Carlin EZ-1HP and EZ-2HP burners use a head

positioning bar to ﬁ x the head setting based on nozzle size. To adjust this setting, bar must be changed to the next larger or smaller bar available. Refer to Section II, Paragraph D for details.

4. READJUST THE TURBULATOR SETTING only

if necessary.

Riello Burners

a. V82 through V89 Move the turbulator setting forward or back one

position at a time to optimize the smoke and CO2 readings.

b. Turn “OFF” burner and remove Riello

Combination Pressure Gauge and Bleeder Valve Assembly. Install pressure port/bleeder plug and tighten. Start burner again.

5. TURN “OFF” BURNER and remove pressure gauge. Install gauge port/bleeder plug and tighten. Start burner again.

GNINRAW

I. TEST CONTROLS.

1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner.

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2. VERIFY PRIMARY CONTROL FEATURES using procedures outlined in Instructions furnished with control or instructions as follows:

a. FEATURES AND CONTROLS

i. The R7184 is a microprocessor-based

control. The indicator light provides diagnostic information for lockout, recycling and patented cad cell status. There is a manual reset button to exit the Lockout Mode and enter the Idle Mode (see Figure

28).

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6. FLAME FAILURE The V8 boiler controls operate the burner

automatically. If for unknown reasons the burner ceases to ﬁ re and the reset button on the primary control has tripped, the burner has experienced ignition failure.

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H. 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 Paragraph I, No. 1. If this does not stop the dripping, remove cut-off 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.

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Figure 28: R7184 Terminals, LED and Reset Button

ii. Pump Priming Cycle: To facilitate purging

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air from the oil lines and ﬁ lters, the R7184 can be placed in a purge routine by pressing and releasing the reset button during the safety check, delayed valve-on, ignition or carry-over periods.

iii. Limited Recycle: This feature limits the

number of recycle trials (for each call for heat) to a maximum of three trials. If the ﬂ ame is lost three times and does not successfully satisfy a call for heat, the R7184 locks out.

iv. Limited Reset (Restricted Mode): In order

to limit the accumulation of unburned oil in the combustion area, the control can only be reset three times. The reset count returns to zero each time a call for heat is successfully completed.

• To reset from Restricted Mode: Press and

hold the reset button for 30 seconds. When the LED ﬂ ashes twice, the device has reset.

v. T-T Jumper: Select models have pre-

installed T-T jumper resistor. To remove, use side-cutting pliers to cut jumper (See Figure 28).

vi. Diagnostic LED: The indicator light on oil

primary control provides lockout, recycle and cad cell indications as follows:

• Flashing at 1 Hz (½ second on, ½ second

off): system is locked out or in Restricted Mode.

• Flashing at ¼ Hz (2 seconds on, 2 seconds

off): control is in Recycle Mode.

• On: cad cell is sensing ﬂ ame.

• Off: cad cell is not sensing ﬂ ame.

vii. Cad Cell Resistance Check: For proper

operation it is important that the cad cell resistance is below 1600 ohms. During a normal call for heat, once the control has entered the Run Mode, press and release the reset button. Indicator light will ﬂ ash 1 to 4 ﬂ ashes. See Table 5 for equivalent cad cell resistance.

TABLE 5: CAD CELL RESISTANCE WHEN

SENSING FLAME

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b. CHECK OIL PRIMARY CONTROL

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• Check contacts between ignitor and the

electrodes.

• Check the oil pump pressure.

• Check the piping to the oil tank.

• Check the oil nozzle, oil supply and oil

ﬁ lter. ii. Check Safety Features Safe Start:

• Place a jumper across cad cell terminals.

• Follow procedure to turn on burner.

Burner must not start, indicator light turns

on and control remains in Idle Mode.

• Remove jumper.

iii. Simulate Ignition or Flame Failure:

• Follow procedure to turn on burner.

• Close hand valve in oil supply line.

• Failure occurs, device enters Recycle

Mode. Indicator light ﬂ ashes at ¼ Hz rate

2 seconds on, 2 seconds off).

• 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. Indicator light

ﬂ ashes at 1 Hz rate (½ second on, ½

second off). Ignition and motor stop and

oil valves closes.

• To reset from Restricted Mode: Press and

hold the reset button for 30 seconds.

When the LED ﬂ ashes twice, the device

has reset. iv. Cad Cell Check: See Figure 29.

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i. Preliminary Steps

• Check wiring connections and power

supply.

• Make sure power is on to the controls.

• Make sure limit control is closed.

Figure 29: Cad Cell Location

• Perform cad cell resistance check as

outlined in control feature. If resistance is below 1600 OHMS and burner runs beyond safety cut-out time, cad cell is good.

• If safety switch shuts down burner and resistance is above 1600 OHMS, open line switch to boiler. Access cad cell under ignitor, clean face of cad cell and see that cell is securely in socket. Check gasket around perimeter of ignitor lid for proper seal. If gasket is missing or damaged, replace gasket. Room light can effect cad cell resistance. Reset safety switch.

• Close line switch to boiler. If burner starts

and runs beyond safety switch cut-off time, cell is good. If not, install new cell.

v. Power Failure Check: After Flame is

established, turn the power off to the control/ burner. The burner should shut down safely. When power is restored a normal ignition sequence should be started.

3. WARNING — Check High Limit Control — Jumper Thermostat Terminals. Allow burner to operate until shut-down by limit. Installation is not considered complete until this check has been made.

