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U.S. Boiler Company V8H5, Service Instructions Manual

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U.S. Boiler Company V8H5 Service Instructions Manual Download Page 28

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 EVALUATE  THE  EXISTING  WATER  SYSTEM.

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WARNING

System supply and return piping must be 
connected to correct boiler pipe.

U.S. Boiler Company recommends sizing the 

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(GPM) to allow a 20°F temperature differen-
tial in the system.  When sizing the system 
circulator, the pressure drop of all radiators, 
baseboard and radiant tubing and all connect-
ing piping must be considered.

CAUTION

Maintain minimum ½ inch clearance from hot 
water piping to combustible materials.

B. CONNECT  SYSTEM  SUPPLY  AND  RETURN 

PIPING  TO  BOILER.

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WARNING

The use of a low water cut-off device, while not 

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is highly recommended.

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rear of this manual.

SECTION  V:  WATER  BOILER  PIPING  AND  TRIM

NOTICE

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and water carry over.

Summary of Contents for V8H5

Page 1: ... i o b o t s r i a p e r r o e c i v r e s r o F g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b n o n o i t a m r o f n i r e l i o b e h t f o p o t n o d e t a c o l l e b a L r e b m u N l e d o M r e l i o B r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I H 8 V r o t c a r t n o C g n i t a e H r e b m...

Page 2: ...ccordance 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 Assoc...

Page 3: ...r 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 7KLV ERLOHU LV VXLWDEOH IRU LQVWDOODWLRQ RQ FRP...

Page 4: ...ns 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 7KLV ERLOHU QHHGV IUHVK DLU IRU VDIH RSHUDWLRQ DQG PXVW EH LQVWDOOHG VR WKHUH DUH SURYLVLRQV IRU DGHTXDWH combustion and ventilation air FOHDQ DQG XQREVWUXFWHG FKLPQH ÀXH LV QHFHVVDU WR DOORZ QR LRXV IXPHV WKD...

Page 5: ...00 833 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 RLOHU 0RGHO 6XI 6 6WHDP DWHU SECTION I PRODUCT DESCRIPTION SPECIFICATION AND DIMENSIONAL DATA 7KH 9 6HULHV ERLOHU LV D FDVW LURQ RLO UHG ZDWHU ERLOHU GHVLJQHG IRU FORVHG IRUFHG FLUFXODWLRQ KHDWLQJ V VWHPV RU D ORZ SUHVVXUH VWHDP ERLOHU GHVLJQHG IRU XVH...

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

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

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

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

Page 10: ...G ERLOHU 3529 6 59 5 1 RI DW OHDVW FOHDUDQFH IURP IURQW MDFNHW SDQHO IRU VHUYLFLQJ DQG UHPRYDO RI IURQW WDQNOHVV KHDWHU LQFUHDVH WR IRU KHDWHU I ERLOHU LV HTXLSSHG ZLWK D UHDU WDQNOHVV KHDWHU SURYLGH DW OHDVW VHUYLFH FOHDUDQFH RQ WKH ULJKW VLGH RI WKH ERLOHU RLOHU ÀXHZD V PD EH FOHDQHG HLWKHU IURP WKH WRS or from WKH ULJKW VLGH 3URYLGH DW OHDVW FOHDUDQFH IURP HLWKHU WKH ULJKW VLGH RI WKH ERLOHU or...

Page 11: ...GHWDLOV or E 2XWGRRU DLU PD EH SURYLGHG ZLWK WKH XVH RI WZR 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 w...

Page 12: ...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 R...

Page 13: ...A L4006A Operating Control N A N A L7224 Boiler Control G 1 Bushed to for Drain Valve Optional Return Return H 1 Return Plugged J 1 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 Safety Valve Relief Valve P Auxiliary Tapping Plug...

Page 14: ...emove hinge pin and set door aside Remove WZR ô ORQJ FDS VFUHZV VHFXULQJ WKH KLQJH EUDFNHW WR WKH ERLOHU VHFWLRQ QVWDOO MDFNHW UHDU SDQHO VXSSRUW EUDFNHW 6HH LJXUH WHP OLJQ EUDFNHW ZLWK WZR WDSSHG KROHV LQ UHDU VHFWLRQ DQG VHFXUH ZLWK WZR ORQJ FDS VFUHZV QVWDOO MDFNHW UHDU SDQHO 6HH LJXUH WHP OLJQ KROHV LQ MDFNHW UHDU SDQHO DQG VXSSRUW EUDFNHW 6HFXUH ZLWK WZR ORQJ VKHHW PHWDO VFUHZV DFNHW URQW 3DQ...

Page 15: ...DSK 1R KHFN WKH EXUQHU VZLQJ GRRU LQVXODWLRQ DQG URSH JDVNHW IRU GDPDJH DQG DGKHVLRQ I GDPDJHG UHSODFH LQVXODWLRQ RU JDVNHW I LQVXODWLRQ RU JDVNHW LV ORRVH UHDWWDFK WR VZLQJ GRRU ZLWK 579 RU VLOLFRQH FDXON QVWDOO EXUQHU VZLQJ GRRU LQ UHYHUVH RUGHU IURP 3DUDJUDSK 1R 8VH WKH IROORZLQJ SURFHGXUH WR SURSHUO FORVH DQG VHFXUH WKH EXUQHU VZLQJ GRRU DIWHU LW KDV EHHQ UHPRYHG DQG UH LQVWDOOHG IRU LHOG VVHP...

