8 8142824R10.5-4/07As an ENERGY STAR® Partner, Burnham Hydronicsha
10Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)A. INSPECT SHIPMENT carefully for any signs of damage.1. All equipmen
By this Warranty Statement the U.S. Boiler Co., Inc. of Lancaster,Pennsylvania i ssues limited warranties subject to the terms and conditionsstated
11C. PROVIDE COMBUSTION AND VENTILATION AIR. Local and National Codes may apply and should be referenced.GNINRAWnoitalitnevdnanoitsubmocetauqed
12SECTION II: KNOCKDOWN BOILER ASSEMBLYA. REMOVAL OF BARE BOILER FROM SKID1. Boiler is secured to skid with 4 bolts, 2 in front and 2 in re
13Figure 5: Boiler Tapping Locations and Usage (Knockdown Boilers Only)SGNIPPATFOESOPRUPgnippaTnoitacoLeziSTPNrelioBmaetSrelioBretaWretaeH-noNretaeH/w
14Figure 6: Knockdown Boiler Jacket AssemblyH. INSTALL TRIM. The following steam or water trim will be concealed or inaccessible after boiler jack
156. 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
16ECITONekamroodgniwsrenrubgnirucesnehW.sedishtobnoyllauqeni-nwardsirooderusStep 3. Use a hand wrench to tighten door hardware and always start with
17 Disconnect the fl ared fi tting to the oil line and remove the aluminum thumb-nut from the nozzle line. Remove the combustion head assembly from
18L. INSTALL CARLIN ELITE EZ OIL BURNER. (See Figure 7).Follow instructions in Paragraph J, Steps 1 through 6.7. Inspect oil nozzle, electrodes a
19c. Initial Air Band Settingi. The nozzle size in GPH INPUT is printed directly on the air band. Loosen the locking screw, move the air band until
2IMPORTANT INFORMATION - READ CAREFULLY The following terms are used throughout this manual to bring attention to the presence of hazards of vario
20i. Remove the nozzle adapter (2) from the drawer assembly by loosening the screw (1).ii. Remove existing nozzle from nozzle adapter.iii. Insert t
21 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 u
22ECITONaniyrucremniatnocstimiLerusserPA404LoD.ebutdelaestonhsartehtnitimilecalp.efillufesustifodneehttasniatnoctahttimilagnicalpersitimilsihtfIod,ebu
23b. Thread 1½” NPT x 15” long nipple into the 1½" NPT x 90° elbow and tighten with a pipe wrench.c. Thread one of the circulator fl ange onto t
24Q. INSTALL TRIM AND CONTROLS WITH CARLIN ELITE EZ BURNER.Follow instructions in Paragraph N, Steps 1 through 7.Steam Boilers Only (see Figur
251. Remove (2) #6 x 1/2" lg. machine screws and J-box cover from junction box.2. Secure 2" x 4" junction box to jacket front panel w
26SECTION III: PACKAGED BOILER ASSEMBLYA. REMOVE CRATE.1. Remove all fasteners at crate skid.2. Lift outside container and remove all other in
27Figure 11B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
28Step 4. From this position the door can be swung clear of the vertical circulator return piping to provide full access to the combustion chamber an
29E. INSPECT COMBUSTION CHAMBER TARGET WALL AND LINER, AND SWING DOOR GASKET.1. Open burner swing door using procedure previously outlined
3REGNADrosihtfoytinicivehtnisdiuqilrosropavelbammalfrehtoroenilosagesuroerotsTONOD.ecnailpparehtoynaGNINRAWytreporpesuacnacecnanetniamroecivres,noitar
30 If the lower (minimum) input is desired, remove the nozzle which was factory installed. Locate the lower (minimum) fi ring rate nozzle that is sup
31 A. EVALUATE THE EXISTING WATER SYSTEM. Design a piping system and install boiler which will prevent oxygen contamination of boiler water and
32Figure 12: Recommended Piping for Combination Heating and Cooling (Refrigeration) System To perform a long term pressure test including the boiler
33Figure 13A: Recommended Water Piping for Circulator Zoned Heating System
34Figure 13B: Recommended Water Piping for Zone Valve Zoned Heating System - Supply Side Circulator
35Figure 13C: Recommended Water Piping for Zone Valve Zoned Heating System - Return Side Circulator
36SECTION V: STEAM BOILER PIPING AND TRIMA. EVALUATE THE EXISTING STEAM SYSTEM. The single most important factor in determining the expect
