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- V8H SERIES
- Installation, Operating And Service Instructions
U.S. Boiler Company V8H SERIES Installation, Operating And Service 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
efficiency established by the
United States Environmental
Protection Agency (EPA).
Price - $5.00
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9700609
Summary of V8H SERIES
Page 1
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 efficiency established by the united states environmental protection agency (epa). Price - $5.00 g n...
Page 2
2 usa boilers a. Current edition of american national standard ansi/nfpa 31, “installation of oil burning equipment”, for recommended installation practices. B. Current edition of american national standard ansi/nfpa 211, “chimneys, fireplaces, vents, and solid fuel burning appliances”, for venting ...
Page 3
3 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 ...
Page 4
4 table of contents i. Product description, specification & dimensional data ..................................... 5 ii. Pre-installation .........................................10 iii. Knockdown boiler assembly ....................12 iv. Packaged boiler assembly .........................24 v. Wate...
Page 5
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...
Page 6
6 figure 1a: v8h3 thru v8h9 w ater boiler without t ankless heater section i: product description, specifica tion and dimensional da ta ( continued ).
Page 7
7 figure 1b: v8h3 thru v8h9 w ater boiler with front t ankless heater section i: product description, specifica tion and dimensional da ta ( continued ).
Page 8
8 figure 1c: v8h3 thru v8h9 w ater boiler with rear t ankless heater section i: product description, specifica tion and dimensional da ta ( continued ).
Page 9
9 figure 1d: v8h3 thru v8h9 steam boiler with or without t ankless heater section i: product description, specifica tion and dimensional da ta ( continued ).
Page 10
10 figure 2: minimum installation clearances to combustible materials (inches) a. Inspect shipment carefully for any signs of damage. 1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition. 2. Any cl...
Page 11
11 c. Provide combustion and ventilation air. Local and national codes may apply and should be referenced. Warning adequate combustion and ventilation air must be provided to assure proper combustion and to maintain safe ambient air temperatures. Do not install boiler where gasoline or other flammab...
Page 12
12 section iii: knockdown boiler assembly a. Removal of bare boiler from skid 1. Boiler is secured to skid with 4 bolts, 2 in front and 2 in rear of shipping skid, see figure 3. Remove all bolts. Figure 3: knockdown boiler removal from skid 2. Tilt boiler to right and to rear. Using right rear leg a...
Page 13
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 flu...
Page 14
14 figure 6: knockdown boiler jacket assembly h. Install trim. The following steam or water trim will be concealed or inaccessible after boiler jacket is installed, see figure 5 for boiler tapping locations and usage. 1. Steam boiler — top tappings: a. Tapping "l" — install 2" npt plug in rear secti...
Page 15
15 6. 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” long sheet metal screws. 7. Install jacket right side access panel. (see figure 6, item 2g). Align right side panel mounting holes with front and rear...
Page 16
16 notice when securing burner swing door make sure door is drawn-in equally on both sides. Step 3. Use a hand wrench to tighten door hardware and always start with the right side flange nut first (see figure 13b). Use an alternating tightening method from right side flange nut to left side flange b...
Page 17
17 7. Inspect oil nozzle, electrodes and head setting. A. Installation/removal of drawer assembly i. Loosen screws, rotate latches and swing open the transformer. Ii. The combustion head assembly can be removed with the blower wheel access cover in place or removed. If the access cover is removed, t...
Page 18
18 iii. Re-install the combustion head assembly into the air tube. It may be necessary to turn nozzle line assembly upside down to ease insertion into the air tube. Then the threaded adapter on the end of the nozzle line is passed through the opening in the left side of the housing. Iv. Run the alum...
Page 19
19 if nozzle needs replacement, follow steps below also refer to figure 7c. I. 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 tighte...
Page 20
20 warning: do not operate a single line system with the by-pass plug installed. Operating a single line system with the by-pass plug installed will result in damage to the pump shaft seal. Note: pump pressure was factory pre-set but must be checked at time of burner start-up. A pressure gauge is at...
