Burnham V8 Series Installation and maintenance instructions

8
8142824R10.5-4/07
As an
ENERGY
STAR®Partner,
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).
Price - $3.00
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2
IMPORTANT INFORMATION - READ CAREFULLY
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.
All boilers must be installed in accordance with National, State and Local Plumbing, Heating
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
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
may differ from this instruction manual. Authorities having jurisdiction should be consulted
before installations are made.
before installations are made.
In all cases, reference should be made to the following Standards:
In all cases, reference should be made to the following Standards:
USA BOILERS
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
A. Current Edition of American National Standard ANSI/NFPA31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
Burning Equipment”, for recommended installation practices.
B. Current Edition ofAmerican National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices forAutomatically Fired Boilers”, for assembly and operations of controls
Safety Devices forAutomatically Fired Boilers”, for assembly and operations of controls
and safety devices.
and safety devices.
D. All wiring on boilers installed in the USA shall be made in accordance with the National
D. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
Burning Equipment", for recommended Installation Practices.
B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
Electrical Code and/or Local Regulations.
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3
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4
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TABLE OF CONTENTS
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
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

5
TABLE 1A: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1D)
TABLE 1B: RATING DATA
Boiler
Boiler
Model No.
Model No.
Dimensions
Dimensions
See Figures 1A - 1D
See Figures 1A - 1D
Water Content - Gallons
Water Content - Gallons
Heat Transfer
Heat Transfer
Surface Area
Surface Area
- Sq. Ft.
- Sq. Ft.
Approximate
Approximate
Shipping Weight
Shipping Weight
(LB.)
(LB.)
"A"
"A"
"B"
"B"
"C"
"C"
Steam
Steam
Boiler
Boiler
Water
Water
Boiler
Boiler
Steam Boiler
Steam Boiler
V82
V82
12-1/8"
12-1/8"
6-5/8"
6-5/8"
5"
5"
10.0
10.0
450
450
V83
V83
17-1/8"
17-1/8"
9-1/8"
9-1/8"
6"
6"
10.3
10.3
12.8
12.8
15.88
15.88
542
542
V84
V84
22-1/8"
22-1/8"
11-5/8"
11-5/8"
6"
6"
12.4
12.4
15.7
15.7
22.92
22.92
634
634
V85
V85
27-1/8"
27-1/8"
14-1/8"
14-1/8"
7"
7"
14.6
14.6
18.5
18.5
29.96
29.96
726
726
V86
V86
32-1/8"
32-1/8"
16-5/8"
16-5/8"
7"
7"
16.7
16.7
21.4
21.4
37.00
37.00
818
818
V87
V87
37-1/8"
37-1/8"
19-1/8"
19-1/8"
8"
8"
18.8
18.8
24.2
24.2
44.04
44.04
910
910
V88
V88
42-1/8"
42-1/8"
21-5/8"
21-5/8"
8"
8"
20.9
20.9
27.1
27.1
51.08
51.08
1002
1002
V89
V89
47-1/8"
47-1/8"
24-1/8"
24-1/8"
8"
8"
23.0
23.0
30.0
30.0
58.12
58.12
1094
1094
NOTE: 1
NOTE: 1
The V82 Boiler is available as a packaged water boiler only.
The V82 Boiler is available as a packaged water boiler only.
2
2
Maximum working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped From Factory (Std.),
Maximum working Pressure: Steam: 15 PSI; Water: 30 PSI Shipped From Factory (Std.),
40 PSI Optional, 50 PSI Optional
40 PSI Optional, 50 PSI Optional
Boiler
Boiler
Model No.
Model No.
*
*
Burner Capacity
Burner Capacity
I=B=R NET Ratings
I=B=R NET Ratings
Minimum Chmney
Minimum Chmney
Requirements
Requirements
AFUE %
AFUE %
GPH
GPH
MBH
MBH
DOE Heating
DOE Heating
Capacity MBH
Capacity MBH
Water
Water
MBH
MBH
Steam
Steam
MBH
MBH
Steam
Steam
Sq. Ft.
Sq. Ft.
Round
Round
In. Dia.
In. Dia.
Rectangle
Rectangle
In. x In.
In. x In.
Height
Height
Ft.
Ft.
Steam
Steam
Water
Water
V82W
V82W
0.60
0.60
84
84
70
70
61
61
6
6
8 x 8
8 x 8
15
15
82.1
82.1
V83W
V83W
1.05
1.05
147
147
123
123
107
107
6
6
8 x 8
8 x 8
15
15
82.6
82.6
V83S
V83S
V83WM
V83WM
0.75
0.75
105
105
91
91
79
79
68
68
283
283
6
6
8 x 8
8 x 8
15
15
85.1
85.1
86.0
86.0
V84W
V84W
1.35
1.35
189
189
159
159
138
138
7
7
8 x 8
8 x 8
15
15
83.2
83.2
V84S
V84S
V84WM
V84WM
1.05
1.05
147
147
127
127
110
110
95
95
396
396
6
6
8 x 8
8 x 8
15
15
85.3
85.3
86.1
86.1
V85W
V85W
1.65
1.65
231
231
196
196
170
170
7
7
8 x 8
8 x 8
15
15
83.9
83.9
V85S
V85S
V85WM
V85WM
1.35
1.35
189
189
164
164
143
143
123
123
512
512
7
7
8 x 8
8 x 8
15
15
85.4
85.4
86.2
86.2
V86W
V86W
1.90
1.90
266
266
227
227
197
197
8
8
8 x 8
8 x 8
15
15
84.6
84.6
V86S
V86S
V86WM
V86WM
1.65
1.65
231
231
201
201
175
175
151
151
629
629
7
7
8 x 8
8 x 8
15
15
85.7
85.7
86.3
86.3
V87S
V87S
V87W
V87W
2.10
2.10
294
294
252
252
219
219
189
189
787
787
8
8
8 x 8
8 x 8
15
15
84.7
84.7
85.0
85.0
V88S
V88S
2.35
2.35
329
329
266
266
200
200
833
833
8
8
8 x 12
8 x 12
15
15
V88W
V88W
2.35
2.35
329
329
275
275
239
239
8
8
8 x 12
8 x 12
15
15
V89S
V89S
2.60
2.60
364
364
298
298
224
224
933
933
9
9
8 x 12
8 x 12
15
15
V89W
V89W
2.60
2.60
364
364
299
299
260
260
9
9
8 x 12
8 x 12
15
15
*
*
Boiler Model Suffix: S=Steam at standard rate, W=Water, WM=Water at minimum rate
Boiler Model Suffix: S=Steam at standard rate, W=Water, WM=Water at minimum rate

6
Figure 1A: V82 thru V89 Water Boiler without Tankless Heater

7
Figure 1B: V83 thru V89 Water Boiler with Front Tankless Heater

8
Figure 1C: V83 thru V89 Water Boiler with Rear Tankless Heater

9
Figure 1D: V83 thru V89 Steam Boiler with or without Tankless Heater

10
Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)
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 filed 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 final 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 floor is
not level, or if water may be encountered on floor
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
flueways 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 flueways.
5. For minimum clearances to combustible materials.
See Figure 2.
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SECTION I: PRE-INSTALLATION
NOTES:
1. Listed clearances comply with American
National Standard ANSI/NFPA 31, Installation of
Oil Burning Equipment.
2. V8 Series boilers can be installed in rooms with
clearances from combustible material as listed
above. Listed clearances cannot be reduced for
alcove or closet installations.
3. For reduced clearances to combustible material,
protection must be provided as described in the
above ANSI/NFPA 31 standard.

11
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 unconfined space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a confined space.
4. For boiler located in an unconfined space of a
conventionally constructed building, the fresh
air infiltration through cracks around windows
and doors normally provides adequate air for
combustion and ventilation.
5. For boiler located in a confined space or an
unconfined space in a building of unusually tight
construction, provide outdoor air.
a. Outdoor air for combustion may be provided
with an optional Burnham V8 InletAir
Accessory Kit, Part Number 611280031 (ONLY
AVAILABLE WITH BECKETT BURNER).
See Section VII for installation details.
or
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
confined space. Use indoor air if two
permanent openings communicate directly
with additional space(s) of sufficient volume
such that combined volume of all spaces
meet criteria for unconfined 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 fixed in the open
position, or interlocked with the equipment to
open automatically during equipment operation.

12
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 floor. 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 finger 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.
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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 flue plate or
sealing rope is damaged, repair or replace as needed.
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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3. Position canopy body within the retaining bar which
borders the flueway 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" flat washers and 1/4" - 20
wing nuts provided.

13
Figure 5: Boiler Tapping Locations and Usage (Knockdown Boilers Only)
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14
Figure 6: Knockdown Boiler Jacket Assembly
H. INSTALLTRIM. 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 flange 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.

15
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 field 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" flange nut and
flat washer) first, then install left side hinge
hardware (5/16" x 3-1/2" lg. hex head flange
bolt) second. Apply additional pressure while
hand tightening the hardware as far as possible,
then release the pressure.
Figure 7: Oil Burner Installation (Beckett Burner Shown)

16
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Step 3. Use a hand wrench to tighten door hardware
and always start with the right side flange
nut first (see figure 11B). Use an alternating
tightening method from right side flange nut
to left side flange bolt to tighten door equally
until sealed without applying excessive torque.
Never tighten left side flange bolt first 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.
NOITUAC
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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.
REGNAD
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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 efficiency
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 flat of the nozzle.
NOITUAC
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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.
e. Remove nozzle line electrode assembly.
f. Remove Beckett MD(V1) or MB(L1) Head.
g. Remove plug from nozzle adapter and install
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.
K. INSTALL CARLIN 102CRD OIL BURNER. (See
Figure 7).
Follow instructions in Paragraph J, Steps 1 through 6.
7. Install oil nozzle in burner, inspect electrodes and
head setting.
REGNAD
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Steam Boilers Only
Knockdown V87 - V89 boilers are provided with
one nozzle, installed in the burner, that provides
the same firing 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.

17
Disconnect the flared fitting 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 specified 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 flared fitting 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 flame 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 flame 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, first tighten the thumb-nut
and then the locking screw.
c. InitialAir 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 final 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 final adjustment, using combustion
testing equipment, the air band may need
minor adjustment to achieve the desired
efficiency.
Water Boilers Only
Knockdown V87 - V89 boilers are provided
with one nozzle, installed in the burner, that
provides the same firing 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
specified in Table 6 of this manual. The
nozzle input is stamped on the hex flat of the
nozzle.
Refer to Paragraph K, 7, a for burner drawer
assembly removal.
Figure 7A: Combustion Head Adjustment

18
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 firing rate.
REGNAD
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NOITUAC
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.reliobehthtiwdedivorp
Steam Boilers Only
Steam boilers must use the lower input nozzle.
The lower input nozzle will provide greater
boiler efficiency 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) firing rate
nozzle installed. Knockdown V87 - V89 boilers
are provided with one nozzle, installed in the
burner, that provides the same firing 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 flared fitting 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 specified as
follows and shown in Figure 27C. 1/8-inch
gap, 1/4 to 5/16-inch above the nozzle
centerline, and flush 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 flame 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 flared fitting 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
high (standard) input oil nozzle installed in
the burner. A second positioning bar and
nozzle for the lower (minimum) firing 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 firing 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 firing 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.

19
c. InitialAir 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
specific 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 final adjustment, using combustion
testing equipment, the air band may need
minor adjustment to achieve the desired
efficiency.
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)
firing 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 efficiency. However, boiler output will be
reduced. Refer to Table 1B for firing rates. If
the higher rate is desired, inspect the installed
nozzle and assure that the nozzle is the correct
size and type as specified in Table 6 of this
manual. The nozzle input is stamped on the hex
flat of the nozzle.
If the lower (minimum) input is desired, remove
the nozzle which was factory installed. Locate
the lower (minimum) firing rate nozzle that is
supplied loose. Confirm the nozzle is the proper
size and type for the lower firing rate as specified
in Table 6 of this manual. Install the proper
nozzle in the burner nozzle adaptor.
Refer to Step 7a for burner drawer assembly
removal.
M. INSTALL RIELLO OIL BURNER. (See Figure 7).
Follow instructions in Paragraph J, Steps 1 through 6.
7. Install oil nozzle in burner, inspect electrodes and
head setting.
REGNAD
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NOITUAC
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Steam Boilers Only
Steam boilers must use the lower input
nozzle. The lower input nozzle will provide
greater boiler efficiency 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)
firing rate nozzle installed. Knockdown
V87 - V89 boilers are provided with one
nozzle, installed in the burner, that provides
the same firing 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 iabove.
b. Nozzle Replacement, refer to Figure 7C.

20
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
specified in Table 6 of this manual.
f. Turbulator Setting, refer to Figure 7D.
i. Confirm 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 specified 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).
iii. Retighten the retaining nut (1).
MODEL F3 NOTE: Zero and three are scale
indicators only. From left to right the first 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 Identification,
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 two-
line system. Also supplied are twoADAPTORS
(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 7C: Nozzle Replacement
Figure 7D: Turbulator Setting
Figure 7E: Pump Connections and Port Identification