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IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made.
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DANGER DO NOT store or use gasoline or other flammable 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.
WARNING This boiler contains very hot water under high pressure. DO NOT unscrew any pipe fittings 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.
SECTION I: PRODUCT DESCRIPTION, SPECIFICATION AND DIMENSIONAL DATA circulator relays and adds energy saving thermal purge The V8H Series boiler is a cast iron oil-fired water boiler features. Energy is saved by starting the circulator and designed for closed forced circulation heating systems or a delaying the burner start when there is residual heat low pressure steam boiler designed for use in closed heating available in the boiler.
SECTION II: PRE-INSTALLATION A. INSPECT SHIPMENT carefully for any signs of not level, or if water may be encountered on floor damage. around boiler. 4. PROVIDE SERVICE CLEARANCE of at least 1. All equipment is carefully manufactured, inspected 24” clearance from front jacket panel for servicing and packed.
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Free area requirements need to consider the a. Outdoor air for combustion may be provided blocking effect of louvers, grilles, or screens with an optional U.S. Boiler Company V8H™ protecting the openings. If the free area of the Fresh Air Accessory Kit (ONLY AVAILABLE...
SECTION III: KNOCKDOWN BOILER ASSEMBLY A. REMOVAL OF BARE BOILER FROM SKID G. INSTALL AND SECURE CANOPY with gasket and hardware provided to ensure gas tight seal — see 1. Boiler is secured to skid with 4 bolts, 2 in front and Figure 4.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) Figure 6: Knockdown Boiler Jacket Assembly H. INSTALL TRIM. The following steam or water trim 2. Install jacket rear panel support bracket. (See will be concealed or inaccessible after boiler jacket is Figure 6, Item 2A). Align bracket with two (2) installed, see Figure 5 for boiler tapping locations and 5/16"-18 tapped holes in rear section and secure usage.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) Figure 7: Oil Burner Installation (Beckett Burner Shown) 2. Locate burner swing door and hinge assembly 6. Install jacket top panel. (See Figure 6, Item 2F). removed in Paragraph I, No. 1. Check the burner Place jacket top panel on boiler and secure to front, swing door insulation and rope gasket for damage rear and left side panels with #8 x ½”...
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) g. Reinstall Beckett MD(V1) or MB(L1) Head. NOTICE h. Reinstall nozzle line electrode assembly. When securing burner swing door make sure door i. Connect copper connector tube. is drawn-in equally on both sides. j. Inspect Beckett head setting on left side of burner by insuring the blue line MD(V1) or the Step 3.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) 7. Inspect oil nozzle, electrodes and head setting. manual. a. Installation/Removal of Drawer Assembly In the case of the EZ-1HP, the proper head positioning bar is still matched by the size Loosen screws, rotate latches and swing of the nozzle, not the input.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) iii. Re-install the combustion head assembly Turn the adjusting crew clockwise to move into the air tube. It may be necessary to turn the combustion head forward, increasing the nozzle line assembly upside down to ease ‘A’...
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) If nozzle needs replacement, follow steps below Also refer to Figure 7C. 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).
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) WARNING: DO NOT operate a single line system e. Place a circular flange gasket in the flange with the by-pass plug installed. Operating a groove on the circulator and mount the circulator single line system with the by-pass plug installed on the flange.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) Figure 8: Limit Sensor Insertion 6. After control is installed and secured, remove NOTICE control cover. Then, remove knockout located directly above factory connected limit harness on Lower rear section Tapping "H" is used for right side flange of control.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) Figure 9: Float-Type Low Water Cut-Off and Figure 10: Pressure Limit Installation for Probe Pressure Limit Installation LWCO Equipped Boilers 5. Install float-type LWCO, if so equipped. b. Refer to Paragraph R for details on use of See Figures 5 and 9.
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SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) c. Refer to Paragraph R for details on use of Make the wiring connections as shown in burner disconnect junction box provided with all appropriate wiring diagram, refer to Figure 22, knockdown boiler builds. 23A, 23B, 24A or 24B.
SECTION III: KNOCKDOWN BOILER ASSEMBLY (continued) If you are using a burner with the disconnect harness, according to source, refer to Figures 1A thru 1D. complete the following assembly instructions for 4. Connect (3) wires from boiler control LWCO or mounting the mating burner disconnect junction box, R8239A Control Center to spade terminals on rear see Figure 11.
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SECTION IV: PACKAGED BOILER ASSEMBLY (continued) Figure 13A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured Step 4. From this position the door can be swung NOTICE clear of the vertical circulator return piping to provide full access to the combustion chamber When securing burner swing door make sure door and burner head (see Figure 13B, Position 3).