Page 21
21 6. After control is installed and secured, remove control cover. Then, remove knockout located directly above factory connected limit harness on right side flange of control. Insert circulator harness end with attached fork terminals thru knockout hole and push-in to engage harness connector into...
Page 22
22 5. Install float-type lwco, if so equipped. See figures 5 and 9. A. Install nipples and unions in "d" tappings. B. Mount hardware to low water cut-off body. Install assembly. C. Install water gage glass on low water cut-off assembly's tee fittings. 6. Install pressure limit control. A. Float lwco...
Page 23
23 figure 11: burner disconnect junction box with power outlet receptacle (mated to burners with disconnect harness) c. Refer to paragraph r for details on use of burner disconnect junction box provided with all knockdown boiler builds. Q. Install trim and controls with riello burner. Water boilers ...
Page 24
24 section iv: packaged boiler assembly a. Remove crate. 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove draft regulator box and miscellaneous trim bag containing safety or relief valve, and pipe fittings. B. Remove ...
Page 25
25 step 4. From this position the door can be swung clear of the vertical circulator return piping to provide full access to the combustion chamber and burner head (see figure 13b, position 3). 2. Perform routine inspection, service or cleaning as necessary. 3. To close burner swing door (see figure...
Page 26
26 figure 13b: t op v iew - burner swing door mounted to cast iron block assembly (jacket removed for clarity) section iv : p ackaged boiler assembl y (continued).
Page 27
27 3. Inspect ceramic rope located on the swing door. The rope must be evenly distributed around the perimeter of the door groove and cannot bunch or overhang. There must not be a gap where the two ends of the rope meet. Repair or replace if the rope is damaged or if there is a gap between the ends....
Page 28
28 a . Evaluate the existing water system. Design a piping system and install boiler which will prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system l...
Page 29
29 figure 14: recommended piping for combination heating and cooling (refrigeration) system 6. If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped must first be removed from the b...
Page 30
30 figure 15a: recommended w ater piping for circulator zoned heating system - supply side circulators section v: w ater b oiler piping and trim (continued).
Page 31
31 figure 15b: recommended w ater piping for zone v alve zoned heating system - supply side circulator section v: w ater b oiler piping and trim (continued).
Page 32
32 section vi: steam boiler piping and trim a. Evaluate the existing steam system. The single most important factor in determining the expected life cycle of a steam boiler, is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler. The...
Page 33
33 figure 16: recommended boiler piping for gravity return steam boiler section vi: steam b oiler piping and trim ( continued ) notice failure to pipe boiler as specified in this manual may result in excessive system noise, water line fluctuations and water carry over ..
Page 34
34 section vii: tankless and indirect water heater piping a. Connect tankless heater piping as shown in figure 17a. See tables 2a and 2b for tankless heater rating. Warning install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fix...
Page 35
35 figure 17a: schematic tankless heater piping table 2a: tankless heater data: rear mounted heater on steam and water boilers table 2b: tankless heater data: front mounted heater on water boilers boiler model heater no. Heater rating (gpm) pressure drop thru heater (psi) steam water steam water v8h...
Page 36
36 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. Section vii: tankless and indirect water...
Page 37
37 a. General venting guidelines 1. Vent system installation must be in accordance with these instructions and applicable provisions of local building codes. Contact local building or fire officials about restrictions and installation inspection in your area. 2. The v8h is designed to be vented into...
Page 38
38 figure 19: proper and improper locations of draft regulator figure 18: recommended vent pipe arrangement and chimney requirements section viii: venting and air intake piping (continued).
Page 39
39 2. After determining location, cut a hole in the wall to accept 4 inch air intake pipe. See figure 20. 3. Remove the metal knockout in right side of burner cover. Install u.S. Boiler company inlet air accessory kit, p/n 611280031. 4. Mount the vacuum relief valve tee assembly (p/n 8116268 include...