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4. Check low water cut off control with water level at normal water line (see Figure 1D). Raise thermostat setting to allow burner to operate. Open boiler drain to allow water level to drop to bottom of sight glass until burner operation is shut-down by low water cut-off.

Close boiler drain and reﬁ ll to normal water line.

Burner should automatically restart during ﬁ ll. Lower thermostat setting.

5. Check operating control on boiler equipped with tankless heaters. With burner off, draw hot water until burner starts, then turn off hot water and check burner shut-down.

J. IF CONTROLS DO NOT MEET

REQUIREMENTS outlined in Paragraph I.,

replace control and repeat checkout procedures.

AQUASTAT SWITCHING ACTION WITHIN L8124C CONTROL

The switching action within the L8124C control has three settings:

1. high limit

2. low limit

3. adjustable differential

HIGH LIMIT OPERATION — The high limit opens and turns off the burner when the water temperature reaches the set point. The high limit automatically resets after the water temperature drops past the set point and through the 10°F differential.

Set the indicator at desired shut-off temperature. LOW LIMIT OPERATION —

On a temperature rise, with the adjustable differential at the minimum setting of 10°F, the burner circuit (R-B) breaks and the circulator circuit (R-W) makes at the low limit set point. On a temperature drop of 10°F below the set point, the R-B circuit makes and the R-W circuit breaks.

ADJUSTABLE DIFFERENTIAL — At any differential setting greater than 10°F, the R-B make temperature and R-W break temperature will remain the same-control setting minus 10°F. The R-B break and R-W make temperature will be the set point temperature plus the difference between the differential setting and 10°F.

EXAMPLE: Set point of 140°F; differential set at 25°F. On a temperature rise, R-B will break and R-W will make at 155°F. On a temperature fall, R-B will make and R-W will break at 130°F.

Set low limit indicator at the minimum temperature recommended for domestic hot water supply. This setting must be at least 20°F below high limit setting to prevent one switch from locking out the other.

Set the differential the desired number of degrees. 25°F differential gives longest burner cycles.

AQUASTAT SWITCHING ACTION WITHIN L8148A CONTROLS

The switching action in the L8148A control has one setting, the high limit. The switching relay is controlled by the low voltage room thermostat. On a call for heat, the relay contacts make to complete the line voltage circulator circuit and also the burner circuit if the boiler water temperature is below the high limit setting. The high limit switch shuts off the burner if boiler water temperature exceeds the high limit setting.

Set the indicator at the desired shut-off temperature.

Warning:

This product contains refractory ceramic ﬁ bers (RCF). RCF has been classiﬁ ed as a possible human carcinogen. After this product is ﬁ red, 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 ﬁ red RCF (combustion chamber insulation,

target walls, canopy gasket, ﬂ ue 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 ﬁ tting clothing

3. Gloves

4. 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 difﬁ culty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difﬁ culties persist.

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

SECTION XI: MAINTENANCE AND SERVICE INSTRUCTIONS

A. MAINTENANCE OF LOW WATER CUT-

OFF DEVICES

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1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their

operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.

It is important to physically remove the probe from

the boiler tapping annually and inspect that probe for accumulation of scale or sediment.

Follow these steps to inspect, clean and/or replace

the probe: a. Turn off electric service to the boiler.

b. Drain boiler water to a level below the tapping

for the probe.

c. Disconnect wiring connections between the low

water cut-off control and the probe.

d. Remove the low water cut-off control from the

probe.

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e. Unscrew the probe from the boiler tapping. f. Inspect that portion of the probe that is exposed

to the boiler water for a scale or sediment buildup.

g. Light deposits may be removed by wiping the

probe with a damp cloth. Wiping the probe with a cloth soaked in vinegar will remove more tenacious lime deposits. The most stubborn deposits may be removed from the probe by using a diluted amount, 3 parts of water to 1 part of phosphoric acid (H

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h. Clean the pipe threads of the probe to remove

old, hardened pipe dope and other foreign matter.

i. Apply a moderate amount of good quality pipe

dope to the pipe threads on the probe, leaving the two end threads bare. Do not use PTFE (Teﬂ on)

tape. j. Screw the probe into the boiler tapping. k. Mount the low water cut-off control on the

probe. l. Reconnect the control to probe wiring. m. Fill the boiler to its normal waterline. n. Add boiler water treatment compound as needed

(refer to Paragraph B.). o. Restore electric service to the boiler. p. Fire burner to bring the water in the boiler to a

boil to drive off free oxygen. q. WARNING — BEFORE RETURNING

BOILER TO SERVICE: Follow the low

water cut-off check out procedure in Section X,

Paragraph I, No. 4.

2. FLOAT TYPE LOW WATER CUT-OFF During the heating season, if an external low water

cut-off is on the boiler, the blow off valve should be opened once a month (use greater frequency where conditions warrant), to ﬂ ush out the sediment chamber so the device will be free to function properly.

Low water cut-offs and water feeders should

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B. BOILER AND SYSTEM CLEANING

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be dismantled annually by qualiﬁ ed personnel, to the extent necessary to insure freedom from obstructions and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc., and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly. Give special attention to solder joints on bellows and ﬂ oat when this type of control is used. Check ﬂ oat for evidence of collapse and check mercury bulb (where applicable) for mercury separation or discoloration.

Do not attempt to repair mechanisms in the ﬁ eld.

Complete replacement mechanisms, including necessary gaskets and installation instructions are available from the manufacturer.

INSTRUCTIONS FOR TROUBLE FREE OPERATION

1. STEAM BOILERS a. Oil, greases & sediments which accumulate in a

new boiler and piping must be removed in order to prevent an unsteady water line and carry over of the water into the supply main above boiler.