Page 16: ...UH IRU WKH SURSHU HOHFWURGH VHWWLQJ 5HDGMXVW HOHFWURGH VHWWLQJ WR WKH SURSHU GLPHQVLRQV LI QHFHVVDU J 5HLQVWDOO HFNHWW 0 9 RU 0 HDG K 5HLQVWDOO QR OH OLQH HOHFWURGH DVVHPEO 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 WDE...

Page 17: ...DWFKHV 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 DU...

Page 18: ...Q 7XUQ WKH DGMXVWLQJ FUHZ FORFNZLVH WR PRYH WKH FRPEXVWLRQ KHDG IRUZDUG LQFUHDVLQJ WKH µ GLPHQVLRQ FRXQWHUFORFNZLVH ZLOO SXOO WKH KHDG EDFN GHFUHDVLQJ WKH µ GLPHQVLRQ 7R ORFN LQ SODFH UVW WLJKWHQ WKH WKXPE QXW DQG WKHQ WKH ORFNLQJ VFUHZ F QLWLDO LU 6KXWWHU DQG 6HWWLQJ L 7KH DLU VKXWWHU KDV D SRLQWHU ZKLFK LQGLFDWHG WKH SHUFHQW RI RSHQLQJ DJDLQVW D FDOLEUDWHG VFDOH IXOO RSHQ 7KH VHWWLQJ LV ORFNHG L...

Page 19: ... VFUHZ XQWLO WKH LQGH PDUNHU LV DOLJQHG ZLWK WKH FRUUHFW LQGH QXPEHU LQ WKH XUQHU 6HWXS KDUW 7DEOH DW WKH UHDU RI WKLV PDQXDO LLL 5HWLJKWHQ WKH UHWDLQLQJ QXW 02 WKUX 6HFWLRQ HUR DQG IRXU DUH VFDOH LQGLFDWRUV RQO URP OHIW WR ULJKW WKH UVW OLQH LV DQG WKH ODVW OLQH 02 WKUX 6HFWLRQ 6DPH DV DERYH H FHSW VFDOH LQGLFDWRUV DUH DQG J 3XPS RQQHFWLRQV DQG 3RUW GHQWL FDWLRQ UHIHU WR LJXUH 7KLV EXUQHU LV VKLS...

Page 20: ...WKH EROW VORWV DUH SDUDOOHO WR WKH ERLOHU IURQW H 3ODFH D FLUFXODU ÀDQJH JDVNHW LQ WKH ÀDQJH JURRYH RQ WKH FLUFXODWRU DQG PRXQW WKH FLUFXODWRU RQ WKH ÀDQJH 1RWH WKDW WKLV LV WKH UHWXUQ SLSLQJ DQG WKH ÀRZ DUURZ RQ WKH FLUFXODWRU VKRXOG SRLQW GRZQ Ð DVWHQ FLUFXODWRU ZLWK ò ORQJ FDS VFUHZV DQG QXWV I DVWHQ WKH VHFRQG FLUFXODWRU ÀDQJH DQG JDVNHW WR WKH FLUFXODWRU J 5HPRYH VXSSOLHG FLUFXODWRU KDUQHVV I...

Page 21: ...7 GUDLQ YDOYH LQWR WKH ò 137 WDSSLQJ ORFDWHG LQ WKH ORZHU ULJKW FRUQHU RI WKH IURQW VHFWLRQ 7LJKWHQ ZLWK ZUHQFK NOTICE Lower rear section Tapping H is used for standard condensate return on steam boilers 7KUHDG VDIHW YDOYH DV VKRZQ LQ LJXUH LQWR ô 137 FRXSOLQJ DQG ô 137 QLSSOH SUHYLRXVO LQVWDOOHG LQ 3DUDJUDSK 1R VWHS E 7LJKWHQ ZLWK ZUHQFK 3LSH GLVFKDUJH DV VKRZQ LQ LJXUH QVWDOODWLRQ RI WKH VDIHW U...

Page 22: ...RO IRU PRUH GHWDLOV E 5HIHU WR 3DUDJUDSK 5 IRU GHWDLOV RQ XVH RI EXUQHU GLVFRQQHFW MXQFWLRQ ER SURYLGHG ZLWK DOO NQRFNGRZQ ERLOHU EXLOGV P INSTALL TRIM AND CONTROLS WITH CARLIN BURNERS Water boilers Only VHH LJXUHV DQG ROORZ LQVWUXFWLRQV LQ 3DUDJUDSK 1 6WHSV WKURXJK Steam Boilers Only VHH LJXUHV DQG ROORZ LQVWUXFWLRQV LQ 3DUDJUDSK 2 6WHSV WKURXJK RQQHFW LHOG LULQJ D 6WHDP RLOHU ZLWK GUROHYHO 2 Car...

Page 23: ... DTXDVWDW FRQWURO WR WKH 5 RQWURO HQWHU V 5 WHUPLQDOV 0DNH WKH ZLULQJ FRQQHFWLRQV DV VKRZQ LQ DSSURSULDWH ZLULQJ GLDJUDP UHIHU WR LJXUH 23A 23B 24A or 24B Note DO NOT UHPRYH 7 7 MXPSHU XQOHVV ZLULQJ GLDJUDP LQGLFDWHV D GLUHFW FRQQHFWLRQ IURP WKHUPRVWDW DQG RU WDQNOHVV KHDWHU DTXDVWDW FRQWURO WR WKH RLO EXUQHU SULPDU FRQWURO V 7 7 terminals OVR UHIHU WR 6HFWLRQ 3DUDJUDSK WHP 9HULI 2LO 3ULPDU RQWURO...