Page 40
40 section ix: electrical a. General 1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the national electrical code, ansi/ nfpa 70, and/or the csa c22.1 electric code. 2. Refer to national electri...
Page 41
41 figure 21a: schematic w iring diagram, w ater boiler without t ankless heater , cold start control (all burner options) section ix: electrical (continued ) (s ee f igure 25 for s chema tic w iring d iagram of appropria te b urner and o il p rimar y c ontrol o ption ).
Page 42
42 figure 21b: schematic w iring diagram, w ater boiler with front or rear t ankless heater , w arm start control (all burner options) section ix: electrical (continued) (s ee f igure 25 for s chema tic w iring d iagram of appropria te b urner and o il p rimar y c ontrol o ption ).
Page 43
43 figure 22: schematic w iring diagram, steam boiler , hydrolevel cg450 probe l wco (all burner options) section ix: electrical (continued) (s ee f igure 25 for s chema tic w iring d iagram of appropria te b urner and o il p rimar y c ontrol o ption ).
Page 44
44 figure 23a: schematic w iring diagram, steam boiler , mcdonnell & miller ps-801 probe l wco (beckett & carlin burners) section ix: electrical (continued) mcdonnell & miller ps-801 terminals may be lettered or numbered as follows: wire color numbered t erminals lettered terminals rd 5 b bk 1 h wh ...
Page 45
45 figure 23b: schematic w iring diagram, steam boiler , mcdonnell & miller ps-801 probe l wco (riello burners) section ix: electrical (continued) mcdonnell & miller ps-801 terminals may be lettered or numbered as follows: wire color numbered t erminals lettered terminals rd 5 b bk 1 h wh 2 n jumper...
Page 46
46 figure 24a: schematic w iring diagram, steam boiler , mcdonnell & miller 67 float l wco (beckett & carlin burners) section ix: electrical (continued) (s ee f igure 25 for s chema tic w iring d iagram of appropria te b urner and o il p rimar y c ontrol o ption ).
Page 47
47 figure 24b: schematic w iring diagram, steam boiler , mcdonnell & miller 67 float l wco (riello burners) section ix: electrical (continued) (s ee f igure 25 for s chema tic w iring d iagram of appropria te b urner and o il p rimar y c ontrol o ption ).
Page 48
48 section ix: electrical (continued) figure 25: schematic wiring diagrams for all burner options w/various oil primary controls.
Page 49
49 figure 26: single pipe oil line section x: oil piping a. General 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is...
Page 50
50 table 3: two-stage units (3450 rpm) - two pipe systems table 4: single-stage units (3450 rpm) - two pipe systems figure 27: two pipe oil lines c. Two pipe oil lines 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 3 (two-stage) and table 4 (sing...
Page 51
51 section xi: system start-up e. Open purge valve. F. Open shut-off valve in cold water supply piping located between the air scoop and expansion tank. G. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. H. When zone is completely purged of air, close zon...
Page 52
52 3. Steam boilers: with an l404f pressure limit - set cut-out pressure (main scale) on the pressure limit for (1) psi and differential pressure (diff.) for .5 psi. These pressures may be varied to suit individual requirements of the system. 4. Steam boilers with tankless domestic water heaters, se...
Page 53
53 prepurge the motor and igniter will operate but the oil valve will remain closed. Refer to oil primary control instructions for more details. 4. Adjust oil pressure. A. When checking a fuel unit's operating pressure, a reliable pressure gauge may be installed in either the bleeder port or the noz...
Page 54
54 figure 29a: "l1" and "v1" head electrode positioning and gun setting (beckett afg) section xi: system st ar t-up (continued).
Page 55
55 8. Steps outlined in paragraph 5 and 6 above must be repeated every time the head/turbulator or air band/ damper setting is readjusted. 9. Turn “off” burner and remove riello combination pressure gauge and bleeder valve assembly. Install pressureport/bleeder plug and tighten. Start burner again. ...