Operate the boiler with steam in the entire

system for a few days allowing the condensate to return to the boiler. If the condensate can temporarily be wasted, operate boiler only for the length of time it takes for condensate to run clear. If the latter cannot be achieved or if the condensate is returned to the boiler, boil out the boiler using the SURFACE BLOW-OFF connection, see Figure 5.

i. Drain boiler until 1” of water is visible in

gauge glass. Run temporary 1½” NPT pipe line from the surface blow-off connection to an open drain or some other location where hot water may be discharged safely. Do not install valve in this line.

ii. Drain about 5 gallons of hot water from

boiler into a container and dissolve into it an appropriate amount of recommended boil out compound. Remove safety valve & add solution to boiler water thru exposed tapping using a funnel.

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iii. Start burner and operate sufﬁ ciently to boil

the water without producing steam pressure. Boil for about 5 hours. Open boiler feed pipe sufﬁ ciently to permit a steady trickle of water from the surface blow-off pipe. Continue this slow boiling and trickle of overﬂ ow for several hours until the water coming from the overﬂ ow is clear.

iv. Stop burner and drain boiler in a manner

and to a location that hot water can be discharged with safety.

v. Reﬁ ll boiler to normal water line. If water

in gauge glass does not appear to be clear, repeat steps (i. thru iii.) and boil out the boiler for a longer time.

b. Low pressure steam boilers such as the V8

Series should be maintained with appropriate water treatment compounds. Add suitable water treatment compounds as recommended by your qualiﬁ ed water treatment company.

c. Remove temporary surface blow-off piping, plug

tapping and reinstall safety valve. Boil or bring water temperature to 180°F promptly in order to drive off the dissolved gases in the fresh water.

d. If unsteady water line, foaming or priming

persist, install gate valve in Hartford Loop and drain valves in return main and at boiler as shown in Figure 14 and proceed as follows: i Connect hoses from drain valves to ﬂ oor

drain. Close gate valve in Hartford Loop and

open drain valve in return main. Fill boiler to normal water level, turn on oil burner and operate boiler at this water level for at least 30 minutes after the condensate begins to run hot, then turn off burner.

Close all radiator valves. Remove all supply

main air valves and plug the openings in supply main.

ii. Draw about 5 gallons of hot water from

boiler into a container and dissolve into it the appropriate amount of a recommended boilout compound. Remove safety valve from boiler and pour this solution into boiler, then reinstall safety valve.

iii. Turn on oil burner and keep operating while

feeding water to boiler slowly. This will raise water level in boiler slowly so that water will be boiling hot and will rise slowly into supply main and back through return main, ﬂ owing from drain hose at about 180°F. Continue until water runs clear from drain hose for at least 30 minutes.

iv. Stop feeding water to boiler but continue

operating oil burner until excess water in boiler ﬂ ows out through supply main and water lowers (by steaming) until it reaches normal level in boiler. Turn off oil burner. Drain boiler. Open all radiator valves. Reinstall all supply main air valves. Open gate valve in Hartford Loop.

v. When boiler has cooled down sufﬁ ciently

(crown sheet of sections are not too hot to touch), close the drain valves at boiler and in return main and feed water slowly up to normal level in boiler. Turn on oil burner and allow boiler to steam for 10 minutes, then turn off burner. Draw off one quart of water from bottom gauge glass ﬁ tting and discard. Draw off another quart sample and if this sample is not clear, repeat the cycle of draining the boiler and return main and reﬁ lling the boiler until sample is clear.

vi. If the boiler water becomes dirty again

at a later date due to additional sediment loosened up in the piping, close gate valve in Hartford Loop, open drain valve in return main, turn on oil burner and allow Condensate to ﬂ ow to drain until it has run clear for at least 30 minutes while feeding water to boiler so as to maintain normal water level. Turn off oil burner, drain boiler, open gate valve in Hartford Loop, then

repeat Step 1 above. e. Make pH or Alkalinity Test. After boiler and system have been cleaned and

reﬁ lled as previously described, test the pH of the water in the system. This can easily be done by drawing a small sample of boiler water and

testing with hydrion paper which is used in the same manner as litmus paper, except it gives speciﬁ c readings. A color chart on the side of the small hydrion dispenser gives the reading in pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7, but lower than 11. Add some of the washout chemical (caustic soda), if necessary, to bring the pH within the speciﬁ ed range.

f. Boiler is now ready to be put into service.

2. WATER BOILERS a. Filling of Boiler and System — General —-In a

hot water heating system, the boiler and entire system (other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler pressure gauge registers 12 psi. To insure that the system is full, water should come out of all air vents when opened.

b. Boiling Out of Boiler and System. The oil and

grease which accumulate in a new hot water boiler can be washed out in the following manner.

i. Remove relief valve using extreme care to

avoid damaging it.

ii. Add an appropriate amount of recommended

boil out compound.

iii. Replace relief valve. iv. Fill the entire system with water. v. Start ﬁ ring the boiler. vi. Circulate the water through the entire

system.

vii. Vent the system, including the radiation. viii. Allow boiler water to reach operating

temperature, if possible.

ix. Continue to circulate the water for a few

hours.

x. Stop ﬁ ring the boiler. xi. Drain the system in a manner and to a

location that hot water can be discharged with safety.

xii. Remove plugs from all available returns

and wash the water side of the boiler as thoroughly as possible, using a highpressure water stream.

xiii. Reﬁ ll the system with fresh water.

c. Add appropriate boiler water treatment

compounds as recommended by your qualiﬁ ed

water treatment company. d. Make pH or Alkalinity Test. After boiler and system have been cleaned and

reﬁ lled as previously described, test the pH of

the water in the system. This can easily be done

by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper, except it gives speciﬁ c readings. A color chart on the side of the small hydrion dispenser gives the reading pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7 but lower than 11. Add appropriate water treatment chemicals, if necessary, to bring the pH within the speciﬁ ed range. With this lower level of protection, care must be exercised to eliminate all of the free oxygen in the system.

e. Boiler is now ready to be put into service.

