U.S. Boiler Company V8H SERIES, V8H3, V8H4, V8H5, V8H6 Installation, Operating And Service Instructions

...

As an

ENERGY

Partner,

STAR U.S. Boiler Company has determined that the V8H3S, V8H3W, V8H4S, V8H4W, V8H5S, V8H5W, V8H6S, V8H6W and V8H7 meet the ENERGY STAR guidelines for Energy

efciency established by the

United States Environmental

Protection Agency (EPA).

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103869-02 - 10/12

Price - $5.00

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.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

This boiler has a limited warranty, a copy of which is included with this boiler. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in

accordance with these instructions.

Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other boiler.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this boiler. Keep this manual and literature in legible condition and posted near boiler for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler.

Installation is not complete unless a pressure relief valve is installed into the tapping located on top left corner of front section- See Piping and Trim Sections of this manual for details.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when installation is complete including verifying that the limit sensor is fully installed (seated in bottom of Well).

Failure to properly install Limit Sensor may result in property damage, personal injury or loss of life due to elevated operating temperatures and/or pressures.

This boiler is suitable for installation on combustible ooring. DO NOT install boiler on carpeting.

DO NOT tamper with or alter the boiler or controls.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has

accumulated. When cleaning this boiler, DO NOT damage combustion chamber liner and/or rear target wall. If damaged,

combustion chamber insulation must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated. DO NOT operate boiler with jumpered or absent controls or safety devices.

DO NOT operate boiler if any control, switch, component, or device has been subject to water.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the boiler.

WARNING

This boiler contains very hot water under high pressure. DO NOT unscrew any pipe ttings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. DO NOT rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. DO NOT touch any components unless they are cool.

High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless heater for domestic water supply, a ow regulator and automatic mixing valve must be installed properly

in tankless heater piping. See Piping and Trim Sections of this manual for details. This boiler must be properly vented and connected to an approved vent system in good condition. DO

NOT operate boiler with the absence of an approved vent system.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

A clean and unobstructed chimney ue is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler is designed to burn No. 2 fuel oil only. DO NOT use gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. DO NOT convert to any solid fuel (i.e. wood, coal). DO NOT convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and

free of re hazards.

All boilers equipped with burner swing door have a potential hazard which if ignored can cause severe

property damage, personal injury or loss of life. Before opening swing door, turn off service switch to

boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing

door fastener completely when service is completed.

I. Product Description, Specication &

Dimensional Data ..................................... 5

II. Pre-Installation .........................................10

III. Knockdown Boiler Assembly ....................12

IV. Packaged Boiler Assembly .........................24

V. Water Boiler Piping & Trim ......................28

VI. Steam Boiler Piping & Trim ......................32

VII. Tankless & Indirect Water Heater Piping ..34

VIII. Venting & Air Intake Piping .....................37

IX. Electrical ...................................................40

X. Oil Piping .................................................49

TABLE OF CONTENTS

XI. System Start-Up ........................................51

XII. Operating ..................................................59

XIII. Maintenance & Service Instructions .........65

XIV. Boiler Cleaning .........................................69

XV. Troubleshooting ........................................71

XVI. Repair Parts ...............................................74

XVII. Burner Specications ................................88

Appendix A - Low Water Cut O ..............89

Appendix B - Figures .................................91

Appendix C - Tables ..................................93

SECTION I: PRODUCT DESCRIPTION, SPECIFICATION

AND DIMENSIONAL DATA

The V8H Series boiler is a cast iron oil-red water boiler designed for closed forced circulation heating systems or a low pressure steam boiler designed for use in closed heating steam systems. This boiler must be vented by natural draft into a 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 UL03. An adequate supply of air for combustion, ventilation and dilution of ue gases must be available in the boiler room.

Water Boilers

The V8H Series water boiler uses an Intelligent Oil

Boiler Control (boiler control). The boiler control replaces the traditional electronic aquastat and

circulator relays and adds energy saving thermal purge features. Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler. A Warm Start Intelligent Oil Boiler Control (Warm Start Boiler Control) is included with a tankless heater option to generate domestic hot water.

Steam Boilers

The V8H Series steam boiler uses a L404F Pressure

Limit and Low Water Cut-off. This boiler has indirect domestic water heater connections to generate domestic hot water. Optionally, this boiler may include a L4006 Temperature Limit and a tankless heater to generate domestic hot water.