Page 24: ...p 2 RRVHQ DQG UHPRYH OHIW VLGH KLQJH KDUGZDUH OJ KH KHDG ÀDQJH EROW Step 3 7KH GXHO SLYRW DUWLFXODWHG KLQJH DOORZV ULJKW VLGH RI GRRU WR EH SXOOHG RXWZDUG DQG URWDWHG WR WKH OHIW DOO LQ RQH PRWLRQ 7R GR VR SODFH RXU ULJKW KDQG XQGHU EXUQHU DLU WXEH DQG OLIW XS VOLJKWO WR KHOS FDUU WKH ZHLJKW RI WKH GRRU DQG EXUQHU 8VH RXU OHIW KDQG WR JUDVS WKH GRRU V OHIW VLGH KLQJH ÀDQJH SXOO RXWZDUG WR URWDWH W...

Page 25: ... ÀDQJH EROW VHFRQG Apply DGGLWLRQDO SUHVVXUH ZKLOH KDQG WLJKWHQLQJ WKH KDUGZDUH DV IDU DV SRVVLEOH WKHQ UHOHDVH WKH pressure Figure 13A Partial Front View Burner Swing Door Mounted to Boiler Fully Closed and Secured NOTICE When securing burner swing door make sure door LV GUDZQ LQ HTXDOO RQ ERWK VLGHV Step 4 8VH D KDQG ZUHQFK WR WLJKWHQ GRRU KDUGZDUH and DOZD V VWDUW ZLWK WKH ULJKW VLGH ÀDQJH QXW ...

Page 26: ...26 Figure 13B Top View Burner Swing Door Mounted to Cast Iron Block Assembly Jacket Removed for Clarity SECTION IV PACKAGED BOILER ASSEMBLY continued ...

Page 27: ...XGHG LQ WULP EDJ 6DIHW RU 5HOLHI 9DOYH PXVW EH LQVWDOOHG ZLWK VSLQGOH LQ YHUWLFDO SRVLWLRQ 3LSH GLVFKDUJH DV VKRZQ LQ LJXUHV DQG QVWDOODWLRQ RI WKH VDIHW RU UHOLHI YDOYH PXVW EH FRQVLVWHQW ZLWK 16 60 RLOHU DQG 3UHVVXUH 9HVVHO RGH 6HFWLRQ 9 WARNING Safety valve discharge piping must be piped near ÀRRU WR HOLPLQDWH SRWHQWLDO RI VHYHUH EXUQV DO NOT pipe in any area where freezing could occur DO NOT i...

Page 28: ...P LV SLSHG LQ SDUDOOHO ZLWK WKH KHDWLQJ ERLOHU XVLQJ DSSURSULDWH YDOYHV WR SUHYHQW WKH FKLOOHG PHGLXP IURP HQWHULQJ WKH ERLOHU 6HH LJXUH OVR FRQVXOW 5HVLGHQWLDO GURQLF HDWLQJ QVWDOODWLRQ DQG HVLJQ 5 XLGH I WKLV ERLOHU LV FRQQHFWHG WR KHDWLQJ FRLOV ORFDWHG LQ DLU KDQGOLQJ XQLWV ZKHUH WKH PD EH H SRVHG WR UHIULJHUDWHG DLU WKH ERLOHU SLSLQJ PXVW EH HTXLSSHG ZLWK ÀRZ FRQWURO YDOYHV WR SUHYHQW JUDYLW F...

Page 29: ...G UVW EH LVRODWHG WR DYRLG D SUHVVXUH ORVV GXH WR WKH HVFDSH RI DLU WUDSSHG PXVW UVW EH UHPRYHG IURP WKH ERLOHU 7R SHUIRUP D ORQJ WHUP SUHVVXUH WHVW LQFOXGLQJ WKH ERLOHU WUDSSHG DLU PXVW UVW EH UHPRYHG IURP WKH ERLOHU ORVV RI SUHVVXUH GXULQJ VXFK D WHVW ZLWK QR YLVLEOH ZDWHU OHDNDJH LV DQ LQGLFDWLRQ WKDW WKH ERLOHU FRQWDLQHG WUDSSHG DLU SECTION V WATER BOILER PIPING AND TRIM continued ...

Page 30: ...30 Figure 15A Recommended Water Piping for Circulator Zoned Heating System Supply Side Circulators SECTION V WATER BOILER PIPING AND TRIM continued ...

Page 31: ...31 Figure 15B Recommended Water Piping for Zone Valve Zoned Heating System Supply Side Circulator SECTION V WATER BOILER PIPING AND TRIM continued ...

Page 32: ...ly pipe boiler may result in improper operation and damage to boiler or structure DO NOT increase steam boiler input above the ratings DO NOT use softened water in steam boilers Accelerated boiler corrosion will result Tie in fresh water supply to the boiler upstream of a water softener Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to bo...

Page 33: ...iler Piping for Gravity Return Steam Boiler SECTION VI STEAM BOILER PIPING AND TRIM continued NOTICE DLOXUH WR SLSH ERLOHU DV VSHFL HG LQ WKLV PDQXDO PD UHVXOW LQ H FHVVLYH V VWHP QRLVH ZDWHU OLQH ÀXFWXDWLRQV and water carry over ...

Page 34: ...RW ZDWHU ZKLOH VHHNLQJ D ZDWHU WHPSHUDWXUH LJKHU WHPSHUDWXUH KRW ZDWHU UHTXLUHG E GLVKZDVKHUV DQG DXWRPDWLF ZDVKHUV LV SRVVLEOH E SLSLQJ WKH KRW ZDWHU IURP WKH KHDWHU SULRU WR HQWHULQJ WKH PL LQJ YDOYH 7KH PL LQJ YDOYH VKRXOG EH WUDSSHG E LQVWDOOLQJ LW EHORZ WKH FROG ZDWHU LQOHW WR KHDWHU WR SUHYHQW OLPH IRUPDWLRQ LQ WKH YDOYH 5HIHU WR LJXUH 86 1 2 7 5 OO ZDWHU FRQWDLQV VRPH VHGLPHQW ZKLFK VHWWOHV...

Page 35: ...ater Steam Water V8H3 V1 2 2 75 3 3 9 4 7 V8H4 V1 2 3 3 25 4 7 5 6 V8H5 V1 2 3 25 3 5 5 6 6 4 V8H6 V1 2 3 75 3 75 7 2 7 2 V8H7 V1 2 3 75 4 7 2 8 V8H8 V1 2 4 4 5 8 9 8 V8H9 V1 2 4 4 5 8 9 8 Boiler Model Heater No Heater Rating GPM Pressure Drop thru Heater PSI V8H3 222A 3 22 V8H4 222A 3 5 22 V8H5 222A 4 30 5 V8H6 222A 4 5 33 V8H7 222A 4 6 33 A54 5 5 36 V8H8 222A 4 75 40 A54 6 39 5 V8H9 222A 4 75 40...

Page 36: ...g with V8H Steam Boiler B CONNECT INDIRECT DOMESTIC WATER HEATER PIPING DV VKRZQ LQ LJXUH 5HIHU WR QGLUHFW DWHU HDWHU QVWDOODWLRQ 2SHUDWLQJ DQG 6HUYLFH QVWUXFWLRQV IRU DGGLWLRQDO information SECTION VII TANKLESS AND INDIRECT WATER HEATER PIPING cont d ...

Page 37: ... VWDFN WHPSHUDWXUH DQG OHVV GLOXWLRQ DLU FDQ LQ VRPH FDVHV FRQWULEXWH WR WKH FRQGHQVLQJ RI VPDOO DPRXQWV RI ZDWHU YDSRU LQ WKH FKLPQH 6XFK FRQGHQVDWLRQ ZKHQ LW RFFXUV FDQ FDXVH FKLPQH GHWHULRUDWLRQ Q H WUHPH FDVHV WKH FKLPQH PD KDYH WR EH OLQHG WR LQVXODWH WKH FKLPQH DQG WKXV SUHYHQW WKH FRQGHQVDWLRQ 7KH DGGLWLRQ RI GLOXWLRQ DLU LQWR WKH FKLPQH PD DVVLVW LQ GU LQJ WKH FKLPQH LQWHULRU VXUIDFHV PDVV...

Page 38: ...38 Figure 19 Proper and Improper Locations of Draft Regulator LJXUH 5HFRPPHQGHG 9HQW 3LSH UUDQJHPHQW DQG KLPQH 5HTXLUHPHQWV SECTION VIII VENTING AND AIR INTAKE PIPING continued ...

Page 39: ...VWHQ ZLWK D VFUHZ DQG QXW LQ FROODU WDEV 7R HQVXUH SURSHU RSHUDWLRQ WKH JDWH PXVW EH OHYHO DFURVV WKH SLYRW SRLQW DQG SOXPE 5HIHU WR YDFXXP UHOLHI YDOYH PDQXIDFWXUHU V LQVWUXFWLRQV QVWDOO UHPDLQGHU RI DLU LQWDNH VHFXULQJ HDFK MRLQW ZLWK DW OHDVW WKUHH VKHHW PHWDO VFUHZV HYHQO VSDFHG QVWDOO DLU LQWDNH WHUPLQDO 6HH LJXUH NOTICE Intake terminal must be at least 12 inches above grade plus snow accumul...

Page 40: ...UH DZD IURP WKHUPRVWDW VR WKHUH ZLOO EH IUHH PRYHPHQW RI URRP DLU DURXQG WKLV FRQWURO HDW QWLFLSDWRU LQ 7KHUPRVWDW VKRXOG EH VHW WR PDWFK WKH UHTXLUHPHQWV RI WKH FRQWURO WR ZKLFK LW LV FRQQHFWHG 6HH LJXUHV WKUX IRU GHVLUHG V VWHP DQG KHDW DQWLFLSDWRU VHWWLQJ I V VWHP WHQGV WR RYHUKHDW DERYH WKH WKHUPRVWDW V WHPSHUDWXUH VHWWLQJ UHGXFH KHDW DQWLFLSDWRU VHWWLQJ E RU DPSV I V VWHP WHQGV WR VKRUW F FOH...