C. FREQUENT WATER ADDITION

ECITON

SITI,NOITAREPOLAMRONGNIRUD,FI

REPRETAWEROMDDAOTYRASSECEN

,WOLEBDETACIDNINAHTHTNOM

.SKAELROF

)htnoM/laG(

A leaky system will increase the volume of make-up

water supplied to the boiler which can signiﬁ cantly shorten the life of the boiler. Entrained in make-up water are dissolved minerals and oxygen. When the fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas. Both can result in reduced boiler life. The accumulation of sediment can eventually isolate the water from contacting the cast iron. When this happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the cast iron through from the inside. Since neither of these failure types are the result of a casting defect the warranty does not apply. Clearly it is in everyone’s best interest to prevent this type of failure. The maintenance of system integrity is the best method to achieve this.

D. ATTENTION TO BOILER WHILE NOT IN

OPERATION.

ECIVRESDEIFILAUQATLUSN

METSYSRUOYKCEHCOTNAICINHCET

:NOITIDDARETAWEVISSECXE

½41:88V11:68V8:48V

ECITON

ti,emitretniwgniruddesutonsireliobfI

ezeerftneverpotdeniardyllufebtsum

.egamad

61:98V31:78V½9:58V6:38V

1. Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners.

2. With steam boilers, at end of season add sufﬁ cient water to ﬁ ll boiler to top of water column and leave it that way until fall when water should be drained again to proper level. If at this time boiler water is dirty, drain water, ﬂ ush out boiler, and reﬁ ll with clean water to prescribed water level.

3. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time.

4. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section X, Paragraphs A through J.

GNINRAW

yamhcihwslortnocsniatnocreliobsihT

tondnanwodtuhsotreliobehtesuac

oteudegamadfI.ecivrestuohtiwtratser

gnitaeheht,ytilibissopasisepipnezorf

nidednettanutfelebtondluohsmetsys

sdraugefasetairporpparo;rehtaewdloc

ehtnodellatsniebdluohssmraladna

ehtfiegamadtneverpotmetsysgnitaeh

.evitareponisireliob

SECTION XII: BOILER CLEANING

GNINRAW

deppiuqesrelioB.ffodenruthctiwsecivresrenrubhtiwdetelpmocebtsumgninaelcreliobllA

,egamadytreporperevesesuacnachcihwdrazahlaitnetopaevahroodgniwsrenrubhtiw

othctiwsecivresffonrut,roodgniwsgninepoerofeB.derongifiefilfossolroyrujnilanosrep

everpotreliob

.detelpmocsiecivresnehwyletelpmocrenetsafroodgniws

nethgitoteruseB.rebmahcnoitsubmocehtedistuorenrubfogniriflatnediccatn

A. CLEAN THE FLUEWAYS (See Figure 30).

1. Prior to cleaning boiler, lay a protective cloth or plastic over combustion chamber blanket to collect debris falling from ﬂ ueways.

2. For access to combustion chamber remove two (2) 5/16" - 18 cap screws, one on the right (1¼" long) and one on the left (3¼" long). If boiler is equipped with ﬂ exible fuel line(s), swing door open.

3. For cleaning from the side: a. Remove the jacket right side access panel to

expose the ﬂ ue cover plates.

b. Loosen nuts securing the ﬂ ue cover plates and

remove the plates. The rope gasket should be removed with the plates with care to avoid damage to the rope gasket.

4. For cleaning from the top: a. Remove as much vent pipe as necessary to allow

removal of the jacket top panel and canopy. b. Remove the jacket top panel. c. Remove the canopy, being careful not to damage

the gasket.

5. Using a 1¼” diameter wire or ﬁ bre bristle brush (30” handle) clean the ﬂ ueways. Brush from the top and/or side using horizontal and diagonal strokes for best results. DO NOT allow brush to strike the target wall or liner in the chamber.

B. CLEAN TOP OF BOILER SECTIONS

(if cleaning from the top).

Brush and vacuum the tops of the boiler sections. C. CLEAN THE COMBUSTION CHAMBER.

Using wire or ﬁ bre bristle brush, clean crown of boiler

and inside of water legs.

GNINRAW

rollawtegratekirtsothsurbwollatonoD

.rebmahcnoitsubmocehtniteknalb

D. AFTER CLEANING, remove protective cloth or

plastic with debris and vacuum as necessary, but be careful not to damage blanket. Inspect target wall, combustion chamber blanket, burner swing door insulation, and rope gasket for signs of damage. If damaged, replace as needed.

E. REASSEMBLE BOILER.

NOITUAC

tnev,yponacsselnurenrubehttratstonoD

revoceulflladnaroodgniwsrenrub,epip

.ecalpnideruceserasetalp

1. Install the canopy taking care to align the gasket without blocking the ﬂ ueways. If gasket is damaged, replace as needed.

