U.S. Boiler Company V8H5 Operating instructions

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
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United States Environmental
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Price - $5.00
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2
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition ofAmerican National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
C. Current Edition ofAmerican Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices forAutomatically 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.
Surfacerustoncastironsectionsmaybeattributedtothemanufacturingprocessaswellascondensation
during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

3
DANGER
DO NOTVWRUHRUXVHJDVROLQHRURWKHUÀDPPDEOHYDSRUVRUOLTXLGVLQWKHYLFLQLW\RIWKLVRUDQ\RWKHUERLOHU
WARNING
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,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
manualswhichareprovidedwiththeboilerbeforeinstalling,starting-up,operating,maintainingorservicing
this boiler. Keep this manual and literature in legible condition and posted near boiler for reference by
owner and service technician.
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in this manual.
Installation,maintenance,andservicemustbeperformedonlybyanexperienced,skilledandknowledgeable
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.
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DO NOT tamper with or alter the boiler or controls.
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accumulated.
Whencleaning thisboiler, DONOT damagecombustion chamberliner and/orrear targetwall. 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.
Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,
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
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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XQVFUHZDQ\SLSH¿WWLQJVQRUDWWHPSW
to disconnect any components of this boiler without positively assuring the water is cool and has no
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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.
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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.
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combustion and ventilation air.
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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FRQYHUWWRDQ\JDVHRXVIXHOLHQDWXUDOJDV/3$OOÀDPPDEOHGHEULVUDJV
paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and
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property damage, personal injury or loss of life. Before opening swing door, turn off service switch to
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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 68 x 8 15
V8H3W 1.05 147 125 109 85.0 68 x 8 15
V8H4S 1.05 147 127 95 396 85.3 68 x 8 15
V8H4W 1.35 189 162 141 85.3 78 x 8 15
V8H5S 1.35 189 164 123 512 85.4 78 x 8 15
V8H5W 1.65 231 198 172 85.3 78 x 8 15
V8H6S 1.65 231 201 151 629 85.7 78 x 8 15
V8H6W 1.90 266 228 198 85.3 88 x 8 15
V8H7S
V8H7W 2.10 294 252 219 189 787 84.7 85.0 88 x 8 15
V8H8S 2.35 329 266 200 833 (81.4) 88 x 12 15
V8H8W 2.35 329 275 239 (82.0) 88 x 12 15
V8H9S 2.60 364 298 224 933 (82.3) 98 x 12 15
V8H9W 2.60 364 299 260 (82.3) 98 x 12 15
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SECTION I: PRODUCT DESCRIPTION, SPECIFICATION
AND DIMENSIONAL DATA
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Water Boilers
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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FDUHIXOO\IRUDQ\VLJQVRI
damage.
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of goods.
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NOTICE
Clearance to venting is for single wall vent
pipe. If Type L vent is used, clearance may be
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manufacturer.
SECTION II: PRE-INSTALLATION
127(6
/LVWHGFOHDUDQFHVFRPSO\ZLWK$PHULFDQ
1DWLRQDO6WDQGDUG$16,1)3$,QVWDOODWLRQRI
2LO%XUQLQJ(TXLSPHQW
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FOHDUDQFHVIURPFRPEXVWLEOHPDWHULDODVOLVWHG
DERYH/LVWHGFOHDUDQFHVFDQQRWEHUHGXFHGIRU
DOFRYHRUFORVHWLQVWDOODWLRQV
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DERYH$16,1)3$VWDQGDUG

11
C. PROVIDE COMBUSTION AND VENTILATION
AIR./RFDODQG1DWLRQDO&RGHVPD\DSSO\DQGVKRXOG
EHUHIHUHQFHG
WARNING
$GHTXDWHFRPEXVWLRQDQGYHQWLODWLRQDLUPXVW
be provided to assure proper combustion and
to maintain safe ambient air temperatures.
DO NOT install boiler where gasoline or other
ÀDPPDEOH YDSRUV RU OLTXLGV RU VRXUFHV RI
hydrocarbons (i.e. bleaches, fabric softeners,
etc.) are used or stored.