37Figure 14: V83 Thru V89 Recommended Boiler Piping For Gravity Return Steam BoilerECITONenilretaw,esionmetsysevissecxenitluseryamlaunamsihtnideificep
38SECTION VI: TANKLESS AND INDIRECT WATER HEATER PIPINGA. CONNECT TANKLESS HEATER PIPING as shown in Figure 15A. See Tables 2A and 2B f
39Figure 15A: Schematic Tankless Heater PipingTABLE 2A: TANKLESS HEATER DATA: Rear Mounted Heater on Steam and Water BoilersTABLE 2B: TANKLESS HEATE
4GNINRAWepipynawercsnutonoD.erusserphgihrednuretawtohyrevsniatnocreliobsihTylevitisoptuohtiwreliobsihtfostnenopmocynatcennocsidottpmettaronsgnittifdna
40Figure 15B: Alliance™ Water Heater Piping with V8 BoilerB. CONNECT ALLIANCE™ INDIRECT WATER HEATER PIPING as shown in Figure 15B.1. Refer to
41A. GENERAL VENTING GUIDELINES 1. Vent system installation must be in accordance with these instructions and applicable provisions of local build
42Figure 17: Proper and Improper Locations of Draft RegulatorFigure 16: Recommended Vent Pipe Arrangement and Chimney Requirements
43Figure 18: Optional Air Intake Piping Installation - Only Available with Beckett Burner2. After determining location, cut a hole in the wall to ac
44A. GENERAL1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of
45Figure 19: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Beckett Burners BOILER SEQUENCE OF OPERATION WITH PROBE LWCOWhe
46Figure 19A: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Carlin Burners
47Figure 19B: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Riello Burners
48Figure 20: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Beckett BurnersBOILER SEQUENCE OF OPERATION WITH PROBE LWCOWhe
49Figure 20A: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Carlin Burners
5TABLE 1A: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1D)TABLE 1B: RATING DATABoiler Boiler Model No.Model No.Dimensions Dimensions See Figures 1A - 1DS
50Figure 20B: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Riello Burners
51Figure 21: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Beckett BurnersBOILER SEQUENCE OF OPERATION WITH FLOAT LWCOWhen th
52Figure 21A: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Carlin Burners
53Figure 21B: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Riello Burners
54Figure 22: Wiring Diagram, Water without Tankless Heater for Beckett BurnersBOILER SEQUENCE OF OPERATIONA call for heat by the thermostat energi
55Figure 22A: Wiring Diagram, Water without Tankless Heater for Carlin Burners
56Figure 22B: Wiring Diagram, Water without Tankless Heater for Riello Burners
57Figure 23A: Wiring Diagram, Water with Front Tankless Heater for Beckett BurnersBOILER SEQUENCE OF OPERATIONA call for heat by the thermostat en
58Figure 23B: Wiring Diagram, Water with Front Tankless Heater for Carlin Burners
59Figure 23C: Wiring Diagram, Water with Front Tankless Heater for Riello Burners
6Figure 1A: V82 thru V89 Water Boiler without Tankless Heater
60BOILER SEQUENCE OF OPERATIONA call for heat by the thermostat energizes the L8124C control which in turn energizes the primary control to turn on
61Figure 23D: Wiring Diagram, Water with Rear Tankless Heater for Carlin BurnersFigure 23E: Wiring Diagram, Water with Rear Tankless Heater for Carl
62Figure 23F: Wiring Diagram, Water with Rear Tankless Heater for Riello Burners
63Figure 24: Single Pipe Oil LineSECTION IX: OIL PIPINGA. GENERAL1. Use fl exible oil line(s) so the burner swing door can be opened without dis
64TABLE 3: TWO-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMSTABLE 4: SINGLE-STAGE UNITS (3450 RPM) - TWO PIPE SYST
65SECTION X: SYSTEM START-UPe. Open purge valve.f. Open shut-off valve in cold water supply piping located between the air scoop and expansion t
66Burners), hold for one (1) second and release to reset primary control.3. On STEAM BOILERS:a. With an L404A1354 - set cut-out pressure (MAIN sca