Page 41: ...tic Wiring Diagram Water Boiler without Tankless Heater Cold Start Control All Burner Options SECTION IX ELECTRICAL continued SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 42: ...iring Diagram Water Boiler with Front or Rear Tankless Heater Warm Start Control All Burner Options SECTION IX ELECTRICAL continued SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 43: ... Schematic Wiring Diagram Steam Boiler Hydrolevel CG450 Probe LWCO All Burner Options SECTION IX ELECTRICAL continued SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 44: ...rlin Burners SECTION IX ELECTRICAL continued McDonnell Miller PS 801 Terminals May Be Lettered or Numbered as Follows Wire Color Numbered Terminals Lettered Terminals RD 5 B BK 1 H WH 2 N Jumper 1 3 H C SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 45: ... Burners SECTION IX ELECTRICAL continued McDonnell Miller PS 801 Terminals May Be Lettered or Numbered as Follows Wire Color Numbered Terminals Lettered Terminals RD 5 B BK 1 H WH 2 N Jumper 1 3 H C SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 46: ...hematic Wiring Diagram Steam Boiler McDonnell Miller 67 Float LWCO Beckett Carlin Burners SECTION IX ELECTRICAL continued SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 47: ...B Schematic Wiring Diagram Steam Boiler McDonnell Miller 67 Float LWCO Riello Burners SECTION IX ELECTRICAL continued SEE FIGURE 25 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPTION ...

Page 48: ...48 SECTION IX ELECTRICAL continued Figure 25 Schematic Wiring Diagrams For All Burner Options w Various Oil Primary Controls ...

Page 49: ... VPDOOHU WKDQ LURQ SLSH RU 2 FRSSHU WXELQJ RSSHU WXELQJ VKDOO KDYH D PLQLPXP ZDOO WKLFNQHVV WARNING Under no circumstances can copper with sweat style connectors be used NOTICE 6RPH MXULVGLFWLRQV UHTXLUH WKH XVH RI D IXVLEOH shutoff valve at the tank and or the burner In DGGLWLRQ VRPH MXULVGLFWLRQV UHTXLUH WKH XVH RI D fusible electrical interlock with the burner circuit KHFN RXU ORFDO RGHV IRU VS...

Page 50: ...K DQG LQFK 2 WXELQJ IRU ERWK VXFWLRQ DQG UHWXUQ OLQHV 5HIHU WR LJXUH Lift H See Fig 25 Maximum Length of Tubing H R See Figure 27 3 8 OD Tubing 3 GPH 1 2 OD Tubing 3 GPH 0 93 100 2 85 100 4 77 100 6 69 100 8 60 100 10 52 100 12 44 100 14 36 100 16 27 100 18 76 Lift H See Fig 25 Maximum Length of Tubing H R See Figure 27 3 8 OD Tubing 3 GPH 1 2 OD Tubing 3 GPH 0 84 100 1 78 100 2 73 100 3 68 100 4 ...

Page 51: ...QJ DQG HOHFWULFDO V VWHP DUH LQVWDOOHG SURSHUO 5HIHU WR QVWDOODWLRQ QVWUXFWLRQV FRQWDLQHG LQ WKLV PDQXDO RQ UP DOO HOHFWULFDO ZDWHU DQG RLO VXSSOLHV DUH WXUQHG RII DW WKH VRXUFH DQG WKDW WKH YHQW LV FOHDU IURP REVWUXFWLRQV WARNING Completely read understand and follow all instructions in this manual before attempting start up B FILL HEATING SYSTEM WITH WATER NOTICE It is important especially in a ...

Page 52: ...S YHQW WWLQJ DQG SURYLGH D SDQ WR FDWFK WKH RLO H 23 1 0 2 6 59 7 21 3257 29 5 RQ EXUQHU VZLQJ GRRU 3 Carlin Elite EZ Burners D QVSHFW DUOLQ KHDG VHWWLQJ RQ OHIW VLGH RI EXUQHU WR HQVXUH WKDW WKH SURSHU KHDG SRVLWLRQLQJ EDU PDWFKHV WKH QR OH WKDW LV LQVWDOOHG LQ GUDZHU DVVHPEO 5HIHU WR 6HFWLRQ 3DUDJUDSK 6WHS E DQG 7DEOH DW WKH UHDU RI WKLV PDQXDO 5HSODFH EDU LI QHFHVVDU E KHFN DLU EDQG VHWWLQJV 5H...

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Page 54: ...54 Figure 29A L1 and V1 Head Electrode Positioning and Gun Setting Beckett AFG SECTION XI SYSTEM START UP continued ...

Page 55: ...SHUDWLRQ DERXW WR WLPHV ZLOO rid oil line of this air 12 217 18 6 72 5 3 UHSHDW 3DUDJUDSK 1R DERYH I WKLV GRHV QRW VWRS WKH GULSSLQJ UHPRYH FXW RII YDOYH DQG VHDW DQG ZLSH ERWK ZLWK D FOHDQ FORWK XQWLO FOHDQ WKHQ UHSODFH DQG UHDGMXVW RLO SUHVVXUH I GULSSLQJ RU DIWHU EXUQ SHUVLVW UHSODFH IXHO SXPS I TEST CONTROLS KHFN WKHUPRVWDW RSHUDWLRQ 5DLVH DQG ORZHU WKHUPRVWDW VHWWLQJ DV UHTXLUHG WR VWDUW DQG ...

