U.S. Boiler Company V8H SERIES Service manual

103869-02 - 10/12
As an
ENERGY
STAR®Partner,
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).
Price - $5.00
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2
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.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
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
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:
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.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
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.

3
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.

4
TABLE OF CONTENTS
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
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
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.

5
TABLE 1A: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1D)
TABLE 1B: RATING DATA
Boiler Model
No.
Dimensions
See Figures 1A thru 1D
Water Content - Gallons
Heat Transfer
Surface Area -
Sq. Ft. Approximate
Shipping Weight
(LB.)
"A" "B" "C" Steam Boiler Water
Boiler Water
Boiler
Steam
Boiler
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
Boiler
Model No.
*
Burner Capacity I=B=R NET Ratings AFUE %
(Thermal Effy.)
Minimum Chimney
Requirements
GPH MBH DOE Heating
Capacity MBH
Water
MBH
Steam
MBH
Steam
Sq. Ft. Steam Water Round In. Dia.
Rectangle
In. x In.
Height
Ft.
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 2.10 294 252 219 189 787 84.7 85.0 8 8 x 8 15
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
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.

6
Figure 1A: V8H3 thru V8H9 Water Boiler without Tankless Heater
SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

7
Figure 1B: V8H3 thru V8H9 Water Boiler with Front Tankless Heater
SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

8
Figure 1C: V8H3 thru V8H9 Water Boiler with Rear Tankless Heater
SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

9
Figure 1D: V8H3 thru V8H9 Steam Boiler with or without Tankless Heater
SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA (continued)

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 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.
SECTION II: PRE-INSTALLATION
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.

11
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(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 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
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.
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
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 II: PRE-INSTALLATION (continued)

12
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.
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.
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.
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.

13
Figure 5: Boiler Tapping Locations and Usage (Knockdown Boilers Only)
PURPOSE OF TAPPINGS
Tapping
Location
Size
NPT
Steam Boiler Water Boiler
Non-Heater w/Heater Non-Heater Front Heater Rear Heater
A ¾" Pressure Limit (Probe LWCO)
Plugged (Float LWCO)
L7248
Boiler Control
L7224
Boiler Control Flush Plug
B ¼" Pressure Gauge Temperature/Pressure Gauge
C ¾" Probe LWCO Std.
Plugged (Float LWCO) N/A
C-C ¾" Flush Plug Flush Plug N/A
D ½" Water Gauge Glass (Probe LWCO)
Water Gauge Glass, Pressuretrol, and LWCO (Float) N/A
F ¾" N/A L4006A Operating Control N/A N/A L7224
Boiler Control
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" Plugged, Optional Second Supply (3 thru 5 Section)
Required Second Supply (6 thru 9 Section) Plugged (3 thru 9 Section)
M ¾" Safety Valve Relief Valve
P ¾" Auxiliary Tapping - Plugged Aux. Tapping -
Plugged N/A Aux. Tapping - Plugged
R ¾" Aux. Tapping - Plugged
(Indirect Return)
Aux. Tapping - Plugged
(Indirect Return) *Auxiliary Tapping - Plugged
S ½" Indirect Limit Indirect Limit *N/A
T 1" Indirect Supply Indirect Supply *N/A
*In lieu of Tankless Heater
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

14
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)

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 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.
Figure 7: Oil Burner Installation (Beckett Burner Shown)
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

16
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 pre-
installed 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)

17
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 thumb-
nut 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 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 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)

18
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 7B: Installation/Removal of
Riello Drawer Assembly
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)
Figure 7A: Combustion Head Adjustment -
102CRD Burner

19
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.
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 7C: Riello Nozzle Replacement
Figure 7D: Riello Turbulator Setting
Figure 7E: Riello Pump Connections and Port Identication
• 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.
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

20
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 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 (See
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.
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)