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SECTION IV: PACKAGED BOILER ASSEMBLY (continued) 3. Inspect ceramic rope located on the swing door. be installed with spindle in vertical position. Pipe The rope must be evenly distributed around the discharge as shown in Figures 15A and 15B. perimeter of the door groove and cannot bunch or Installation of the safety or relief valve must be overhang.
Figures connected to correct boiler pipe. 15A and 15B in order to regulate water flow for U.S. Boiler Company recommends sizing the maintenance of higher boiler water temperature. system circulator to supply sufficient flow (GPM) to allow a 20°F temperature differen-...
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SECTION V: WATER BOILER PIPING AND TRIM (continued) 6. If it is required to perform a long term pressure To perform a long term pressure test including the test of the hydronic system, the boiler should first boiler, ALL trapped air must first be removed from be isolated to avoid a pressure loss due to the escape the boiler.
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler Company's Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
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SECTION VII: TANKLESS AND INDIRECT WATER HEATER PIPING required by dishwashers and automatic washers is A. CONNECT TANKLESS HEATER PIPING as possible by piping the hot water from the heater shown in Figure 17A. See Tables 2A and 2B for prior to entering the mixing valve.
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SECTION VII: TANKLESS AND INDIRECT WATER HEATER PIPING (cont'd) Figure 17A: Schematic Tankless Heater Piping TABLE 2A: TANKLESS HEATER DATA: TABLE 2B: TANKLESS HEATER DATA: Rear Mounted Heater on Steam and Water Boilers Front Mounted Heater on Water Boilers Pressure Drop Pressure Drop Heater Rating Boiler...
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SECTION VII: TANKLESS AND INDIRECT WATER HEATER PIPING (cont'd) Figure 17B: Indirect Domestic Water Heater Piping with V8H Steam Boiler B. CONNECT INDIRECT DOMESTIC WATER HEATER PIPING as shown in Figure 17B. 1. Refer to Indirect Water Heater Installation, Operating, and Service Instructions for additional information.
For a vertical vent, place the increaser on the INSTALLATION - Outdoor air for combustion may smokebox outlet collar. Otherwise, locate the be provided with an optional U.S. Boiler Company increaser in the horizontal vent at the entrance to V8H™ Fresh Air Accessory Kit (ONLY AVAILABLE the chimney.
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SECTION VIII: VENTING AND AIR INTAKE PIPING (continued) Figure 18: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 19: Proper and Improper Locations of Draft Regulator...
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(3) sheet metal screws evenly spaced. 3. Remove the metal knockout in right side of burner cover. Install U.S. Boiler Company Inlet Air 6. Install air intake terminal. See Figure 20. Accessory Kit, P/N 611280031. NOTICE 4.
SECTION IX: ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source.
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SECTION IX: ELECTRICAL (continued) Figure 25: Schematic Wiring Diagrams For All Burner Options w/Various Oil Primary Controls...
SECTION X: OIL PIPING A. GENERAL WARNING 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply Under no circumstances can copper with sweat piping. style connectors be used. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel NOTICE oil filter is recommended for the firing rates below...
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SECTION X: OIL PIPING (continued) C. TWO PIPE OIL LINES TABLE 4: SINGLE-STAGE UNITS (3450 RPM) - TWO PIPE SySTEMS 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Lift "H" Maximum Length of Tubing Table 3 (two-stage) and Table 4 (single-stage) show (See Fig.
SECTION XI: SYSTEM START-UP WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber.
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SECTION XI: SYSTEM START-UP (continued) 3. STEAM BOILERS: 3. Carlin Elite EZ Burners With an L404F Pressure Limit - set cut-out a. Inspect Carlin head setting on left side of burner pressure (MAIN scale) on the pressure limit for to ensure that the proper head positioning bar (1) PSI and differential pressure (DIFF.) for .5 PSI.
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SECTION XI: SYSTEM START-UP (continued) prepurge the motor and igniter will operate but the might be necessary to move the head forward oil valve will remain closed. Refer to Oil Primary or back one position at a time to optimize the Control Instructions for more details.
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SECTION XI: SYSTEM START-UP (continued) features, Paragraph I, Step 2 of this Section and Section XV, Troubleshooting, Paragraph B. If the failure re-occurs, call your heating contractor immediately before pressing the reset button. WARNING DO NOT attempt to start the burner when excess oil has accumulated, when the boiler is full of vapor, or when the combustion chamber is very hot.