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WKHDSSOLDQFHVDUHLQVWDOOHGWKURXJKRSHQLQJVQRW
IXUQLVKHGZLWKGRRUVDUHFRQVLGHUHGDSDUWRIWKH
VSDFH
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 $GGLQSXWVRIDOODSSOLDQFHVLQWKHVSDFHDQGURXQG
WKHUHVXOWWRWKHQHDUHVW%78SHUKRXU
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LQSXWRIDOODSSOLDQFHVLQVSDFH,IWKHUHVXOWLV
JUHDWHUWKDQRUHTXDOWRIW3%78SHUKRXU
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VSDFHLVFRQVLGHUHGDFRQ¿QHGVSDFH.
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FRQYHQWLRQDOO\FRQVWUXFWHGEXLOGLQJ, the fresh
DLULQ¿OWUDWLRQWKURXJKFUDFNVDURXQGZLQGRZV
DQGGRRUVQRUPDOO\SURYLGHVDGHTXDWHDLUIRU
FRPEXVWLRQDQGYHQWLODWLRQ
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XQFRQ¿QHGVSDFHLQDEXLOGLQJRIXQXVXDOO\WLJKW
FRQVWUXFWLRQSURYLGHRXWGRRUDLU
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ZLWKDQRSWLRQDO86%RLOHU&RPSDQ\9+
)UHVK$LU$FFHVVRU\.LW(ONLYAVAILABLE
ON BECKETT BURNERS WITH PLASTIC
COVER APPLICATION, P/N 102119-01).
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LQVWDOODWLRQDQGDLULQWDNHSLSLQJGHWDLOV 
or
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SHUPDQHQWRSHQLQJVZKLFKFRPPXQLFDWHGLUHFWO\
RUE\GXFWZLWKWKHRXWGRRUVRUVSDFHVFUDZORU
DWWLFIUHHO\FRPPXQLFDWLQJZLWKWKHRXWGRRUV
/RFDWHRQHRSHQLQJZLWKLQLQFKHVRIWRS
RIVSDFH/RFDWHUHPDLQLQJRSHQLQJZLWKLQ
LQFKHVRIERWWRPRIVSDFH0LQLPXPGLPHQVLRQ
RIDLURSHQLQJLVLQFKHV6L]HHDFKRSHQLQJSHU
IROORZLQJ
L.Direct communication with outdoors.
0LQLPXPIUHHDUHDRIVTXDUHLQFKSHU
%78SHUKRXULQSXWRIDOOHTXLSPHQW
LQVSDFH
LL.Vertical ducts.0LQLPXPIUHHDUHDRI
VTXDUHLQFKSHU%78SHUKRXULQSXWRI
DOOHTXLSPHQWLQVSDFH'XFWFURVVVHFWLRQDO
DUHDVKDOOEHVDPHDVRSHQLQJIUHHDUHD
LLL.Horizontal ducts.0LQLPXPIUHHDUHDRI
VTXDUHLQFKSHU%78SHUKRXULQSXWRI
DOOHTXLSPHQWLQVSDFH'XFWFURVVVHFWLRQDO
DUHDVKDOOEHVDPHDVRSHQLQJIUHHDUHD
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SHUPDQHQWRSHQLQJVFRPPXQLFDWHGLUHFWO\
ZLWKDGGLWLRQDOVSDFHVRIVXI¿FLHQWYROXPH
VXFKWKDWFRPELQHGYROXPHRIDOOVSDFHV
PHHWFULWHULDIRUXQFRQ¿QHGVSDFH6L]HHDFK
RSHQLQJIRUPLQLPXPIUHHDUHDRIVTXDUH
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HTXLSPHQWLQVSDFHVEXWQRWOHVVWKDQ
VTXDUHLQFKHV
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D $OORXWVLGHRSHQLQJVVKRXOGEHVFUHHQHGDQG
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EORFNLQJHIIHFWRIORXYHUVJULOOHVRUVFUHHQV
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ORXYHUVDQGJULOOHVKDYHSHUFHQWIUHHDUHD
F /RXYHUVDQGJULOOHVPXVWEH¿[HGLQWKHRSHQ
SRVLWLRQRULQWHUORFNHGZLWKWKHHTXLSPHQWWR
RSHQDXWRPDWLFDOO\GXULQJHTXLSPHQWRSHUDWLRQ
SECTION II: PRE-INSTALLATION (continued)

12
SECTION III: KNOCKDOWN BOILER ASSEMBLY
A. REMOVAL OF BARE BOILER FROM SKID
 %RLOHULVVHFXUHGWRVNLGZLWKEROWVLQIURQWDQG
LQUHDURIVKLSSLQJVNLGVHH)LJXUH5HPRYHDOO
EROWV
Figure 3: Knockdown Boiler Removal from Skid
 7LOWERLOHUWRULJKWDQGWRUHDU8VLQJULJKWUHDUOHJ
DVSLYRWURWDWHERLOHULQDFORFNZLVHGLUHFWLRQ
DQGORZHUOHIWVLGHRIERLOHUWRÀRRU7LOWERLOHUDQG
UHPRYHVNLG
B. MOVE BOILER TO PERMANENT POSITION
E\VOLGLQJRUZDONLQJ
C. TEST BOILER FOR LEAKSEHIRUHLQVWDOOLQJ
FRQWUROVWULPDQGMDFNHWDQGEHIRUHFRQQHFWLQJWR
heating system.
 /RRVHQQXWVRQWLHURGVXQWLORQO\¿QJHUWLJKW
 ,QVWDOOSUHVVXUHJDXJHDWOHDVW36,FDSDFLW\
DKRVHWRWKHFLW\ZDWHUDQGDYDOYHLQWKHVXSSO\
tapping. Plug remainder of tappings.
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36,EXWQRPRUHWKDQ36,JDXJHSUHVVXUH
WARNING
Assure that there is not air left inside boiler when
checking for leaks. DO NOT test for leaks with
pressurized air.
 ([DPLQHERLOHUFDUHIXOO\LQVLGHDQGRXWVLGHIRUOHDNV
or damage due to shipment or handling.
D. DRAIN WATER FROM BOILER. Remove gauge,
YDOYHDQGSOXJVIURPWKRVHWDSSLQJVWREHXVHG/HDYH
RWKHUWDSSLQJVSOXJJHGRUEXVKHGDFFRUGLQJWR)LJXUH
E. INSPECT JOINTS BETWEEN SECTIONS. All
MRLQWVDUHIDFWRU\VHDOHG,IWKHUHDUHDQ\VSDFHVGXHWR
VKLSPHQWRUKDQGOLQJVHDOWKHPZLWKERLOHUSXWW\
F. INSPECT FLUE COVER PLATES for tightness.
,IORRVHUHWLJKWHQPRXQWLQJKDUGZDUH,IÀXHSODWHRU
VHDOLQJURSHLVGDPDJHGUHSDLURUUHSODFHDVQHHGHG
G. INSTALL AND SECURE CANOPYZLWKJDVNHW
DQGKDUGZDUHSURYLGHGWRHQVXUHJDVWLJKWVHDO²VHH
)LJXUH
Figure 4: Boiler Canopy Installation
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LQVXODWLRQ3ODFHRQHVWULSDFURVVWKHWRSRIWKH
IURQWVHFWLRQDQGWKHRWKHUDFURVVWKHUHDUVHFWLRQDV
VKRZQLQ)LJXUH
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SLHFHV3ODFHHDFKSLHFHDORQJWKHVLGHVDOORZLQJ
WKHHQGVWRRYHUODSWKHIURQWDQGUHDUSLHFHV
CAUTION
DO NOTDOORZDQ\ÀXHZD\EORFNDJHE\JDVNHW
 3RVLWLRQFDQRS\ERG\ZLWKLQWKHUHWDLQLQJEDUZKLFK
ERUGHUVWKHÀXHZD\RSHQLQJVRQWRSRIWKHEDUH
ERLOHUEORFNDVVHPEO\
NOTICE
Jacket support bracket must be facing left side of
ERLOHUVHH)LJXUH-DFNHWZLOOQRW¿WLIEUDFNHW
is not oriented correctly.
 6HFXUHFDQRS\WRERLOHUZLWKWZR[
ORQJFDUULDJHEROWVÀDWZDVKHUVDQG
ZLQJQXWVSURYLGHG

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
C¾" Probe LWCO Std.
Plugged (Float LWCO) N/A
C-C ¾" Flush Plug Flush Plug N/A
D½" 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)
L2"
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
R¾"
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. INSTALLTRIM.7KHIROORZLQJVWHDPRUZDWHUWULP
ZLOOEHFRQFHDOHGRULQDFFHVVLEOHDIWHUERLOHUMDFNHWLV
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usage.
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thru V8H5, if only one supply riser is used.
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2. :$7(5%2,/(5²7RSWDSSLQJV
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I. INSTALL BOILER JACKET.6HH)LJXUH
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IURPULJKWVLGHODWFKLQJVWXGDQGRQH
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door remove hinge pin and set door aside. Remove
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KLQJHEUDFNHWWRWKHERLOHUVHFWLRQ
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$OLJQKROHVLQMDFNHWUHDUSDQHODQGVXSSRUWEUDFNHW
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VFUHZV
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KHDWHURSHQLQJ6HH)LJXUH,WHPV&DQG
'(QJDJHWZRRIWKHFROODUUHWDLQLQJ
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VXSSRUWEHKLQGWKHSDQHOZLWKRQHKDQGZKLOH
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RYHUHGJHRIRSHQLQJXQWLODOOHLJKWWDEVDUH
VHFXULQJFROODU
E ,QVWDOOMDFNHWIURQWSDQHO/RFDWHWZR
GLDPHWHUKROHVRQHURXQGRQHREURXQGRQIURQW
SDQHODSSUR[LPDWHO\´XSIURPWKHERWWRPRI
WKHSDQHO$OLJQWKHVHKROHVZLWKWKHVLPLODUO\
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6HFXUHZLWKWZR[ORQJFDS
VFUHZV
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()ROGSDQHODWSHUIRUDWLRQNHHSLQJLQVXODWLRQ
LQZDUG$OLJQOHIWVLGHSDQHOPRXQWLQJKROHVZLWK
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ORQJVKHHWPHWDOVFUHZV
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

15
 ,QVWDOOMDFNHWWRSSDQHO6HH)LJXUH,WHP)
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UHDUDQGOHIWVLGHSDQHOVZLWK[ò´ORQJVKHHW
PHWDOVFUHZV
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ZLWKIURQWDQGUHDUSDQHOKROHV6HFXUHZLWK[ò´
ORQJVKHHWPHWDOVFUHZV
 $WWDFKWKHODEHOVVKLSSHGLQWKHLQVWUXFWLRQHQYHORSH
DVIROORZV
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:DWHU/HYHO3ODWH)RUP1RVKLSSHGLQ
6WHDP7ULP&DUWRQ$OLJQSODWHZLWKWZR
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OLQHZLWKWKHORZHUVLJKWJODVVWDSSLQJRIWKH
MDFNHWULJKWVLGHDFFHVVSDQHO$WWDFKSODWHZLWK
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)LJXUH,WHP*
J. INSTALL BECKETT OIL BURNER.
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JDVNHW,ILQVXODWLRQRUJDVNHWLVORRVHUHDWWDFKWR
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%
Step 1./LIWWKHGRRUXSXQWRWKHEXLOWLQFDVWUDPS
GRRUUHVWSURWUXGLQJIURPWKHERWWRPRIWKHIURQW
VHFWLRQFDVWLQJVHH)LJXUH$ZKLOHURWDWLQJ
WKHDUWLFXODWHGKLQJHDQGGRRUWRWKHULJKWDQG
HQJDJLQJWKHVORWRQULJKWVLGHRIGRRUXQWRWKH
VWXGSURWUXGLQJIURPWKHIURQWVHFWLRQ
Step 2. Use one hand to help hold door in position
E\DSSO\LQJSUHVVXUHGLUHFWO\WRWKHGRRUZKLOH
UHLQVWDOOLQJWKHVHFXULQJKDUGZDUHZLWK\RXU
opposite hand. Always install right side
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ÀDWZDVKHU¿UVWWKHQLQVWDOOOHIWVLGHKLQJH
KDUGZDUH[OJKH[KHDGÀDQJH
bolt) second. $SSO\DGGLWLRQDOSUHVVXUHZKLOH
KDQGWLJKWHQLQJWKHKDUGZDUHDVIDUDVSRVVLEOH
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
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Step 3. 8VHDKDQGZUHQFKWRWLJKWHQGRRUKDUGZDUH
and DOZD\VVWDUWZLWKWKHULJKWVLGHÀDQJH
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NeverWLJKWHQOHIWVLGHÀDQJHEROW¿UVWRUWLJKWHQ
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CAUTION
DO NOT install burner without gasket.
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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.
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L &RQQHFWFRSSHUFRQQHFWRUWXEH
M ,QVSHFW%HFNHWWKHDGVHWWLQJRQOHIWVLGHRI
EXUQHUE\LQVXULQJWKHEOXHOLQH0'9RUWKH
OLQHRQWKHODEHO0%/DUHDOLJQHGUHDGMXVWLI
QHFHVVDU\
N 7LJKWHQNQXUOHGQXW
O 6ZLQJLJQLWHUFORVHGURWDWHWDEVDQGWLJKWHQWZR
LJQLWHUVFUHZV
P5HSODFHEXUQHUFRYHUDQGWLJKWHQEXUQHUFRYHU
NQREV
 )RUZDWHUERLOHUDSSOLFDWLRQVUHIHUWR7DEOHDW
WKHUHDURIWKLVPDQXDOIRUSURSHUQR]]OHDQGEXUQHU
settings.
D 5HPRYHQR]]OHIRUZDWHUDSSOLFDWLRQDWWDFKHGWR
FRSSHUFRQQHFWRUWXEH
E /RRVHQWZRLJQLWHUODWFKLQJVFUHZVURWDWH
WDEVDQGVZLQJRSHQLJQLWHUDERXWKLQJH
F /RRVHQNQXUOHGQXWDQGGLVFRQQHFWFRSSHU
FRQQHFWRUWXEH
G )RU9+UHPRYHWKH/RZ¿UH%DIÀH
H 5HPRYHQR]]OHOLQHHOHFWURGHDVVHPEO\
I 5HPRYH%HFNHWW0'9RU0%/+HDG
J 5HPRYHQR]]OHIRUVWHDPDSSOLFDWLRQIURP
QR]]OHDGDSWHUDQGLQVWDOOWKHZDWHUDSSOLFDWLRQ
QR]]OHSURYLGHGLQ6WHSDDERYH5HIHUWR
%XUQHU6SHFL¿FDWLRQV7DEOHDWWKHUHDURIWKLV
PDQXDOIRUSURSHUQR]]OHDQGEXUQHUVHWWLQJV
7KHQR]]OHPXVWEHVHFXUHO\LQVWDOOHGWRDVVXUH
OHDNIUHHMRLQWVEHWZHHQWKHQR]]OHDQGDGDSWHU
:KHQLQVWDOOLQJWKHQR]]OHEHFDUHIXOQRWWR
EXPSRUPRYHWKHEXUQHUHOHFWURGHV
K ,QVSHFWDQGPHDVXUHEXUQHUHOHFWURGHV5HIHU
WR)LJXUH$IRUWKHSURSHUHOHFWURGHVHWWLQJ
5HDGMXVWHOHFWURGHVHWWLQJWRWKHSURSHU
GLPHQVLRQVLIQHFHVVDU\
L 5HLQVWDOO%HFNHWW0'9RU0%/+HDG
M 5HLQVWDOOQR]]OHOLQHHOHFWURGHDVVHPEO\
N &RQQHFWFRSSHUFRQQHFWRUWXEH
O ,QVSHFW%HFNHWWKHDGVHWWLQJRQOHIWVLGHRI
EXUQHUE\LQVXULQJWKHEOXHOLQH0'9RUWKH
OLQHRQWKHODEHO0%/DUHDOLJQHGUHDGMXVWLI
QHFHVVDU\
P7LJKWHQNQXUOHGQXW&RQQHFWWKHÀDUHG¿WWLQJ
RQWKHFRSSHURLOOLQHWRWKHQR]]OHOLQHDQG
tighten.
Q 6ZLQJLJQLWHUFORVHGURWDWHWDEVDQGWLJKWHQWZR
LJQLWHUVFUHZV
K. INSTALL CARLIN ELITE EZ OIL BURNER,
3 thru 6 Section6HH)LJXUH
)ROORZLQVWUXFWLRQVLQ3DUDJUDSK-6WHSVWKURXJK
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

17
 ,QVSHFWRLOQR]]OHHOHFWURGHVDQGKHDGVHWWLQJ
D ,QVWDOODWLRQ5HPRYDORI'UDZHU$VVHPEO\
L /RRVHQVFUHZVURWDWHODWFKHVDQGVZLQJ
open the transformer.
LL7KHFRPEXVWLRQKHDGDVVHPEO\FDQEH
UHPRYHGZLWKWKHEORZHUZKHHODFFHVVFRYHU
LQSODFHRUUHPRYHG,IWKHDFFHVVFRYHULV
UHPRYHGWKHKHDGDVVHPEO\ZLOOQRWKDYHWR
EHURWDWHG
 'LVFRQQHFWWKHÀDUHG¿WWLQJWRWKHRLOOLQH
DQGUHPRYHWKHDOXPLQXPWKXPEQXWIURP
WKHQR]]OHOLQH5HPRYHWKHFRPEXVWLRQ
KHDGDVVHPEO\IURPWKHDLUWXEH5RWDWLQJ
WKHDVVHPEO\XSVLGHGRZQZLOOHDVH
removal.
LLL/RRVHQWKHFODPSVFUHZRQWKHUHWHQWLRQ
ULQJDVVHPEO\DQGVOLGHWKHUHWHQWLRQULQJRII
the adaptor.
 ,QVSHFWWKHQR]]OHIRUVL]HDQGW\SH6HH
%XUQHU6SHFL¿FDWLRQV7DEOHDWWKHUHDURI
this manual.
LY 5HSODFHWKHUHWHQWLRQULQJDVVHPEO\VOLSSLQJ
RQHRIWKHULYHWHGDUPVWKURXJKWKHLQFK
JDSEHWZHHQWKHHOHFWURGHWLSV7KLVDUP
VKRXOGEHVWUDLJKWXS$OVREHVXUHWKDW
WKHUHWHQWLRQULQJFODPSLVWLJKWDJDLQVWWKH
shoulder on the adaptor. Then tighten the
FODPSLQJVFUHZ
Y &KHFNWKHHOHFWURGHVHWWLQJVVSHFL¿HGDV
IROORZVDQGVKRZQLQ)LJXUH%LQFK
JDSWRLQFKDERYHWKHQR]]OH
FHQWHUOLQHDQGÀXVKWRLQFKDKHDGRI
WKHQR]]OHWLS
YL 5HLQVWDOOWKHFRPEXVWLRQKHDGDVVHPEO\
KROGLQJLWXSVLGHGRZQZKLOHLQVHUWLQJ
LQWRWKHKRXVLQJ7KHÀDPHUHWHQWLRQULQJ
HQGRIWKHDVVHPEO\PXVWEHOLIWHGDQG
JXLGHGWKURXJKWKHWKURWWOHFRQHDUHGXFHG
GLDPHWHULQWKHHQGRIWKHDLUWXEH'2
127)25&(,7
YLL $IWHUDWWDFKLQJWKHSURSHUSRVLWLRQLQJEDU
UHIHUWR3DUDJUDSKEEHORZUXQWKHWKXPE
QXWRQWRWKHQR]]OHOLQHDQGWLJKWHQLWOLJKWO\
&RQQHFWWKHÀDUHG¿WWLQJRQWKHFRSSHURLO
OLQHWRWKHQR]]OHOLQHDQGWLJKWHQ
E &RPEXVWLRQ+HDG3RVLWLRQLQJ%DUV
L 7KH(OLWH(=+3DQG(=+3EXUQHUVDUH
VXSSOLHGZLWKWKHSURSHUSRVLWLRQLQJEDU
LQVWDOOHGRQWRWKHKRXVLQJWKDWPDWFKHVWKH
LQSXWRLOQR]]OHLQVWDOOHGLQWKHEXUQHU
9HULI\WKDWWKHLQVWDOOHGSRVLWLRQLQJEDU
PDWFKHVWKHLQSXWRLOQR]]OHLQVWDOOHGLQWKH
EXUQHUUHIHUWR7DEOHDWWKHUHDURIWKLV
manual.
 ,QWKHFDVHRIWKH(=+3WKHSURSHUKHDG
SRVLWLRQLQJEDULVVWLOOPDWFKHGE\WKHVL]H
RIWKHQR]]OHQRWWKHLQSXW)RUH[DPSOHLI
QR]]OHVL]HLV*3+LQSXW#SVLLV
DSSUR[LPDWHO\*3+DQGWKHSURSHUEDU
LV*3+
LL 0RGHO(=+33RVLWLRQLQJ%DUV
*3+*3+*3+
*3+*3+*3+
GPH.
LLL 0RGHO(=+33RVLWLRQLQJ%DUV
*3+*3+*3+*3+
F ,QLWLDO$LU%DQG6HWWLQJ
L 7KHQR]]OHVL]HLQ*3+,1387LVSULQWHG
GLUHFWO\RQWKHDLUEDQG/RRVHQWKHORFNLQJ
VFUHZPRYHWKHDLUEDQGXQWLOWKHSRLQWHU
RQWKHDLUVKXWWHUDQGKRXVLQJOLQHVXSZLWK
WKHDSSURSULDWH*3+,13877LJKWHQWKH
ORFNLQJVFUHZV
LL 7KH(OLWHEXUQHUVXVHFDOLEUDWHGDLUEDQGV
PDUNHGLQQR]]OHVL]HV0RGHOV(=+3
DQG(=+3KDYHDLUEDQGVFDOLEUDWHGWR
deliver the proper amount of air for their
VSHFL¿FSXPSSUHVVXUH7KHDLUEDQGVRQ
+3PRGHOVDUHGHVLJQHGWREHVHWE\WKH
UDWLQJVWDPSHGRQWKHQR]]OH
LLL 7KHEXUQHULVQRZVHWDWWKHDSSUR[LPDWH
DLUEDQGVHWWLQJIRUWKHJDOORQDJHLQGLFDWHG
'XULQJ¿QDODGMXVWPHQWXVLQJFRPEXVWLRQ
WHVWLQJHTXLSPHQWWKHDLUEDQGPD\QHHG
PLQRUDGMXVWPHQWWRDFKLHYHWKHGHVLUHG
HI¿FLHQF\
L. INSTALL CARLIN 102CRD OIL BURNER,
7 thru 9 Section6HH)LJXUH
)ROORZLQVWUXFWLRQVLQ3DUDJUDSK-6WHSVWKURXJK
 ,QVSHFWHOHFWURGHVKHDGVHWWLQJDQGIDFWRU\LQVWDOOHG
RLOQR]]OH
D ,QVWDOODWLRQ5HPRYDORI'UDZHU$VVHPEO\
L /RRVHQVFUHZVURWDWHODWFKHVDQGVZLQJ
open the transformer.
 'LVFRQQHFWWKHÀDUHG¿WWLQJWRWKHRLO
OLQHDQGUHPRYHWKHDOXPLQXPWKXPE
QXWIURPWKHQR]]OHOLQH5HPRYHWKH
FRPEXVWLRQKHDGDVVHPEO\IURPWKHDLU
WXEH5RWDWLQJWKHDVVHPEO\XSVLGHGRZQ
ZLOOHDVHUHPRYDO,QVSHFWWKHQR]]OHIRU
VL]HDQGW\SHUHIHUWR6HFWLRQ;9,,%XUQHU
6SHFL¿FDWLRQV7DEOHDWWKHUHDURIWKLV
manual.
LL &KHFNWKHHOHFWURGHVHWWLQJVVSHFL¿HGDV
IROORZVDQGVKRZQLQ)LJXUH&LQFK
JDSLQFKDERYHWKHQR]]OHFHQWHUOLQH
DQGLQFKDKHDGRIWKHQR]]OHWLS
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

18
LLL 5HLQVWDOOWKHFRPEXVWLRQKHDGDVVHPEO\
LQWRWKHDLUWXEH,WPD\EHQHFHVVDU\WRWXUQ
QR]]OHOLQHDVVHPEO\XSVLGHGRZQWRHDVH
LQVHUWLRQLQWRWKHDLUWXEH7KHQWKHWKUHDGHG
DGDSWHURQWKHHQGRIWKHQR]]OHOLQHLV
passed through the opening in the left side of
the housing.
LY 5XQWKHDOXPLQXPNQXUOHGWKXPEQXWRQWR
WKHQR]]OHOLQHDQGWLJKWHQKDQGWLJKW
Y &RQQHFWWKHÀDUHG¿WWLQJRQWKHFRSSHURLO
OLQHWRWKHQR]]OHOLQHDQGWLJKWHQ
YL 6ZLQJWKHWUDQVIRUPHUWRWKHFORVHGSRVLWLRQ
URWDWHODWFKHVDQGWLJKWHQVFUHZV
E &RPEXVWLRQ+HDG6HWWLQJ$GMXVWPHQW
L 9HULI\FRPEXVWLRQKHDGVHWWLQJUHIHUWR
7DEOHDWWKHUHDURIWKLVPDQXDO5HDG
WKHVFDOHHPERVVHGLQWKHKRXVLQJZKLFKLV
FDOLEUDWHGLQLQFKGLYLVLRQVGLPHQVLRQ
µ$¶WKHSRVLWLRQRIWKHÀDPHUHWHQWLRQULQJ
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Figure 7B: Installation/Removal of
Riello Drawer Assembly
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)
Figure 7A: Combustion Head Adjustment -
102CRD Burner

19
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installed.
Figure 7C: Riello Nozzle Replacement
Figure 7D: Riello Turbulator Setting
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the rear of this manual for details.
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)

20
WARNING: DO NOT operate a single line system
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued)