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  5. Installation, Operating And Service Instructions

U.S. Boiler Company V13A RO/FO Installation, Operating And Service Instructions

Manual is about: V1 RO/FO SERIES OIL FIRED BOILER

Summary of V13A RO/FO

  • Page 1

    103625-01 - 1/13 price - $5.00 installation, operating and service instructions for v1™ ro/fo series oil - fired boiler for service or repairs to boiler, call your heating contractor or oil supplier. When seeking information on boiler, provide boiler model number and serial number as shown on rating...

  • Page 2

    2 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. Danger indicates an imminently hazardous situation which, if not avoided, will resul...

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    3 danger do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. Warning improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in t...

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    4 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...

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    5 section i: general informa tion figure: 1: vi-ro/fo w ater boiler with t ankless heater , beckett afg burner.

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    6 section i: general informa tion (continued) boiler model no. Dimensions w ater content - gallons heat t ransfer surface area - sq. Ft. Actual shipping w eight (lb.) “a” v13a ro/fo 15-7/8" 13.5 13.95 519 v14a ro/fo 19-7/8" 15.9 19.64 603 note: maximum w orking pressure: w ater: 30 psi (w ater only)...

  • Page 7

    7 a. Inspect shipment carefully for any signs of damage. 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of created boiler to the carrier in good condition. 2. Any claims for damage or shortage in shipment must be filed immediately against th...

  • Page 8

    8 iii: installation instructions a. Remove crate - 1. Remove all fasteners at crate skid. 2. Lift outside container and remove with all other inside protective spacers and bracing. Remove parts carton containing safety relief valve, boiler drain valve, circulator, fittings and miscellaneous hardware...

  • Page 9

    9 3. Check that cerafelt gasket is in place on top of the cast iron block. 4. Using screwdriver and pliers, remove the 6½" knock out from the rear panel, as shown in figure 3, step 2. 5. Insert the canopy onto the top of the block and fasten with the four (4) bolts and nuts provided as shown in figu...

  • Page 10

    10 1. For forced circulation hot water heating, refer to figure 6 for recommended boiler piping. Consult i=b=r ,"residential hydronic heating installation and design guide". 2. Plug lower rear 1½" tapping if it is not to be used. 3. Install relief valve and fittings in top of front section, see figu...

  • Page 11

    11 remove the circulator and install a pipe tee between the circulator and boiler return along with a second tee in the supply piping as shown in figure 7. The bypass should be the same size as the supply and return lines with valves located in the bypass and supply outlet as illustrated in figure 7...

  • Page 12

    12 iii: installation instructions (continued) figure 9: schematic tankless heater piping supply line. The flow regulator also limits the flow of supply water regardless of inlet pressure variations in the range of 20 to 125 psi. Warning install automatic mixing valve at tankless heater outlet to avo...

  • Page 13

    13 iv: venting (natural vent - chimney) j. Install breeching. For normal installation in a large confined space refer to local codes for proper selection of the breeching materials. For installation in a confined space such as an under- counter installation, special consideration must be given to th...

  • Page 14

    14 iv: venting (natural vent - chimney) (continued) note: 1. Type l vent material generally means stainless steel inner liner and stainless steel outer covering and separated with 1" thick special high temperature insulation - factory assembled and rated. 2. In a confined space, provide ventilation ...

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    15 figure 13: installation of fo in a confined space with remote chimney note: 1. Type l vent material generally means stainless steel inner liner and stainless steel outer covering and separated with 1" thick special high temperature insulation - factory assembled and rated. 2. In a confined space,...

  • Page 16

    16 iv: venting (natural vent - chimney) (continued) 1. Install draft regulator following instructions furnished with regulator. See figure 14. 2. Consider the chimney overall. Chimneys that have a high heat loss may become less suitable as the heat loss of the home goes down and the efficiency of th...

  • Page 17

    17 v: 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 electr...

  • Page 18

    18 v: electrical (continued) figure 15: schematic w iring diagram, with t ankless heater , w arm start control (beckett burner) r efer t o f igure 16 for schema tic wiring diagram of appropria te burner and oil primar y control option.

  • Page 19

    19 v: electrical (continued) figure 16: schematic wiring diagrams for beckett genisys oil primary control note: apply this burner schematic to appropriate steam or water boiler control schematic, refer to figure 15.

  • Page 20

    20 vi: system start-up a. Always inspect installation before starting burner. 1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to installation instructions contained in this manual. 2. Confirm all electrical, water and oil supplies are turned ...

  • Page 21

    21 vi: system start-up (continued) 4. Checkout put the system into operation and observe at least one complete cycle to make sure that the controller operates properly. See operating section to use boiler control display to assist in determining system operation. E. Check / adjust oil burner before ...

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    22 vi: system start-up (continued) figure 17: "l1" fixed head electrode positioning and gun setting (beckett afg) figure 18: "f" fixed head electrode positioning and gun setting (beckett afg).

  • Page 23

    23 vi: system start-up (continued) f. Start oil burner. 1. Open vent fitting on fuel pump. 2. Press red reset button on primary control, hold for one (1) second and release to reset primary control. 3. Turn ‘on’ burner service switch and allow burner to run until oil flows from vent fitting in a sol...