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SECTION XI: SYSTEM START-UP (continued) yellow light turns on. This indicates that reset three times. The reset count returns to the button has been held long enough. zero each time a call for heat is successfully completed. To reset a Restricted Mode •...
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SECTION XI: SYSTEM START-UP (continued) 10 additional minutes. (press the up arrow > 6100 Ohms Flame loss, burner shuts down button 10 times). Pressing the down arrow > 9999 Ohms Check for broken cell or wire. subtracts a minute from the TFI time (see R7284 displays resistance in ohms during Figure 30B).
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SECTION XI: SYSTEM START-UP (continued) 3. CHECK HIGH LIMIT a. Adjust system thermostat(s) to highest setting. b. Allow burner to run until boiler water temperature exceeds high limit setting. The burner should shut down and circulators continue running. c. Allow the temperature to drop below control setting.
SECTION XII: OPERATING A. WATER BOILERS SEQUENCE OF OPERATION Water Boilers Without Tankless Heaters (Cold Start), Sequence Of Operation: a. The V8H Boiler is equipped with a Cold Start Intelligent Oil Boiler Control (Cold Start Boiler Control). The Cold Start Boiler Control replaces the traditional electronic aquastat and circulator relays and adds energy saving thermal purge features.
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SECTION XII: OPERATING (CONTINUED) d. If the thermostat is not satisfied and the 4. Viewing the Operating Mode Options Operating Setpoint (SP) is reached the system In operating mode the user may view (but not circulator will continue to operate and the burner change) boiler operating status, settings and will stop.
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SECTION XII: OPERATING (CONTINUED) c. Low Limit (LL_) Cold Start Boiler Control The Warm Start Boiler Control is factory Adjustment Mode Options programmed with a Low Limit Setpoint of 140-240°F Adjust High Limit Setting 110°F. On falling temperature the boiler 10-30°F Adjust High Limit Differential turns “on”...
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SECTION XII: OPERATING (CONTINUED) TABLE 6: CIRCULATOR PRE-PURGE TIME ExAMPLE, TABLE 7: DOMESTIC HOT WATER DEMAND, PARAMETER PP_= 2 MINUTES (PARAMETER ZC_= DH) ZC and ZR Call for Heat Circulator Status Call for Boiler Boiler Status, Terminal System Priority Heat Function Temp.
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SECTION XII: OPERATING (CONTINUED) TABLE 8: ZONE REqUEST, PARAMETER ZC_= ZR TABLE 9: ExTERNAL LOW LIMIT, PARAMETER ZC_= ELL Call for Heat Circulator Status Call for Heat Circulator Status Input Input Output Output Input Input Output Output ii. When ZC_ is set equal to Zone Request (ZR) When there is no IWH the Cold Start Boiler B.
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Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
SECTION XIII: MAINTENANCE AND SERVICE INSTRUCTIONS A. MAINTENANCE OF LOW WATER CUT- h. Clean the pipe threads of the probe to remove OFF DEVICES old, hardened pipe dope and other foreign matter. i. Apply a moderate amount of good quality pipe WARNING dope to the pipe threads on the probe, leaving the two end threads bare.
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SECTION XIII: MAINTENANCE AND SERVICE INSTRUCTIONS (cont'd) Operate the boiler with steam in the entire Connect hoses from drain valves to floor system for a few days allowing the condensate drain. Close gate valve in Hartford Loop and to return to the boiler. If the condensate can open drain valve in return main.
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SECTION XIII: MAINTENANCE AND SERVICE INSTRUCTIONS (cont'd) c. Add appropriate boiler water treatment e. Make pH or Alkalinity Test. compounds as recommended by your qualified After boiler and system have been cleaned and water treatment company. refilled as previously described, test the pH of d.
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SECTION XIII: MAINTENANCE AND SERVICE INSTRUCTIONS (cont'd) More make-up water and higher concentrations of 3. Always keep the manual fuel supply valve shut off contaminants damage the boiler sooner. Our warranty if the burner is shut down for an extended period of does not cover corrosion and sediment-related time.
SECTION XIV: BOILER CLEANING WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber.
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SECTION XIV: BOILER CLEANING (continued) Figure 34: Cleaning of Boiler Flueways WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.
SECTION XV: TROUBLESHOOTING A. COMBUSTION 6. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller 1. NOZZLES — Although the nozzle is a relatively amounts will cause excessive wear on the pump, inexpensive device, its function is critical to the but more importantly water doesn’t burn.
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SECTION XV: TROUBLESHOOTING (continued) B. OIL PRIMARY CONTROL (Oil Primary) g. Oil valve stuck open or closed. 1. Burner (Oil Primary) will not come on. Note: The Safety Monitoring Circuit (SMC) is a. No power to Oil Primary. designed to provide lockout in the event of a b.
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SECTION XV: TROUBLESHOOTING (continued) b. If the Boiler Control detects an error it will flash "Err" (boiler control error) followed by a number. Use this text and number to identify the boiler problem and corrective action in Table 11 below. TABLE 11: BOILER CONTROL ERROR NUMBERS Display Status...
All V8H™ Series Boiler Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax...
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SECTION XVI: REPAIR PARTS (continued) Item Description Part No. V8H3 V8H4 V8H5 V8H6 V8H7 V8H8 V8H9 1. BARE BOILER ASSEMBLy Front Section (Non-Htr.), Machined Water 71728103 ---(OR)--- 71728104 Front Section (Non-Htr.), Machined Steam Front Heater Section, Machined Water 71728101 ---(OR)--- 71728102 Front Heater Section, Machined Steam Center Section...
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SECTION XVI: REPAIR PARTS (continued) Item Description Part No. V8H3 V8H4 V8H5 V8H6 V8H7 V8H8 V8H9 1. BARE BOILER ASSEMBLy (Continued) Combustion Chamber Blanket, 1/2" x 18-3/4" x 8-3/8" 82028035 Combustion Chamber Blanket, 1/2" x 18-3/4" x 13-3/8" 82028045 Combustion Chamber Blanket, 1/2" x 18-3/4" x 18-3/8" 82028055 Combustion Chamber Blanket, 1/2"...
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SECTION XVI: REPAIR PARTS (continued) V8H3 Thru V8H9 Water Boilers - Trim and Controls...
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SECTION XVI: REPAIR PARTS (continued) Item Description Part No. V8H3 V8H4 V8H5 V8H6 V8H7 V8H8 V8H9 4. V8H3 Thru V8H9 WATER BOILERS - TRIM AND CONTROLS Temperature & Pressure Gauge, ¼" NPT x 2½" Dia., 1½" 100282-01 Lg. Shank Honeywell #123870A Immersion Well, ¾" NPT 80160426 x 1½"...
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SECTION XVI: REPAIR PARTS (continued) BECKETT AFG OIL BURNER PART NOS. FOR V8H SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Boiler Model V8H3W/S V8H4W/S...
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SECTION XVI: REPAIR PARTS (continued) BECKETT AFG OIL BURNER PART NOS. FOR V8H SERIES BOILERS (continued) NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Boiler Model V8H6W/S V8H7W/S...
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SECTION XVI: REPAIR PARTS (continued) CARLIN EZ and 102CRD OIL BURNER PART NUMBERS FOR V8H SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Installation and Operating Instructions for Packaged Heating/Burner Units, Carlin Elite EZ-1HP and EZ-2HP Oil Burners (Form CCT-569A) for an exploded view of the burner and a list of spare parts.
APPENDIX A - LOW WATER CUT OFF (LWCO) WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When Select the appropriate size tee using the LWCO manufacturer’s instructions.
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APPENDIX A - LOW WATER CUT OFF (LWCO) (continued) A 24 VAC LWCO is used primarily for gas fired How to Test boilers where a 24 volt control circuit exists within the Shut off fuel supply. Lower water level until water boiler.
APPENDIX B - FIGURES Figure Page Description Number Number Section I - Product Description, Specification & dimensional Data Figure 1A V8H3 thru V8H9 Water Boiler without Tankless Heater Figure 1B V8H3 thru V8H9 Water Boiler with Front Tankless Heater Figure 1C V8H3 thru V8H9 Water Boiler with Rear Tankless Heater Figure 1D V8H3 thru V8H9 Steam Boiler with or without Tankless Heater...
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APPENDIX B - FIGURES (continued) Figure Page Description Number Number Section Ix - Electrical Schematic Wiring Diagram, Water Boiler without Tankless Heater, Cold Start Control Figure 21A (All Burner Options) Schematic Wiring Diagram, Water Boiler with Front or Rear Tankless Heater, Warm Start Control Figure 21B (All Burner Options) Figure 22...
APPENDIX C - TABLES Table Page Description Number Number Section I - Product Description, Specification & Dimensional Data Table 1A Dimensional Data (See Figures 1A thru 1D) Table 1B Rating Data Section VII - Tankless and Indirect Water Heater Piping Table 2A Tankless Heater Data: Rear Mounted Heater on Steam &...
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U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...