Page 56
56 yellow light turns on. This indicates that the button has been held long enough. • release the reset button. The yellow light will turn off and the burner will start up again. • at burner start up, click the reset button while the igniter is till on. This will transition the control to a dedicate...
Page 57
57 figure 30b: r7284 oil primary terminals, display and function buttons 10 additional minutes. (press the up arrow button 10 times). Pressing the down arrow subtracts a minute from the tfi time (see figure 30b). Section xi: system start-up (continued) > 6100 ohms flame loss, burner shuts down > 999...
Page 58
58 figure 31: cad cell location • close line switch to boiler. If burner starts and runs beyond safety switch cut-off time, cell is good. If not, install new cell. • close hand valve in oil supply line. • failure occurs, device enters recycle mode. • device tries to restart system after approximatel...
Page 59
59 section xii: operating a. Water boilers sequence of operation 1. 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 tradi...
Page 60
60 section xii: operating (continued) d. If the thermostat is not satisfied and the operating setpoint (sp) is reached the system circulator will continue to operate and the burner will stop. When the boiler water temperature drops below the setpoint less the differential setting the burner will res...
Page 61
61 section xii: operating (continued) c. Low limit (ll_) the warm start boiler control is factory programmed with a low limit setpoint of 110°f. On falling temperature the boiler turns “on” and the “zc” terminal and system circulator outputs are de-energized when the boiler temperature is less than ...
Page 62
62 section xii: operating (continued) g. Start temperature (t_) the amount of “heat available” is calculated by taking the difference between measured boiler water temperature and the start temperature setting. Useful “heat available” is dependent on the type of heating emitter installed in the hom...
Page 63
63 table 9: external low limit, parameter zc_= ell call for heat circulator status t-t input zr input c1 output zc output off off off on on off on on on on off off off on off off call for heat circulator status t-t input zr input c1 output zc output off off off off on off on off on on on on off on o...
Page 64
64 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 65
65 section xiii: maintenance and service instructions a. Maintenance of low water cut- off devices warning probe and float type low water cut-off devices require annual inspection and maintenance. 1. Probe type low water cut-off although these devices are solid state in their operation, the probe is...
Page 66
66 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 temporarily be wasted, operate boiler only for the length of time it takes for condensate to run clear. If the latter cannot be achieved or if the condensate is...
Page 67
67 e. Make ph or alkalinity test. After boiler and system have been cleaned and refilled as previously described, test the ph of the water in the system. This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper,...
Page 68
68 more make-up water and higher concentrations of contaminants damage the boiler sooner. Our warranty does not cover corrosion and sediment-related damage. Clearly it is in everyone's best interest to prevent this type of failure. You can do your part by ensuring that your system is leak-free, keep...
Page 69
69 section xiv: boiler cleaning a. Clean the flueways (see figure 34). 1. Prior to cleaning boiler, lay a protective cloth or plastic over combustion chamber blanket to collect debris falling from flueways. Several models do not utilize a combustion chamber blanket, see section xiv, repair parts, it...
Page 70
70 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 o...
Page 71
71 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 v8h boiler is the result of extensive testing to obtain the best flame shape and efficient combu...
Page 72
72 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 ...
Page 73
73 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. Display status recommended corrective actions err t...
Page 74
74 section xvi: repair parts 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...
Page 75
75 item no. Description part no. V8h3 v8h4 v8h5 v8h6 v8h7 v8h8 v8h9 1. Bare boiler assembly 1a front section (non-htr.), machined water ---(or)--- front section (non-htr.), machined steam 71728103 1 1 1 1 1 1 1 71728104 1 1 1 1 1 1 1 front heater section, machined water ---(or)--- front heater secti...
Page 76
76 bare boiler assembly (continued) section xvi: r ep air p ar ts (continued).
Page 77
77 item no. Description part no. V8h3 v8h4 v8h5 v8h6 v8h7 v8h8 v8h9 1. Bare boiler assembly (continued) 1p combustion chamber blanket, 1/2" x 18-3/4" x 8-3/8" 82028035 1 --- --- --- --- --- --- combustion chamber blanket, 1/2" x 18-3/4" x 13-3/8" 82028045 --- 1 --- --- --- --- --- combustion chamber...
Page 78
78 jacket assembly section xvi: r ep air p ar ts (continued).
Page 79
79 item no. Description part no. V8h3 v8h4 v8h5 v8h6 v8h7 v8h8 v8h9 2. Jacket assembly - insulated jacket panel(s) 2a jacket rear support bracket 7042801 1 1 1 1 1 1 1 2b jacket rear panel assembly 60428005 1 1 1 1 1 1 1 2c plastic collar extension - jkt. Frt. Panel w/htr. Opg. 8032704 1 1 1 1 1 1 1...
Page 80
80 v8h3 thru v8h9 steam boilers - trim and controls section xvi: repair parts (continued).
Page 81
81 item no. Description part no. V8h3 v8h4 v8h5 v8h6 v8h7 v8h8 v8h9 3. V8h3 thru v8h9 steam boilers - trim and controls 3a 6" draft regulator 8116288 1 1 1 1 --- --- --- 7" draft regulator 8116289 --- --- --- --- 1 1 1 3b pressure gauge 100325-01 1 1 1 1 1 1 1 3c probe, hydrolevel el-1214 (for hydro...
Page 82
82 v8h3 thru v8h9 water boilers - trim and controls section xvi: repair parts (continued).
Page 83
83 item no. Description part no. V8h3 v8h4 v8h5 v8h6 v8h7 v8h8 v8h9 4. V8h3 thru v8h9 water boilers - trim and controls 4a temperature & pressure gauge, ¼" npt x 2½" dia., 1½" lg. Shank 100282-01 1 1 1 1 1 1 1 4b honeywell #123870a immersion well, ¾" npt x 1½" insulation (wn) --(or)-- honeywell #123...
Page 84
84 beckett afg burner section xvi: r ep air p ar ts (continued).
Page 85
85 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. (continued on next page) boiler model v8h3w/s v8h4w/s v8h5w/s air tube c...
Page 86
86 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 v8h8w/s v8h9w/s air tube combin...
Page 87
87 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 (fo...
Page 88
88 table 12: b urner s pecifica tions boiler model firing rate gph beckett afg carlin riello settings 1 nozzle 2 pump pressure burner model settings 1 nozzle 2 pump pressure burner model settings 1 nozzle pump pressure head (s et ting) air shutter air band gph x angle t ype head bar air band gph x a...
Page 89
89 appendix a - low water cut off (lwco) wiring of typical lwco 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 on the same floor level as the boiler). In addition, so...
Page 90
90 a 24 vac lwco is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler. However, a 24 vac lwco can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. Appendix a - low water cut ...
Page 91
91 appendix b - figures figure number page number description section i - product description, specification & dimensional data figure 1a 6 v8h3 thru v8h9 water boiler without tankless heater figure 1b 7 v8h3 thru v8h9 water boiler with front tankless heater figure 1c 8 v8h3 thru v8h9 water boiler w...
Page 92
92 appendix b - figures (continued) figure number page number description section ix - electrical figure 21a 41 schematic wiring diagram, water boiler without tankless heater, cold start control (all burner options) figure 21b 42 schematic wiring diagram, water boiler with front or rear tankless hea...
Page 93
93 table number page number description section i - product description, specification & dimensional data table 1a 5 dimensional data (see figures 1a thru 1d) table 1b 5 rating data section vii - tankless and indirect water heater piping table 2a 35 tankless heater data: rear mounted heater on steam...
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.