  • Page 24

    24 vi: system start-up (continued) 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. 5. Cad cell locat...

  • Page 25

    25 vi: system start-up (continued) transition the control to a dedicated pump prime mode, during which the motor, igniter, and valve are powered for four (4) minutes. The yellow light will be on. • at the end of four (4) minutes, the yellow light will turn off and the control will automatically retu...

  • Page 26

    26 vi: system start-up (continued) • after third recycle mode trial, safety switch locks out within safety switch timing indicated on label and control enters restricted mode. Ignition and motor stop and oil valves closes. D. Power failure check: after flame is established, turn the power off to the...

  • Page 27

    27 vii: operating a. Water boilers sequence of operation 1. Water boilers with tankless heaters (warm start), sequence of operation: a. The v1 ro/fo boiler is equipped with a warm start intelligent oil boiler control (warm start boiler control). The warm start boiler control replaces the traditional...

  • Page 28

    28 press and release the “ i ” key on the boiler control to change from one parameter to the next. Each setting will alternately flash between the relevant display code and its corresponding value. Operating mode options t status numbers: standby running self test) bt boiler temperature p operati...

  • Page 29

    29 vii: operating (continued) setpoint of 10°f. The low limit differential is the number of degrees the boiler temperature must decrease below the low limit setpoint before the warm start boiler control takes actions to warm the boiler. These actions include starting the burner and stopping water fl...

  • Page 30

    30 vii: operating (continued) forced off for a dhw call for heat. Refer to table 7a. When an outdoor air reset option card is installed and there is a dhw call for heat there is an adjustable dhw temperature setpoint and priority timer included. Refer to table 7b. Call for heat circulator status t-t...

  • Page 31

    31 viii: maintenance and service instructions a. Water boilers: 1.Filling of boiler and system. General — in a hot water heating system, the boiler and entire system (other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler...

  • Page 32

    32 viii: maintenance and service instructions (continued) c. Attention to boiler while not in operation notice if boiler is not used during winter time, it must be fully drained to prevent freeze damage. 1. Prevent freeze damage important: if boiler is not used during winter time, it must be fully d...

  • Page 33

    33 ix: cleaning of boiler a. To clean flueways 1. Free control capillary tubing, see figure 1. Remove screws from plastic clips securing capillary to jacket. Loosen screw at control well, remove sensing element and place where it will not get damaged. 2. Remove right side jacket panel by removing sc...

  • Page 34

    34 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 about 1805°f, such as during direct flame contac...

  • Page 35

    35 x: troubleshooting a. Combustion 1. Nozzles — although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the v1 ro/fo boiler is the result of extensive testing to obtain the best flame s...

  • Page 36

    36 b. Oil primary control(oil primary) 1. Burner (oil primary) will not come on. A. No power to oil primary. B. Oil primary is in lockout or restricted mode. Press reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into r...

  • Page 37

    37 x: 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. Display status recommended corrective actions err  temperatur...

  • Page 38

    38 xi: repair parts all v1™ ro/fo series 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 o...

  • Page 39

    39 bare boiler assembly key no. Description ro/fo boiler size/quantity part number v13a v14a *1 v13(a) rear outlet canopy carton w/mounting hardware 1 --- 611220351 v14(a) rear outlet canopy carton w/mounting hardware --- 1 611220451 v13(a) front outlet canopy carton w/mounting hardware 1 --- 611220...

  • Page 40

    40 xi: rep air p arts (continued) figure 25: flush jacket components.

  • Page 41

    41 flush jacket components key no. Description ro/fo boiler size/quantity part number v13a v14a 1 complete flush jacket assembly - complete with key item nos. 2 thru 5 1 --- 60422035 --- 1 60422045 2 * jacket left side panel assembly 1 --- 60422032 --- 1 60422042 3 * jacket ro/fo top & rear wrapper ...

  • Page 42

    42 xi: rep air p arts (continued) figure 26: v1 ro/fo t rim and controls.

  • Page 43

    43 xi: repair parts (continued) trim and controls key no. Description ro/fo boiler size/quantity part number v13a v14a 1 trim / control group 1a l7224a1038 warm start aquastat 1 1 104389-01 1b oil primary control, beckett genisys 7505b 1 1 103447-01 1c temperature / pressure gauge, 2-1/2" dia. 1 1 1...

  • Page 44

    44 for replacement oil burner p ar ts, cont act your wholesaler or the burner manuf acturer: r. W . Beckett corp ., 38251 center ridge rd., p . O. Box 1289, el yria, ohio , 1-800-645-2876 44036 xi: r ep air p arts (continued) figure 27: beckett afg oil burner rep air p arts.

  • Page 45

    45 xi: repair parts (continued) beckett afg oil burner part nos. For v1 ro/fo 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 v13a ro/fo v14a ro/fo air...

  • Page 46

    46 figure a2: wiring of typical lwco figure a1: lwco location appendix a: low water cut off (lwco) on hot water boilers when a low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.E. Baseboard...

  • Page 47

    47 appendix a: low water cut off (lwco) on hot water boilers (continued) how to test shut off fuel supply. Close shut-off valves in system supply and return piping located in near boiler piping above lwco as shown in figure a1. Open drain valve to lower water level until water is below the lwco prob...

  • Page 48

    48 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.