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Page 60: ...S RZQ Ø and I NH V PD EH XVHG WR YLHZ ERLOHU RSHUDWLQJ VWDWXV LJXUH 4 Viewing the Operating Mode Options Q RSHUDWLQJ PRGH WKH XVHU PD YLHZ EXW QRW FKDQJH ERLOHU RSHUDWLQJ VWDWXV VHWWLQJV DQG WURXEOHVKRRWLQJ LQIRUPDWLRQ 7R YLHZ RLOHU RQWURO GLVSOD LQIRUPDWLRQ Press and release the I NH RQ WKH RLOHU RQWURO WR FKDQJH IURP RQH SDUDPHWHU WR WKH QH W DFK VHWWLQJ ZLOO DOWHUQDWHO ÀDVK EHWZHHQ WKH UHOHYDQW...

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Page 64: ...pirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection 7DNH VWHSV WR DVVXUH DGHTXDWH YHQWLODWLRQ DVK DOO H SRVHG ERG DUHDV JHQWO with soap and water after contact DVK ZRUN FORWKHV VHSDUDWHO IUom other laundry and rinse washing machine after use to avoid contaminating other clothes LVFDUG XVHG 5 FRPSRQHQWV E VHDOLQg in an airtight plastic bag RCF and crystalline silica are not clas...

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Page 66: ...RZQ LQ LJXUH DQG SURFHHG DV IROORZV L RQQHFW KRVHV IURP GUDLQ YDOYHV WR ÀRRU GUDLQ ORVH JDWH YDOYH LQ DUWIRUG RRS DQG RSHQ GUDLQ YDOYH LQ UHWXUQ PDLQ LOO ERLOHU WR QRUPDO ZDWHU OHYHO WXUQ RQ RLO EXUQHU DQG RSHUDWH ERLOHU DW WKLV ZDWHU OHYHO IRU DW OHDVW PLQXWHV DIWHU WKH FRQGHQVDWH EHJLQV WR UXQ KRW WKHQ WXUQ RII EXUQHU Close all radiator valves Remove all supply main air valves and plug the openi...

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Page 68: ...RLOHU WR WRS RI ZDWHU FROXPQ DQG OHDYH LW WKDW ZD XQWLO IDOO ZKHQ ZDWHU VKRXOG EH GUDLQHG DJDLQ WR SURSHU OHYHO I DW WKLV WLPH ERLOHU ZDWHU LV GLUW GUDLQ ZDWHU ÀXVK RXW ERLOHU DQG UH OO ZLWK FOHDQ ZDWHU WR SUHVFULEHG ZDWHU OHYHO OZD V NHHS WKH PDQXDO IXHO VXSSO YDOYH VKXW RII LI WKH EXUQHU LV VKXW GRZQ IRU DQ H WHQGHG SHULRG RI time 7R UHFRQGLWLRQ WKH KHDWLQJ V VWHP LQ WKH IDOO VHDVRQ DIWHU D SURO...

Page 69: ...r D AFTER CLEANING UHPRYH SURWHFWLYH FORWK RU SODVWLF ZLWK GHEULV DQG YDFXXP DV QHFHVVDU EXW EH FDUHIXO QRW WR GDPDJH EODQNHW QVSHFW WDUJHW ZDOO FRPEXVWLRQ FKDPEHU EODQNHW EXUQHU VZLQJ GRRU LQVXODWLRQ DQG URSH JDVNHW IRU VLJQV RI GDPDJH I GDPDJHG UHSODFH DV QHHGHG E REASSEMBLE BOILER CAUTION DO NOT start the burner unless canopy vent pipe EXUQHU VZLQJ GRRU DQG DOO ÀXH FRYHU SODWHV DUH secured in p...

Page 70: ...QH 7KH LQWHULRU RI WKH FKLPQH ÀXH PXVW EH inspected and cleaned before the start of the heating season and should be inspected periodically throughout WKH KHDWLQJ VHDVRQ IRU DQ REVWUXFWLRQV FOHDQ DQG XQREVWUXFWHG FKLPQH ÀXH LV QHFHVVDU WR DOORZ QR LRXV fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s HI FLHQF SECTION XIV BOILER CLEANI...

Page 71: ...KH VPDOOHU WKH ULQJ UDWH WKH VPDOOHU WKH VORWV EHFRPH LQ WKH QR OH DQG WKH PRUH SURQH WR SOXJJLQJ LW EHFRPHV ZLWK WKH same amount of dirt SECTION XV TROUBLESHOOTING 7 5 DWHU LQ WKH IXHO LQ ODUJH DPRXQWV ZLOO stall the fuel pump Water in the fuel in smaller DPRXQWV ZLOO FDXVH H FHVVLYH ZHDU RQ WKH SXPS EXW PRUH LPSRUWDQWO ZDWHU GRHVQ W EXUQ W FKLOOV WKH ÀDPH DQG FDXVHV VPRNH DQG XQEXUQHG IXHO WR SD...

Page 72: ...cur if the Oil Primary Control locks out three 3 times during a call for heat This is indicated by red light reset button solid on C INTELLIGENT OIL BOILER CONTROL ROG 6WDUW RLOHU RQWURO is used on Boilers ZLWKRXW 7DQNOHVV HDWHUV Warm Start Boiler Control is used on Boilers ZLWK 7DQNOHVV HDWHUV KHQ D SUREOHP RFFXUV ZLWK WKH ERLOHU RSHUDWLRQ WKH RLOHU RQWURO HDVLO SURYLGHV VSHFL F YDOXDEOH LQIRUPDW...

Page 73: ...ed powered during safety output relay check sequence or un powered during running or powered in idle in combination with water temperature above 264 F limit Cycle power to the control Replace control if problem persists UU Line Voltage Fault 80 Vac YROWDJH RXW RI VSHFL FDWLRQ KLJK RU ORZ FKHFN 9 UU Fuse missing Internal fuse is blown or missing The fuse protects the Aquastat from miswiring the L1 ...

Page 74: ...ORFDO 8 6 RLOHU RPSDQ KROHVDOH GLVWULEXWRU 6KRXOG RX UHTXLUH DVVLVWDQFH LQ ORFDWLQJ D 8 6 RLOHU RPSDQ LVWULEXWRU LQ RXU DUHD RU KDYH TXHVWLRQV UHJDUGLQJ WKH DYDLODELOLW RI 8 6 RLOHU RPSDQ SURGXFWV RU UHSDLU SDUWV SOHDVH FRQWDFW 8 6 RLOHU RPSDQ XVWRPHU 6HUYLFH DW RU D Bare Boiler Assembly ...

Page 75: ... Lg 80861035 2 Tie Rod 3 8 16 x 37 Lg 80861105 2 Tie Rod 3 8 16 x 42 Lg 80861106 2 1G 3 8 Flat Washer 80860600 4 4 4 4 4 4 4 1H 3 8 16 Hex Nut 80860423 4 4 4 4 4 4 4 1J Heater Cover Plate Gasket Front Heater 8036068 1 1 1 1 1 1 1 Heater Cover Plate Gasket Rear Heater 8036058 1 1 1 1 1 1 1 1K Blank Heater Cover Plate WN Front Heater 7036002 1 1 1 1 1 1 1 Tapped Heater Cover Plate WF L Front Heater ...

Page 76: ...76 Bare Boiler Assembly Continued SECTION XVI REPAIR PARTS continued ...

Page 77: ...2802 2 2 2 2 2 2 2 1W 5 16 18 x 5 8 Lg Plated Cap Screw 80861377 2 2 2 2 2 2 2 1X Intermediate Hinge Painted Black 7022801 1 1 1 1 1 1 1 1Y Hinge Pin 80861707 2 2 2 2 2 2 2 1Z 042 Dia x 15 16 Lg Hairpin Cotter 80861667 2 2 2 2 2 2 2 1AA 5 16 18 x 2 Lg Stud Threaded Both Ends 80861606 1 1 1 1 1 1 1 1BB 5 16 Flat Washer Plated 80860611 1 1 1 1 1 1 1 1CC 5 16 18 Flange Nut Plated 80860443 1 1 1 1 1 1...

Page 78: ...78 Jacket Assembly SECTION XVI REPAIR PARTS continued ...

Page 79: ...952 02 102952 03 1 102952 04 1 102952 05 1 102952 06 1 102952 07 1 102952 08 1 102952 09 1 2F Jacket Top Panel Assembly 604280221 604280321 1 604280421 1 604280521 1 604280621 1 604280721 1 604280821 1 604280921 1 2G Jacket Right Side Access Panel Assembly without Heater Opening 604280231 604280331 1 604280431 1 604280531 1 604280631 1 604280731 1 604280831 1 604280931 1 Jacket Right Side Access P...

Page 80: ...80 V8H3 Thru V8H9 Steam Boilers Trim and Controls SECTION XVI REPAIR PARTS continued ...

Page 81: ...s Set 6 ConBraCo 20 104 10 8056091 1 1 1 1 1 1 1 3L Low Water Cut off McDonnell Miller 67 BC 8 80160597 1 1 1 1 1 1 1 3M Bushing 1 NPT x FPT Malleable 806600507 1 1 1 1 1 1 1 3N Drain Valve NPT ConBraCo 35 302 03 806603061 1 1 1 1 1 1 1 3P Nipple NPT x 8 Lg 806600221 1 1 1 1 1 1 1 3Q Coupling NPT Malleable 806602561 1 1 1 1 1 1 1 3R Safety Valve FIP 15 psi ConBraCo 13 511 B15 81660530 1 1 1 1 1 1 ...

Page 82: ...82 V8H3 Thru V8H9 Water Boilers Trim and Controls SECTION XVI REPAIR PARTS continued ...

Page 83: ...ver Painted Sherpa Blue 61328251 1 1 1 1 1 1 1 4G 2 x 4 Junction Box Painted Sherpa Blue 61328252 1 1 1 1 1 1 1 4H Plug Square Head 1 NPT Packaged 806603515 1 1 1 1 1 1 1 Reducing Bushing 1 NPT x FPT Knockdown 806600507 4J Nipple NPT x 8 Lg 806600221 1 1 1 1 1 1 1 4K Relief Valve Conbraco FIP x FIP 10 408 05 30 PSI 81660319 1 1 1 1 1 1 1 10 303 07 40 PSI 81660370 10 303 10 50 PSI 81660302 4L 6 Dra...

Page 84: ...84 Beckett AFG Burner SECTION XVI REPAIR PARTS continued ...

Page 85: ...ector Tube Assembly 5636 5636 5636 Electrode Clamp 149 149 149 Electrode Clamp Screw 4219 4219 4219 Electrode Insulator Assembly 5780 5780 5780 Support Spacer Assembly 5992 5992 5992 Escutcheon Plate 3493 Adjusting Plate Assembly 5941 5941 Head 5912 5913 5913 Head Screws 4221 4221 4221 Flange Gasket 3811 3811 3811 AFG Housing 5874GY 5874GY 5874GY Motor 21805E 218 21805E 218 21805E 218 Nozzle Adapt...

Page 86: ... 5636 Electrode Clamp 149 149 149 149 Electrode Clamp Screw 4219 4219 4219 4219 Electrode Insulator Assembly 5780 5780 5780 5780 Support Spacer Assembly 5992 5992 5992 5992 Escutcheon Plate Adjusting Plate Assembly 5941 5941 5941 5941 Head 5913 5913 5913 5913 Head Screws 4221 4221 4221 4221 Flange Gasket 3811 3811 3811 3811 AFG Housing 5874GY 5874GY 5874GY 5874GY Motor 21805E 218 21805E 218 21805E...

Page 87: ...PDQXIDFWXUHU 7 DUOLQ RPEXVWLRQ 7HFKQRORJ QF 0DSOH 6WUHHW DVW RQJPHDGRZ 0 7HOHSKRQH DFVLPLOH RIELLO 40 OIL BURNER PART NUMBERS FOR V8H SERIES BOILERS 127 KHQ RUGHULQJ SDUWV DOZD V JLYH WKH VHULDO DQG PRGHO QXPEHUV VKRZQ RQ WKH ERLOHU DQG EXUQHU 5HIHU WR 0RGHOV QVWDOODWLRQ 0DQXDO 5LHOOR 6HULHV 5HVLGHQWLDO 2LO XUQHUV RU 0RGHO QVWDOODWLRQ 0DQXDO 5LHOOR 6HULHV 5HVLGHQWLDO 2LO XUQHUV IRU DQ H SORGHG YLH...

Page 88: ...0 40 F5 5 5 2 0 1 20 x 80B 145 V8H5W 1 65 V1 2 10 5 1 35 x 60B 140 1 35 1 50 1 35 1 35 x 60B 150 40 F5 5 2 4 0 1 35 x 70B 145 V8H6S 1 65 V1 2 10 3 1 35 x 60B 140 EZ 2HP 1 50 1 75 1 35 x 60A 170 40 F10 3 2 3 0 1 50 x 45B 145 V8H6W 1 90 V1 3 10 3 5 1 50 x 45B 160 EZ 66 5 100 1 65 x 60B 140 40 F10 3 7 2 0 1 65 x 60B 145 V8H7S V8H7W 2 10 V1 4 10 3 1 65 x 45B HAGO 170 102CRD 3 3 50 1 75 x 60B 140 40 F1...

Page 89: ...H SUREH 2 LQ WKH VXSSO RU UHWXUQ SLSLQJ DV VKRZQ EHORZ LWCO Location 6HOHFW WKH DSSURSULDWH VL H WHH XVLQJ WKH 2 PDQXIDFWXUHU V LQVWUXFWLRQV 2IWHQ WKH EUDQFK FRQQHFWLRQ PXVW KDYH D minimum diameter to SUHYHQW EULGJLQJ EHWZHHQ WKH SUREH DQG WKH WHH OVR the run of the tee must have a minimum diameter to SUHYHQW WKH HQG RI WKH SUREH IURP WRXFKLQJ RU EHLQJ ORFDWHG WRR FORVH WR WKH LQVLGH ZDOO RI WKH U...

Page 90: ...QJ FRQQHFWLRQV DQG LQVWUXFWLRQV WR DOORZ IRU WKLV DSSOLFDWLRQ APPENDIX A LOW WATER CUT OFF LWCO continued How to Test 6KXW RII IXHO VXSSO RZHU ZDWHU OHYHO XQWLO ZDWHU level is 2 WKH 2 HQHUDWH D ERLOHU GHPDQG E WXUQLQJ XS WKHUPRVWDW RLOHU VKRXOG QRW DWWHPSW WR RSHUDWH QFUHDVH WKH ZDWHU OHYHO E OOLQJ WKH V VWHP 7KH ERLOHU VKRXOG DWWHPSW WR RSHUDWH RQFH WKH ZDWHU OHYHO LV DERYH WKH 2 ...

Page 91: ...imit Installation for Probe LWCO Equipped Boilers Figure 11 23 Burner Disconnect Junction Box with Power Outlet Receptacle Section IV Packaged Boiler Assembly Figure 12 24 Packaged Boiler Removal from Skid Figure 13A 25 Partial Front View Burner Swing Door Mounted to Boiler Fully Closed and Secured Figure 13B 26 Top View Burner Swing Door Mounted to Cast Iron Block Assembly Jacket Removed for Clar...

Page 92: ...r McDonnell Miller 67 Float LWCO Riello Burners Figure 25 48 Schematic Wiring Diagrams For All Burner Options w Various Oil Primary Controls Section X Oil Piping Figure 26 49 Single Pipe Oil Line Figure 27 50 Two Pipe Oil Lines Section XI System Start Up Figure 28 53 Adjusting Fuel Pump Pressure Figure 29A 54 L1 and V1 Head Electrode Positioning and Gun Setting Beckett AFG Figure 29B 55 Electrode ...

Page 93: ...ipe Systems Table 4 50 Single Stage Units 3450 RPM Two Pipe Systems Section XII Operating Table 5 59 Sequence of Operation Table 6 62 Circulator Pre purge Time Example Parameter pp_ 2 minutes Table 7A 62 Domestic Hot Water Demand Parameter B Table 7B 62 Domestic Hot Water Demand Parameter B Outdoor Air Reset Option Card Installed Table 8 63 Zone Request Parameter B 5 Table 9 63 External Low Limit ...

Page 94: ...94 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 95: ...95 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 96: ...96 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net ...

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