67b. Locate oil pressure adjusting screw and turn screw to obtain proper pump pressure, refer to Table 6 at rear of manual.c. To check the cutoff pr
68Figure 27A: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)Figure 27B: "L1" and "V1"
69 Carlin Elite EZ Burnersa. Carlin EZ-1HP and EZ-2HP burners use a head positioning bar to fi x the head setting based on nozzle size. To adjust th
7Figure 1B: V83 thru V89 Water Boiler with Front Tankless Heater
70sehsalFsmhoniecnatsiseRlleCdaC1004nahtsseL2008nahtsseldna004nahteroM30061nahtsseldna008nahteroM40005nahtsseldna0061nahteroMFigure 29: Cad Cell Loca
71 • Perform cad cell resistance check as outlined in control feature. If resistance is below 1600 OHMS and burner runs beyond safety cut-
72AQUASTAT SWITCHING ACTION WITHIN L8148A CONTROLS The switching action in the L8148A control has one set-ting, the high limit. The switching rel
73Warning: This product contains refractory ceramic fi bers (RCF). RCF has been classifi ed as a possible human carcinogen. After this product is fi r
74SECTION XI: MAINTENANCE AND SERVICE INSTRUCTIONSA. MAINTENANCE OF LOW WATER CUT-OFF DEVICESGNINRAWffo-tucretawwolepyttaolfdnaeborPdnanoi
75 Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler. If the condensate can temporari
76testing with hydrion paper which is used in the same manner as litmus paper, except it gives specifi c readings. A color chart on the side of the sma
771. Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners.2. With steam boilers, at
78SECTION XII: BOILER CLEANINGA. CLEAN THE FLUEWAYS (See Figure 30).1. Prior to cleaning boiler, lay a protective cloth or plastic over combusti
79Figure 30: Cleaning of Boiler FluewaysGNINRAWytreporpsuoireS.noitidnocdoogniyenmihcdevorppanaotdetcennocebtsumreliobehTforoiretniehT.yenmihcetauqeda
8Figure 1C: V83 thru V89 Water Boiler with Rear Tankless Heater
80A. COMBUSTION1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil b
81SECTION XIV: REPAIR PARTSAll V8 Series Boiler Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require
82Bare Boiler Assembly
83metI.oNnoitpircseD.oNtraP28V38V48V58V68V78V88V98VYLBMESSARELIOBERAB.1A1retaWdenihcaM,).rtH-noN(noitceStnorF---)RO(---maetSdenihcaM,).rtH-noN(noitceS
84Bare Boiler Assembly (Continued)
85metI.oNnoitpircseD.oNtraP28V38V48V58V68V78V88V98VYLBMESSARELIOBERAB.1 )deunitnoC(P1"8/3-3x"4/3-81x"2/1,teknalBrebmahCnoitsubmoC520820
86Jacket Assembly
87metI.oNnoitpircseD.oNtraP28V38V48V58V68V78V88V98V.2YLBMESSATEKCAJ )s(lenaPtekcaJhtiwdedulcninoitalusnI-A2tekcarBtroppuSraeRtekcaJ1082407 11111111B2y
88V83 Thru V89 Steam Boilers - Trim and Controls
89metI.oNnoitpircseD.oNtraP38V48V58V68V78V88V98VSLORTNOCDNAMIRT-SRELIOBMAETS98VurhT38V.3A3rotalugeRtfarD"68826118 1111 ---------rotalugeRtfarD&qu
9Figure 1D: V83 thru V89 Steam Boiler with or without Tankless Heater
90V82 Thru V89 Water Boilers - Trim and Controls
91METI.ONNOITPIRCSED.oNtraP28V38V48V58V68V78V88V98VSLORTNOCDNAMIRT-SRELIOBRETAW98VurhT28V.4A46" rotalugeRtfarD8826118 11111 ------------7" r
92Beckett AFG Burner
93BECKETT OIL BURNER PART NOS. FOR V8 SERIES BOILERSNOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner
94ledoMrelioB68V78V88V98VnoitanibmoCebuTriANQADM07GFANQADM07GFANQADM07GFANQADM07GFA.oNcepSs'ttekceB1337BCB2337BCB3337BCB4337BCBdnaBriA29432943294
95CARLIN OIL BURNER PART NUMBERS FOR V8 SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the bo
96Table 6: BURNER SPECIFICATIONSrelioBledoMgniriFetaRHPGGFAttekceBnilraColleiRsgnitteS2elzzoN3pmuPerusserPrenruBledoMsgnitteS2elzzoN3pmuPerusserPrenr
97XV. LOW WATER CUT OFF (LWCO)GNINRAW.)OCWL(ffOtuCretaWwoLtekramretfanallatsniotseriwyrotcaftucotTPMETTATONOD.ffOtuCretaWwoLrofdeifitnediyllacificeps
98SERVICE RECORDDATE SERVICE PERFORMED
99water boiler for its intended purposes and its maintenanceaccordance with U. S. Boiler Co., Inc. recommendations andhydronics industry standards. Th
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