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

Heat Transfer

Dimensions

Boiler Model

No.

V8H3 17-1/8" 9-1/8" 6" 10.3 12.8 15.88 542 V8H4 22-1/8" 11-5/8" 6" 12.4 15.7 22.92 634 V8H5 27-1/8" 14-1/8" 7" 14.6 18.5 29.96 726 V8H6 32-1/8" 16-5/8" 7" 16.7 21.4 37.00 818 V8H7 37-1/8" 19-1/8" 8" 18.8 24.2 44.04 910 V8H8 42-1/8" 21-5/8" 8" 20.9 27.1 51.08 1002 V8H9 47-1/8" 24-1/8" 8" 23.0 30.0 58.12 1094 NOTE: 1 Maximum working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped From Factory (Std.),

40 PSI Optional, 50 PSI Optional

See Figures 1A thru 1D

"A" "B" "C" Steam Boiler

Water Content - Gallons

Water Boiler

Surface Area -

Sq. Ft.

Water Boiler

Steam

Boiler

Approximate

Shipping Weight

(LB.)

TABLE 1B: RATING DATA

Boiler

Model No.

V8H3S 0.75 1.05 91 68 283 85.1 6 8 x 8 15

V8H3W 1.05 147 125 109 85.0 6 8 x 8 15

V8H4S 1.05 147 127 95 396 85.3 6 8 x 8 15

V8H4W 1.35 189 162 141 85.3 7 8 x 8 15

V8H5S 1.35 189 164 123 512 85.4 7 8 x 8 15

V8H5W 1.65 231 198 172 85.3 7 8 x 8 15

V8H6S 1.65 231 201 151 629 85.7 7 8 x 8 15

V8H6W 1.90 266 228 198 85.3 8 8 x 8 15

V8H7S

V8H7W

V8H8S 2.35 329 266 200 833 (81.4) 8 8 x 12 15

V8H8W 2.35 329 275 239 (82.0) 8 8 x 12 15

V8H9S 2.60 364 298 224 933 (82.3) 9 8 x 12 15

V8H9W 2.60 364 299 260 (82.3) 9 8 x 12 15

* Boiler Model Sufx: S=Steam, W=Water

Burner Capacity I=B=R NET Ratings

GPH MBH

2.10 294 252 219 189 787 84.7 85.0 8 8 x 8 15

DOE Heating

Capacity MBH

Water

MBH

Steam

MBH

Steam Sq. Ft.

AFUE %

(Thermal Effy.)

Steam Water

Minimum Chimney

Requirements

Round

In. Dia.

Rectangle

In. x In.

Height

Ft.

SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

Figure 1A: V8H3 thru V8H9 Water Boiler without Tankless Heater

SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

Figure 1B: V8H3 thru V8H9 Water Boiler with Front Tankless Heater

SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

Figure 1C: V8H3 thru V8H9 Water Boiler with Rear Tankless Heater

SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

Figure 1D: V8H3 thru V8H9 Steam Boiler with or without Tankless Heater

SECTION II: 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 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 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 oor is

not level, or if water may be encountered on 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 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 ueways.

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

NOTICE

Clearance to venting is for single wall vent pipe. If Type L vent is used, clearance may be

reduced to the minimum required by the vent pipe

manufacturer.

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. V8H 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.

SECTION II: PRE-INSTALLATION (continued)

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and should

be referenced.

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion and to maintain safe ambient air temperatures.

DO NOT install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored.

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(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 unconned space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a conned space.

4. For boiler located in an unconned space of a

conventionally constructed building, the fresh

air inltration through cracks around windows and doors normally provides adequate air for combustion and ventilation.

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

a. Outdoor air for combustion may be provided

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

with an optional U.S. Boiler Company V8H™ Fresh Air Accessory Kit (ONLY AVAILABLE

ON BECKETT BURNERS WITH PLASTIC COVER APPLICATION, P/N 102119-01).

Refer to Fresh Air Accessory Kit Instructions for installation and air intake piping details.

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

conned space. Use indoor air if two

permanent openings communicate directly with additional space(s) of sufcient volume such that combined volume of all spaces meet criteria for uncon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 xed in the open

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

SECTION III: 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 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 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.

WARNING

Assure that there is not air left inside boiler when checking for leaks. DO NOT test for leaks with pressurized air.

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 ue plate or sealing rope is damaged, repair or replace as needed.

CAUTION

DO NOT allow any ueway blockage by gasket.

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

NOTICE

Jacket support bracket must be facing left side of

boiler - see Figure 4. Jacket will not t if bracket

is not oriented correctly.

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

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

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

PURPOSE OF TAPPINGS

Tapping

Location

Size NPT

Non-Heater w/Heater Non-Heater

A ¾"

B ¼" Pressure Gauge Temperature/Pressure Gauge

C ¾"

C-C ¾" Flush Plug Flush Plug N/A

D ½"

F ¾" N/A L4006A Operating Control N/A N/A

G 1½" Bushed to ¾" for Drain Valve (Optional Return) Return H 1½" Return Plugged J 1½" Surface Blowoff - Plugged Flush Plug K 2" Front Supply (3 thru 9 Section) Front Supply (3 thru 9 Section)

L 2"

M ¾" Safety Valve Relief Valve

P ¾" Auxiliary Tapping - Plugged

Water Gauge Glass, Pressuretrol, and LWCO (Float)

Water Gauge Glass (Probe LWCO)

Plugged, Optional Second Supply (3 thru 5 Section)

Required Second Supply (6 thru 9 Section)

Steam Boiler Water Boiler

Pressure Limit (Probe LWCO)

Plugged (Float LWCO)

Probe LWCO Std.

Plugged (Float LWCO)

L7248

Boiler Control

Plugged (3 thru 9 Section)

Aux. Tapping -

Plugged

Front Heater

L7224

Boiler Control

N/A

Rear Heater

Flush Plug

L7224

Boiler Control

Aux. Tapping -

Plugged

R ¾"

S ½" Indirect Limit

T 1" Indirect Supply

Aux. Tapping - Plugged

(Indirect Return)

* In lieu of Tankless Heater

Aux. Tapping - Plugged

(Indirect Return)

Indirect Limit

Indirect Supply

Auxiliary Tapping - Plugged

N/A

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

Figure 6: Knockdown Boiler Jacket Assembly

H. INSTALL 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 V8H3

thru V8H5, 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 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 (see Figure 7). 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.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

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 101265-01). 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 eld service (refer to Figures 13A and 13B):

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 13A), 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" ange nut and at washer) rst, then install left side hinge hardware (5/16" x 3-1/2" lg. hex head ange

bolt) second. Apply additional pressure while hand tightening the hardware as far as possible,

then release the pressure.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

NOTICE

When securing burner swing door make sure door

is drawn-in equally on both sides.

Step 3. Use a hand wrench to tighten door hardware

and always start with the right side ange nut rst (see Figure 13B). Use an alternating

tightening method from right side ange nut to left side ange bolt to tighten door equally until sealed without applying excessive torque. Never tighten left side ange bolt 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 ange bolt is tightened before right side ange nut, right side of door can not be drawn-in to provide an air tight seal, as shown in Figure 13C. Applying excessive torque will only cause thread damage.

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

CAUTION

DO NOT install burner without gasket.

6. Back out (4) 5/16”-18 x 3/4” long cap screws factory installed into burner swing door about 1/4". Insert oil burner into the opening of the burner door, rotate slightly clockwise to align burner mounting ange teardrop cutouts with cap screw hex heads and engage all four cap screws simultaneously. Then, rotate the burner slightly counterclockwise, level it and fully tighten all four cap screws.

7. Inspect electrodes, head setting and factory installed oil nozzle.

NOTICE

The burner for knockdown boilers has a preinstalled nozzle for steam applications. For water boiler applications, refer to Paragraph 8 in this Section for installation instructions to change nozzles.

a. Remove burner cover.

b. Loosen two (2) igniter latching screws, rotate

tabs and swing open igniter about hinge.

c. Loosen knurled nut and disconnect copper

connector tube.

d. Remove nozzle line electrode assembly.

e. Remove Beckett MD(V1) or MB(L1) Head.

f. Inspect and measure burner electrodes. Refer

to Figure 29A for the proper electrode setting. Readjust electrode setting to the proper

dimensions if necessary.

g. Reinstall Beckett MD(V1) or MB(L1) Head.

h. Reinstall nozzle line electrode assembly.

i. Connect copper connector tube.

j. 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.

k. Tighten knurled nut.

l. Swing igniter closed, rotate tabs and tighten two

(2) igniter screws.

m. Replace burner cover and tighten burner cover

knobs.

8. For water boiler applications, refer to Table 12 at the rear of this manual for proper nozzle and burner

settings.

a. Remove nozzle for water application attached to

copper connector tube.

b. Loosen two (2) igniter latching screws, rotate

tabs and swing open igniter about hinge.

c. Loosen knurled nut and disconnect copper

connector tube.

d. For V8H3, remove the Low re Bafe.

e. Remove nozzle line electrode assembly.

f. Remove Beckett MD(V1) or MB(L1) Head.

g Remove nozzle for steam application from

nozzle adapter and install the water application nozzle provided in Step 8a above. Refer to Burner Specications, Table 12 at the rear of this manual for proper nozzle and burner settings. 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 29A 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. Connect the ared tting

on the copper oil line to the nozzle line and

tighten.

n. Swing igniter closed, rotate tabs and tighten two

(2) igniter screws.

K. INSTALL CARLIN ELITE EZ OIL BURNER, 3 thru 6 Section (See Figure 7).

Follow instructions in Paragraph J, Steps 1 through 6.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

7. Inspect oil nozzle, electrodes and head setting.

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 ared 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.

Inspect the nozzle for size and type. See

Burner Specications, Table 12 at the rear of

this manual.

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 specied as

follows and shown in Figure 29B. 1/8-inch gap, 1/4 to 5/16-inch above the nozzle centerline, and ush to 1/16-inch ahead of the nozzle tip.

vi. Re-install the combustion head assembly

holding it upside down while inserting into the housing. The 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 7b below, run the thumbnut onto the nozzle line and tighten it lightly. Connect the ared tting on the copper oil line to the nozzle line and tighten.

b. Combustion Head Positioning Bars

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

supplied with the proper positioning bar installed onto the housing that matches the input oil nozzle installed in the burner. Verify that the installed positioning bar matches the input oil nozzle installed in the burner, refer to Table 12 at the rear of this

manual.

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

speci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 nal adjustment, using combustion testing equipment, the air band may need minor adjustment to achieve the desired efciency.

L. INSTALL CARLIN 102CRD OIL BURNER, 7 thru 9 Section (See Figure 7).

Follow instructions in Paragraph J, Steps 1 through 6.

7. Inspect electrodes, head setting and factory installed oil nozzle.

a. Installation/Removal of Drawer Assembly

i. Loosen screws, rotate latches and swing

open the transformer.

Disconnect the ared tting to the oil

line and remove the aluminum thumbnut 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 Section XVII Burner Specications, Table 12 at the rear of this

manual.

ii. Check the electrode settings specied as

follows and shown in Figure 29C. 1/8-inch gap, 1/4-inch above the nozzle centerline, and 3/16-inch ahead of the nozzle tip.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

iii. 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.

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

the nozzle line and tighten hand-tight.

v. Connect the ared tting on the copper oil

line to the nozzle line and tighten.

vi. 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 12 at the rear of this manual. Read the scale embossed in the housing, which is calibrated in 1/16-inch divisions (dimension ‘A’) the position of the ame retention ring in relation to the air cone can be determined at a glance. Refer to Figure 7A.

ii. By moving the electrode and combustion

head assembly forward or backward, the location of the 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 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, 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 tighten screw to lock in place after nal adjustment. Refer to Table 12 at the rear of this manual

for initial settings.

iii. The burner is now set at the approximate

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

M. INSTALL RIELLO OIL BURNER. (See Figure 7).

Follow instructions in Paragraph J, Steps 1 through 6.

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

a. Installation/Removal of Drawer assembly, refer

to Figure 7B.

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.

Figure 7A: Combustion Head Adjustment -

102CRD Burner

Figure 7B: Installation/Removal of

Riello Drawer Assembly

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

If nozzle needs replacement, follow steps below

Also refer to Figure 7C.

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 29D for the proper electrode settings.

Figure 7C: Riello Nozzle Replacement

Figure 7D: Riello Turbulator Setting

• 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. Check factory installed oil nozzle for size and

type. Refer to Burner Specications, Table 12 at

the rear of this manual for details.

d. Re-install Drawer Assembly into Combustion

Head per Step 7a above.

e. Insertion Depth, verify the distance between

the tip of the end cone is equal to the distance specied in Table 12 at the rear of this manual.

f. Turbulator Setting, refer to Figure 7D.

i. Conrm the turbulator setting is correct

for input oil nozzle installed in the burner, readjust, if needed, to index mark specied in Table 12 at the rear 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 12 at the rear of this manual).

iii. Retighten the retaining nut (1).

MODEL F5 (3 thru 5 Section): Zero and four

are scale indicators only. From left to right the rst line is 4 and the last line 0.

MODEL F10 (6 thru 9 Section): Same as above,

except, scale indicators are 0 and 5.

g.. Pump Connections and Port Identi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.

Figure 7E: Riello Pump Connections and Port Identication

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

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.

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.

N. INSTALL TRIM AND CONTROLS WITH

BECKETT BURNER. - Water Boilers Only

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

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

(See

CAUTION

DO NOT apply pressure to the gauge case - this may result in inaccurate readings.

2. Lower front section tapping “G” is used for standard return on water boilers, see Figure 5. If circulator (supplied with boiler) is to be mounted in return piping connected directly to 1½" NPT boiler return tapping "G", use the piping arrangements outlined in steps a. thru e. as follows: (see Figures 15A and 15B)

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.

b. Screw drain valve into ¾" NPT side outlet of the

1½” NPT x 90° elbow.

c. Thread 1½” NPT x 18” long nipple (supplied

by others) into the 1½" NPT x 90° elbow and tighten with a pipe wrench.

d. Thread one of the circulator ange onto the

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

e. Place a circular ange gasket in the ange

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

f. Fasten the second circulator ange and gasket to

the circulator.

g. Remove supplied circulator harness from Part

Bag. Remove circulator junction box cover and knockout in circulator junction box ange. Insert harness end with two wires having bare-stripped ends through knockout hole and push-in to engage harness connector into ange. Connect harness conductors to circulator junction box wires as follows - White to White and Blue to Yellow (or, Blue) and secure with wire nuts (installer provided).

3. 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 15A and 15B. Installation of the relief valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

WARNING

Safety valve discharge piping must be piped near oor to eliminate potential of severe burns. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps.

4. On boilers without a heater opening, install the well into the 3/4” NPT tapping “A” located on the front of the boiler in the upper left corner. See Figures 1A and 5. Tighten the well and fully insert limit sensor into immersion well such that the tip on the limit sensor touches the bottom of the immersion well. See Figure 8. Secure control to immersion well with setscrew.

WARNING

Aquastat bulb must be fully inserted into the

well.

5. On boilers with a heater opening, install the well in either the 1/2” NPT or 3/4” NPT tapping on the tankless heater plate or cover plate. See Figures 1B, 1C and 5. Tighten the well and fully insert limit sensor into immersion well such that the tip on the limit sensor probe touches the bottom of the immersion well. See Figure 8. Secure control to immersion well with setscrew.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

Figure 8: Limit Sensor Insertion

6. After control is installed and secured, remove control cover. Then, remove knockout located directly above factory connected limit harness on right side ange of control. Insert circulator harness end with attached fork terminals thru knockout hole and push-in to engage harness connector into ange. Connect wires to control terminals as follows - Blue to C1 and White to C2 and tighten securely. Reinstall control cover.

7. Connect Field Wiring.

a. Water boilers without tankless heater. Connect

the eld wiring to the aquastat control. Make the wiring connections as shown on Figure 21A.

b. Water boilers with front or rear tankless heater.

Connect the eld wiring to the aquastat control. Make the wiring connections as shown on Figure

21B.

c. Refer to Paragraph R for details on use of

burner disconnect junction box provided with all knockdown boiler builds.

O. 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.

CAUTION

DO NOT apply pressure to the gauge case - this may result in inaccurate readings.

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.

NOTICE

Lower rear section Tapping "H" is used for standard condensate return on steam boilers.

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

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

WARNING

Safety valve discharge piping must be piped near oor to eliminate potential of severe burns. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps.

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

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.

WARNING

Read the manufacturer's instructions packed with the probe LWCO for proper pipe dope application. DO NOT use Teon tape on probe threads. Use of

teon can render the probe LWCO inoperational.

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

tappings to the right of the probe LWCO.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

Figure 9: Float-Type Low Water Cut-Off and

Pressure Limit Installation

5. Install oat-type LWCO, if so equipped. See Figures 5 and 9.

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 ttings.

6. Install Pressure Limit Control. a. Float LWCO only: Remove ¼" NPT plug from

top of Low Water Cut-Off. Install Syphon and Limit into this tapping. See Figure 9.

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 Figures 5 and 10.

c. DO NOT tighten the limit by holding the case;

apply a wrench to the brass hex below the case.

d. An L404F pressure limit does not require

leveling.

7. Connect the eld wiring to the LWCO or the R8239A Control Center/J-box, or burner disconnect J-box. a. If equipped with tankless heater, connect 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

appropriate wiring diagram, refer to Figure 22,

23A, 23B, 24A or 24B.

Note: DO NOT remove "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.

Also refer to Section XI, Paragraph I, Item 2,

"Verify Oil Primary Control" for more details.

Figure 10: Pressure Limit Installation for Probe

LWCO Equipped Boilers

b. Refer to Paragraph R for details on use of

burner disconnect junction box provided with all knockdown boiler builds.

P. INSTALL TRIM AND CONTROLS WITH

CARLIN BURNERS.

Water boilers Only (see Figures 1A, 1B, 1C and 5).

Follow instructions in Paragraph N, Steps 1 through 7.

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

Follow instructions in Paragraph O, Steps 1 through 6.

7. Connect Field Wiring

a. Steam Boiler with Hydrolevel CG450 LWCO,

Carlin Burner.

Connect the eld wiring to the R8239A Control

Center. If equipped with tankless heater, connect eld wiring from the aquastat control to the R8239A Control Center’s “R-G” terminals. Make the wiring connections as shown in Figure 22.

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

Carlin Burner.

Connect the eld wiring to the LWCO or the

burner disconnect J-box. If equipped with tankless heater, connect eld wiring from the aquastat control to the oil burner primary control’s “T-T” Terminals. Make the wiring connections as shown in appropriate wiring diagram, refer to Figure 23A, 23B, 24A or 24B.

Note: DO NOT remove "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.

Also refer to Section XI, Paragraph I, Item 2,

"Verify Oil Primary Control" for more details.

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

c. Refer to Paragraph R for details on use of

burner disconnect junction box provided with all knockdown boiler builds.

Q. INSTALL TRIM AND CONTROLS WITH

RIELLO BURNER.

Water Boilers Only (see Figures 1A, 1B, 1C and 5).

Follow instructions in Paragraph N, Steps 1 through 7.

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

Follow instructions in Paragraph O, Steps 1 through 6.

7. Connect Field Wiring

a. Steam boiler with Hydrolevel CG450,

McDonnell & Miller PS-801 or McDonnell & Miller 67 LWCO, Riello Burner.

Connect the eld wiring to the R8239A Control

Center. If equipped with tankless heater, connect eld wiring from the aquastat control to the R8239A Control Center’s “R-G” terminals.

Make the wiring connections as shown in appropriate wiring diagram, refer to Figure 22,

23A, 23B, 24A or 24B.

Note: DO NOT remove "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.

Also refer to Section XI, Paragraph I, Item 2,

"Verify Oil Primary Control" for more details.

b. Refer to Paragraph R for details on use of

burner disconnect junction box provided with all knockdown boiler builds.

R. BURNERS SUPPLIED BY U.S. BOILER

COMPANY 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.

Figure 11: Burner Disconnect Junction Box with Power Outlet Receptacle

(Mated to Burners with Disconnect Harness)

SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

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 11.

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 eld wiring phase of Paragraphs N & O (Beckett), P (Carlin) or Q (Riello) Install end of harness from low water cut-off (LWCO), R8239A

Control Center or Boiler Control into appropriate

knockout of burner disconnect junction box

SECTION IV: 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 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 12. Remove all bolts.

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 oor. Tilt boiler and remove crate skid. Care should be exercised to prevent damage to jacket or burner.

Figure 12 : Packaged Boiler Removal from Skid

according to source, refer to Figures 1A thru 1D.

4. Connect (3) wires from boiler control LWCO or R8239A Control Center to spade terminals on rear of power outlet receptacle. Make the connections as shown in appropriate wiring diagram based on boiler conguration, refer to Figures 21A thru 25.

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.

CAUTION

DO NOT drop boiler. DO NOT bump boiler jacket

against oor.

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 eld service.

1. TO OPEN BURNER SWING DOOR (see Figures 13A and 13B).

Step 1. Loosen and remove right side latching

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

Step 2. Loosen and remove left side hinge hardware

(5/16" x 3-1/2" lg. hex head 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 ange, pull outward to rotate the hinge, this motion will move the door outward and to the left approximately 3" (see Figure 13B, Position 2).

SECTION IV: PACKAGED BOILER ASSEMBLY (continued)

Figure 13A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured

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 13B, Position 3).

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

3. To close Burner Swing Door (see Figures 13A and 13B):

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 13B, Position 2.

Step 2. Grasp the door's left side hinge 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 13A), 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" ange nut and at washer) rst, then

install left side hinge hardware (5/16" x 3-1/2"

lg. hex head ange bolt) second. Apply

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

pressure.

When securing burner swing door make sure door

is drawn-in equally on both sides.

Step 4. Use a hand wrench to tighten door hardware

and always start with the right side ange nut rst. Use an alternating tightening method

from right side ange nut to left side ange

bolt to tighten door equally until sealed without applying excessive torque. Never tighten left side ange bolt rst or tighten either piece of hardware 100% without using the alternating tightening method described above.

Failure to follow the prescribed procedure could

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 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.

NOTICE

SECTION IV: PACKAGED BOILER ASSEMBLY (continued)

Figure 13B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)

SECTION IV: PACKAGED BOILER ASSEMBLY (continued)

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. INSTALL BECKETT OIL BURNER. Refer

to Section III, Paragraph J for burner installation

instructions.

NOTICE

The burner for packaged boilers has a pre-installed nozzle for steam applications. For water boiler applications, refer to Section III, Paragraph J, No. 8, steps ‘a’ through ‘m’ for nozzle installation, electrode and head setting inspection.

G. INSTALL CARLIN ELITE EZ OIL BURNER,

2 THRU 6 SECTION. Refer to Section III, Paragraph

K for installation instructions.

H. INSTALL CARLIN 102CRD OIL BURNER, 7

THRU 9 SECTION. Refer to Section III, Paragraph L

for installation instructions.

I. INSTALL RIELLO OIL BURNER. Refer to Section

III, Paragraph M for installation instructions.

J. INSTALL SAFETY OR RELIEF VALVE IN

TAPPING "M", see Figure 5.

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 15A and 15B. Installation of the safety or relief valve must be consistent with ANSI/ASME Boiler and Pressure

Vessel Code, Section IV.

WARNING

Safety valve discharge piping must be piped near oor to eliminate potential of severe burns. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps.

K. PACKAGED STEAM 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 Figures

5 and 10.

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. An L404F pressure limit does not require leveling.

L. PACKAGED WATER BOILERS WITH

CIRCULATORS. If your boiler build comes with

factory supplied circulator and circulator is to be mounted in return piping connected directly to 1½" boiler return tapping "G", use piping and wiring arrangements outlined in Section III: Knockdown Boiler Assembly, Paragraph N, Step 2.

Figure 13C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed

SECTION V: WATER BOILER PIPING AND TRIM

NOTICE

Failure to pipe boiler as specied in this manual may result in excessive system noise, water line uctuations

and water carry over.

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 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 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.

WARNING

System supply and return piping must be connected to correct boiler pipe.

U.S. Boiler Company recommends sizing the

system circulator to supply sufcient ow

(GPM) to allow a 20°F temperature differential in the system. When sizing the system circulator, the pressure drop of all radiators, baseboard and radiant tubing and all connecting piping must be considered.

B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO BOILER. See Figures 15A and 15B.

Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

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

14. Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

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 ow control valves to prevent gravity circulation of boiler water during the operation of the cooling system.

3. If boiler is used with an Indirect Domestic Water Heater, install the Indirect Water Heater as a separate heating zone. Refer to the Indirect Water Heater 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 15A and 15B in order to regulate water ow for maintenance of higher boiler water temperature.

WARNING

The use of a low water cut-off device, while not

required unless radiation level is below the boiler,

is highly recommended.

CAUTION

Maintain minimum ½ inch clearance from hot water piping to combustible materials.

5. If a Low Water Cut-Off (LWCO) 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. Refer to Appendix A at the

rear of this manual.

SECTION V: WATER BOILER PIPING AND TRIM (continued)

6. If it is required to perform a long term pressure

test of the hydronic system, the boiler should rst

be isolated to avoid a pressure loss due to the escape of air trapped must rst be removed from the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must 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 14: Recommended Piping for Combination Heating and Cooling (Refrigeration) System

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