2. Reinstall ﬂ ue cover plates, making sure rope gasket on each plate is in place and forms a gas tight seal. If damaged replace as needed.

3. Reinstall jacket top panel and/or jacket upper right side access panel with #8 x ½" long sheet metal screws.

4. Reinstall vent pipe on canopy and secure to collar with sheet metal screws.

5. Close burner swing door. Secure door to front section with 5/16" ﬂ ange nut and washer (right side) and 5/16" x 3½" lg. bolt (left side).

ECITON

ekamroodgniwsrenrubgnirucesnehW

.sedishtobnoyllauqeni-nwardsirooderus

Tighten swing door hardware to provide adequate

seal to rope gasket around perimeter of door.

Use an alternating tightening method from right side

ﬂ ange nut to left side cap screw to pull door tight equally.

Figure 30: Cleaning of Boiler Flueways

GNINRAW

cepsniebtsumeulfyenmihceht

ytreporpsuoireS.noitidnocdoogniyenmihcdevorppanaotdetcennocebtsumreliobehT

foroiretniehT.yenmihcetauqedaniroytridaotdetcennocsireliobehtfitluserdluocegamad

dnanosaesgnitaehehtfotratsehterofebdenaelcdnadet

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.ycneiciffes'reliobehtgniniatniamdrawotetubirtnoclliwdnaylefastnevotefilfossol

SECTION XIII: TROUBLE SHOOTING

A. COMBUSTION

1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the V8 boiler is the result of extensive testing to obtain the best ﬂ ame shape and efﬁ cient combustion. Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are mass-produced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have.

2. FLAME SHAPE — Looking into the combustion chamber through the observation port, the ﬂ ame should appear straight with no sparklers rolling up toward the crown of the chamber. If the ﬂ ame drags to the right or left, sends sparklers upward or makes wet spots on the target wall, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described above.

3. FUEL LEAKS — Any fuel leak between the pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the ignitor, and around the air inlet. Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a ﬁ re hazard.

4. AIR LEAKS — Any such leaks should be repaired, as they may cause erratic burning of the fuel and in extreme cases may become a ﬁ re hazard.

5. GASKET LEAKS — If 11.5 to 12.5% CO2 with a #1 smoke cannot be obtained in the breeching, look for air leaks around the burner mounting gasket, observation door, and canopy gasket. Such air leaks will cause a lower CO2 reading in the breeching. The smaller the ﬁ ring rate the greater effect an air leak can have on CO2 readings.

6. DIRT — A fuel ﬁ lter is a good investment. Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the ﬁ ring rate, the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt.

7. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump, but more importantly water doesn’t burn. It chills the ﬂ ame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the ﬂ ueways of the boiler.

and

8. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower, poor combustion or delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get larger and the ﬂ ame shape gets longer. An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to bury the tank and lines deep enough to keep the oil above 40°F.

9. HIGH ALTITUDE INSTALLATIONS — Air openings must be increased at higher altitudes. Use instruments and set for 11.5 to 12.5% CO

10. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode settings, ﬂ ame shape, air or water in the fuel lines.

11. SHUT DOWN NOISE — If the ﬂ ame runs out of air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, or it may be air trapped in the nozzle line. It may take several ﬁ ring cycles for that air to be fully vented through the nozzle. Water in the fuel or poor ﬂ ame shape can also cause shut down noises.

ECITON

snurrenrubehtfI.ecruosrehtona

ehtfotuogniwardnehwyllufsseccus

.etisboj

B. OIL PRIMARY CONTROL

1. Burner (control) will not come on. a. No power to control. b. Control is in lockout or restricted mode. Press

reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into restricted mode. To reset from restricted mode, refer to Section X,

Paragraph I, No. 2 for details. c. CAD cell seeing light. d. CAD assembly defective. e. Control motor relay is stuck closed (see note

below).

2. Burner (control) will light, then shut down after a short time, then restart after one (1) minute.

a. CAD cell is defective.

doogyrevA.ERUDECORPTSETKCEHC

otsismelborpedisleufgnitalosiroftset

"42ahtiwdnametsysleufehttcennocsid

evi

fyrailixuanafotuoerif,gnibutfohtgnel

morflio2#mraw,hserf,naelcfoliapnollag

otdetalosisimelborpehtnehtliapyrailixua

ehtnodesugniebsenilleufroleufeht

b. Air leaking into oil line causing ﬂ ame out. c. Defective nozzle causing ﬂ ame to be erratic. d. Excessive airﬂ ow or draft causing ﬂ ame to leave

burner head.

e. Excessive back pressure causing ﬂ ame to be

erratic.

3. Control locks out after Trial For Ignition (TFI). a. No oil to burner.

b. Shorted electrodes. c. Nozzle clogged. d. Airﬂ ow too high. e. Ignitor module defective. f. CAD cell defective. g. Oil valve stuck open or closed.

Note: The Safety Monitoring Circuit (SMC) is

designed to provide lockout in the event of a stuck or welded motor relay.

ECITON

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lliwtuokcol)]IFT[noitingIroFlairTsa

der

aybdetacidnisituokcoL.rucco

.lortnoc

rofllacagnirudsemit)3(eerhttuo

dnaderybdetacidnisisihT.taeh

.no-diloss'DELrebma

yramirplioehtnodetacolno-dilosDEL

-skcollortnocehtfiruccolliwpu-hctaL

SECTION XIV: REPAIR PARTS

All V8 Series Boiler Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.

Bare Boiler Assembly

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Bare Boiler Assembly (Continued)

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Jacket Assembly

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--------------------

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V83 Thru V89 Steam Boilers - Trim and Controls

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V82 Thru V89 Water Boilers - Trim and Controls

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ocyeH,elcatpeceRteltuOrewoP2256318 11111111

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Beckett AFG Burner

BECKETT OIL BURNER PART NOS. FOR V8 SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.

ledoMrelioB28V38V48V58V

noitanibmoCebuTriANSAMM07GFANQAMM07GFANQADM07GFANQADM07GFA

.oNcepSs'ttekceB9137BCBV2237BC

dnaBriA

tuNdnaBriA0514051405140514

wercSdnaBriA8914891489148914

rettuhSriA11223907390739073

wercSrettuhSriA8914891489

leehWrewolB9992999299929992

gnilpuoC4542454245424542

elffaBetaRgniriFwoL---]1[0885------

tunkcoLdelrunKdaehkluB6

ylbmessAebuTrotcennoC6365636563656365

pmalCedortcelE94-194-194-194-1

wercSpmalCedortcelE9124912491

ylbmessArotalusnIedortcelE0875087508750875

ylbmessArecapSredipS305-5305-5305-5305-5

etalPnoehctucsE39433943

ylbmessAetalPgnitsujdA------

daeH2195219531953195

swercSdaeH1224122412241224

teksaGegnalF89413894138941389413

gni

suoHGFA7785778577857785

rotoM50812508125081250812

retpadAelzzoN31-231-231-231-2

ylbmessAedortcelEeniLelzzoNBM07LNMM07L

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)egatSelgniS(

6263

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66-3666-3666-3666-3

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etalPcitatS48334833P3833P3833

rotingIU17715U17715U17715U17715

wercSegniHrotingI7124712471247124

wercSgnidloHrotingI29

tiKteksaGrotingI40315403154031540315

drauGeriW15201152011520115201

xoBnoitcnuJ0775077507750775

alF6007600760076007

rotceteDem

lioCevlaVdioneloSliO55712557125571255712

droCevlaVdioneloSliO70812708127081270812

fMW38VdnaS38Vnodesu0885]1[

U2042812U2042812U2042812U

24292429242924

ylnosetargniri

BV5237BCB8237BCB

294329432943

148914

249124

4951495

NDM07LNDM07LN

2042812

(Continued on Next Page)

BECKETT OIL BURNER PART NOS. FOR V8 SERIES BOILERS (continued)

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.

ledoMrelioB68V78V88V98V

noitanibmoCebuTriANQADM07GFANQADM07GFANQADM07GFANQADM07GFA

.oNcepSs'ttekceB1337BCB2337BCB3337BCB4337BCB

dnaBriA2943294329432943

tuNdnaBriA0514051405140514

wercSdnaBriA8914891489148914

rettuhSriA9073907390739073

A8914891489148914

gnilpuoC4542454245424542

kluB666-3666-3666-3666-3

daeH3195319531953195

rotoM50812508125081250812

rotingIU17715U17715U17715U17715

I2924292429242924

emalF6007600760076007

wercSrettuhSri

leehWrewolB9992999299929992

elffaBetaRgniriFwoL------------

tunkcoLdelrunKdaeh

ylbmessAebuTrotcennoC6365636563656365

pmalCedortcelE94-194-194-194-1

wercSpmalCedortcelE91249

ylbmessArotalusnIedortcelE0875087508750875

ylbmessArecapSredipS305-5305-5305-5305-5

etalPnoehctucsE

ylbmessAetalPgnitsujdA

swercSdaeH1224122412241224

teksaGegnalF89413894138941389413

gni

suoHGFA7785778577857785

retpadAelzzoN31-231-231-231-2

ylbmessAedortcelEeniLelzzoNDM07LNDM07L

tuCnaelC,pmuPliO

)egatSelgniS(,

149

5149514951495

U4044812U4044812U4044812U4044812

12491249124

NDM07LNDM07LN

egatS-owT,pmuPliOU3852U3852U3852U3852

tiKevlaVdioneloSliO

)pmuPegatS-owThtiwderiuqeR(

etalPcitatSP3833P3833P3833P3833

wercSegniHrotingI7124712471247124

wercSgnidloHroting

tiKteksaGrotingI40315403154031540315

drauGeriW15201152011520115201

xoBnoitcnuJ0775077507750775

rotceteD

lioCevlaVdioneloSliO55712557125571255712

droCevlaVdioneloSliO70812708127081270812

U2042812U2042812U2042812U2042812

CARLIN OIL BURNER PART NUMBERS FOR V8 SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner.

Refer to Installation and Operation Instructions For Carlin Model 102 CRD Oil Burner (Form No. 96858) for an exploded view of the burner and a list of spare parts.

Refer to Installation and Operating Instructions for Packaged Heating/Burner Units, Carlin Elite EZ-1HP and EZ-2HP Oil Burners (Form CCT-569A) for an exploded view of the burner and a list of spare parts.

For replacement Carlin oil burner parts, contact your wholesaler or the burner manufacturer:

CCT, Carlin Combustion Technology, Inc.

70 Maple Street

East Longmeadow, MA 01028

Telephone: (413) 525-7700 Facsimile: (413) 525-8306

RIELLO OIL BURNER PART NUMBERS FOR V8 SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner.

Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) or Model F10 Installation Manual, Riello 40 Series Residential Oil Burners (2902554) for an exploded view of the burner and a list of spare parts.

For replacement Riello oil burner parts, contact your wholesaler or the burner manufacturer:

Riello Corporation of America 35 Pond Park Road Hingham, Massachusetts 02043 Telephone: (617) 749-8292 Facsimile: (617) 740-2069 Toll Free: (outside Massachusetts) (800) 992-7637

Riello Canada Inc. 2165 Meadowpine Blvd. Mississauga, Ontario L5N 6H6 Telephone: (905) 542-0303 Facsimile: (905) 542-1525 Toll Free: (800) 387-3898

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P°06x52.2

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.2B°08x02.1541

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5.054.0A06x05.00513F-044.30.0

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3-DRC201

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i;esooldeppihs[notracrenrub-relioBnwodkconKS/W38V

:elffabetargnirifwolaezilitutahtsdliubttekceB

)renrubnidellatsni(relioBdegakcaPS38V

.pu-tratsrenrubgnirudevobanwohssgnittesotdetsujdaerebtsumdnaISP041tates

Table 6: BURNER SPECIFICATIONS

.detonesiwrehtosselnuselzzonnavaleDezilitusrenrubllA

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57.01L015.A06x06.004156.0/06.035.0B06x06.00515F-0452.20.1B°09x07.0541

MW38V

W28V06.01L70 A06x05.0041

S38V

50.1)0(1V015.A06x58.004100.1/58.057.0B06x58.00515F-0457.30.1B°08x09.0541

MW48V

S48V

W38V50.11L015.1A06x58.004100.1/58.008.0B06x58.00515F

53.1)0(1V011 B06x01.104152.1/01.108.0B06x01.10515F-045.50

MW58V

S58V

W48V53.1)0(1V012

56.1)2(1V013 B06x53.1041

S68V

W58V56.1)2(1V015 B06x53.104105.1/53.102.1B06x53.10515F-040.60.4B°08x53.1541

01.2)4(1V013

MW68V

S78V

W78V

W68V09.1)3(1V015.3B54x05.10610.208.1A06x56.104101F-048.30.4

06.2)6(1V017

53.2)4(1V015

S98V

S88V

W98V

W88V

XV. LOW WATER CUT OFF (LWCO)

GNINRAW

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.)OCWL(ffOtuCretaWwoLtekramretfanallatsniotseriwyrotcaftucotTPMETTATONOD

.snoitcurtsnis'rerutcafunam)OCWL(ffOtuCretaWwoLehtwollof,sesacllanI

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same ﬂ oor level as the boiler). In addition, some jurisdictions require the use of a LWCO with a hot water boiler.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

What Kind

Typically, in residential applications, a probe type LWCO is used instead of a ﬂ oat type, due to their relative costs and the simplicity of piping for a probe LWCO.

How to Pipe

A “tee” is commonly used to connect the probe LWCO to the supply or return piping, as shown below.

draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

conﬁ gurations. The 120 VAC conﬁ guration can be universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown below.

LWCO Location

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch connection must have a minimum diameter to

prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located

above the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas ﬁ red

boilers where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.

How to Test

Shut off fuel supply. Lower water level until water level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to operate. Increase the water level by ﬁ lling the system. The boiler should attempt to operate once the water level is above the LWCO.

SERVICE RECORD

DATE SERVICE PERFORMED

Limited Warranty

FOR RESIDENTIAL CAST IRON WATER BOILERS

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

ONE YEAR LIMITED WARRANTY

ON RESIDENTIAL GRADE WATER BOILERS

U.S. Boiler Co., Inc. warrants to the original owner that its residential grade water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a water boiler is found to be defective in material or workmanship during this one year period, U.S. Boiler Co., Inc. will, at its option, repair or replace the defective part.

LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER

U.S. Boiler Co., Inc. warrants to the original owner that the heat exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation. If a claim is made under this warranty during the first ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option, repair or replace the heat exchanger. If a claim is made under this warranty after the 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-rated service charge set forth below, repair or replace the heat exchanger. The service charge applicable to a heat exchanger warranty claim is

based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows:

sraeY

ecivreSnI

egrahCecivreS

fo%sa

ecirPliateR

sraeY

ecivreSnI

egrahCecivreS

fo%sa

ecirPliateR

NOTE: If the heat exchanger model involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the pub Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended

only to the original owner at the original place of installation within the

United States and Canada. These warranties are applicable only to

water boilers designated as residential grade by U.S. Boiler Co., Inc.

and installed in a single or two-family residence and do not apply to

steam boilers of any kind or to commercial grade boilers.

2. Components Manufactured by Others: Upon expiration of the one

year limited warranty on residential grade water boilers, all boiler

components manufactured by others but furnished by U.S. Boiler

Co., Inc. (such as oil burner, circulator and controls) will be subject

only 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 water

boiler in strict compliance with U.S. Boiler Co., Inc. installation

instructions. U. S. Boiler Co., Inc. specifically disclaims liability of any

kind 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

01-11121 3141516171

50151025203 53

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81 91021222 3242

0454055506560757

lished price as shown in the Burnham

water boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthorized modification, or is damaged as

a result of being otherwise improperly operated or serviced including, but not limited to, damage from any of the following: operation with

insufficient water, allowing the boiler to freeze, subjecting the boiler to flood conditions, and operation with unapproved water or fuel additives which cause deposits or corrosion.

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

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

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

8. Limitation of Warranties: These warranties set forth the entire obligation of U.S. Boiler Co., Inc. with respect to any defect in a residential grade water boiler and U.S. Boiler Co., Inc. shall have no express obligations, responsibilities or liabilities of any kind whatsoever other than those set forth herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING

ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED

dna52

evoba

WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, 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 to

complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will not void the owner’s rights under these warranties.

Upon discovery of a condition believed to be related to a defect in

material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the owner should write 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. Boiler

Co., Inc. or its representative the parts claimed to be defective and, if requested 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. In addition, the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND

YOU MAY AL TO STATE.

SO HAVE OTHER RIGHTS WHICH VARY FROM STATE

03/03

Limited Warranty

FOR RESIDENTIAL CAST IRON STEAM BOILERS

By this Warranty Statement the U.S. Boiler Co., Inc. of Lancaster,

Pennsylvania i ssues limited warranties subject to the terms and conditions

stated below. These limited warranties apply to residential cast iron boilers labeled Independence®, Independence® PV and V8™ Series,

these warranties are issued only to the original homeowner at the original place of installation.

FIRST YEAR - LIMITED WARRANTY FOR

RESIDENTIAL CAST IRON STEAM BOILERS

U.S. Boiler Co., Inc. warrants its residential cast iron steam boilers labeled Independence, Independence PV and V-8 Series to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of one year from the date of original installation. In the event that any part of such a steam boiler is found to be defective in material or workmanship during the one-year period, then U.S. Boiler Co., Inc. will repair or replace, at its option, the defective part.

SECOND THROUGH 10 YEAR - LIMITED

WARRANTY FOR THE CAST IRON SECTION

ASSEMBLY OF RESIDENTIAL CAST IRON STEAM BOILERS

U.S. Boiler Co., Inc. warrants the cast iron section assembly of its residential cast iron steam boilers labeled Independence, Independence PV and V-8 Series, to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of 10 years from the date of original boiler installation. In the event that such cast iron section assembly is found to be defective in material or workmanship during this period, U.S. Boiler Co., Inc. will repair or replace, at its option, the defective cast iron section assembly.

LIFETIME NIPPLE LEAKAGE WARRANTY

U.S. Boiler Co., Inc. warrants the cast iron nipples that join the sections to be free from defects in material and workmanship for the lifetime of the original owner at the time of installation. In the event that such cast iron nipples are found to be defective in material or workmanship during this period, U.S. Boiler Co., Inc. will repair or replace at its option, the cast iron section assembly.

ADDITIONAL TERMS AND CONDITIONS

1. This warranty does not cover expenses for removal or reinstallation.

The homeowner will be responsible for the cost of removing and

reinstalling the defective part or its replacement and all labor and

material connected therewith. Replacement material will be invoiced

to the distributor in the usual manner and will be subject to

adjustment upon proof of defect.

2. This warranty, in no way, can be considered as a guarantee of

workmanship of an installer connected with the installation of the

U.S. Boiler Co., Inc. boiler or as imposing on U.S. Boiler Co., Inc.

liability of any nature for unsatisfactory performance as a result of

faulty workmanship in the installation, which liability is expressly

disclaimed.

3. This warranty will not be applicable if the boiler is used or

operated over its rated capacity; or installed for uses other than

home heating; or is not maintained in accordance with U.S. Boiler

Co., Inc. recommendation or accepted good practice as determined

by hydronics industry standards.

4. This warranty will not be applicable if the boiler has been

damaged as a result of being improperly serviced or operated,

including but not limited to the following: operated with

insufficient water, allowed to freeze; subject to flood conditions ;

or operated with water conditions and/or fuels or additives

which cause unusual deposits or corrosion in or on the heat

exchanger.

5. This warranty applies only to boilers installed within the United States, and Canada.

6. In order for this warranty to be effective:

a.) The boiler must have been properly installed in a

single or two-family residential dwelling. This warranty does not apply to boilers installed in apartments or to commercial or industrial installation.

b.) The boiler must have been assembled in strict

compliance with installation instructions furnished with the boiler by U.S. Boiler Co., Inc.

c.) Boiler components must not have been damaged in

handling during shipment or installation.

7. The foregoing provisions of this warranty shall be effective to the maximum extent permitted by applicable law, and, to the extent that any such provision would otherwise be inconsistent with applicable law, such provision shall be limited in effect to the minimum extent necessary to avoid such unconscionable result or inconsistency with applicable law.

8. The remedy for breach of this warranty is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use; and the remedy for breach of this warranty or for negligence does not extend to liability for incidental, special or consequential damages or losses such as loss of the use of the materials, inconvenience or loss of time. Some states do not allow the exclusion or limitation of incidentalor consequential damages so the above limitation or exclusion may not apply to you.

9. This w arranty is in lieu of all others, and any and all express or implied warranties (including, without limitation, any implied warranties of merchantability or fitness for a particular purpose) are expressly limited in duration to the period of the warranty as previously stated herein. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.

10.Not withstanding any of the above provisions, U.S. Boiler Co., Inc. liabilityunder this warranty shall not exceed the selling price of the product found to be defective.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service the homeowner is

requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will not void the homeowner’s rights under this warranty.

Upon discovery of a condition believed to be related to a defect in

material or workmanship covered by this warranty statement, the homeowner should notify the installer who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the homeowner should write to U.S. Boiler Co., Inc., at P.O. Box 3079, Lancaster, PA 17604 giving full particulars in support of the claim.

The homeowner is required to make available for inspection by U.S.

Boiler Co., Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Co., Inc., to ship said parts prepaid to Burnham Hydronics at the above address for inspection or repair. In

addition, the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with his claim before

resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND

YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

03/03

Burnham V8 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual