Burnham V85, V86, V87, V88, V89 Installation & Service Instructions Manual

8

DNAGNITAREPO,NOITALLATSNI

ROFSNOITCURTSNIECIVRES

SEIRES8V

RELIOBDERIF-LIO

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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.

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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3

GNINRAW

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

4

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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"

5"

10.0

450

V83

17-1/8"

9-1/8"

6"

10.3

12.8

15.88

542

V84

22-1/8"

11-5/8"

6"

12.4

15.7

22.92

634

V85

27-1/8"

14-1/8"

7"

14.6

18.5

29.96

726

V86

32-1/8"

16-5/8"

7"

16.7

21.4

37.00

818

V87

37-1/8"

19-1/8"

8"

18.8

24.2

44.04

910

V88

42-1/8"

21-5/8"

8"

20.9

27.1

51.08

1002

V89

47-1/8"

24-1/8"

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

70

61

6

8 x 8

15

82.1

V83W

1.05

147

123

107

6

8 x 8

15

82.6

V83S

V83WM

0.75

105

91

79

68

283

6

8 x 8

15

85.1

86.0

V84W

1.35

189

159

138

7

8 x 8

15

83.2

V84S

V84WM

1.05

147

127

110

95

396

6

8 x 8

15

85.3

86.1

V85W

1.65

231

196

170

7

8 x 8

15

83.9

V85S

V85WM

1.35

189

164

143

123

512

7

8 x 8

15

85.4

86.2

V86W

1.90

266

227

197

8

8 x 8

15

84.6

V86S

V86WM

1.65

231

201

175

151

629

7

8 x 8

15

85.7

86.3

V87S

V87W

2.10

294

252

219

189

787

8

8 x 8

15

84.7

85.0

V88S

2.35

329

266

200

833

8

8 x 12

15

V88W

2.35

329

275

239

8

8 x 12

15

V89S

2.60

364

298

224

933

9

8 x 12

15

V89W

2.60

364

299

260

9

8 x 12

15

*

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

70

123

91

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

61

79

Steam

MBH

68

95

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

5

6

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

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

7

8

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

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

9

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

10

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.

or

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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.

11

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.

12

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

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13

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.

14

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.

15

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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

e

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

16

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.

17

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.

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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.

18

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.

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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.

19

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

20

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)

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.

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.

21

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.

22

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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

disconnect junction box provided with all knockdown boiler builds.

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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.

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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.

23

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

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 19.

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

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 22 and 23A.

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

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 22 and 23A.

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.

24

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)

25

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

26

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

27

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

28

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

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 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

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.

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

E.

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.

29

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. 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

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. Install the proper nozzle in the burner nozzle adaptor.

GNINRAW

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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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4. An L404F pressure limit does not require leveling.

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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.

30