Burnham V8 Series manual Install Trim and Controls with Carlin 102CRD Burner

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b.Thread 1½” NPT x 15” long nipple into the 1½" NPT x 90° elbow and tighten with a pipe wrench.

c.Thread one of the circulator flange onto the nipple and tighten with a pipe wrench. Position flange so that the bolt slots are parallel to the boiler front.

d.Place a circular flange gasket in the flange groove on the circulator and mount the circulator on the flange. Note that this is the return piping and the flow arrow on the circulator should point down Ð. Fasten circulator with 7/16” - 14 x 1½" long cap screws and 7/16" - 14 nuts.

e.Fasten the second circulator flange and gasket to the circulator.

6.Install relief valve, as shown in Figure 1A, 1B, and 1C, onto ¾” NPT x 8” nipple previously installed in Paragraph H, No. 2, step b. Tighten with wrench.

Pipe discharge as shown in Figures 13A, 13B and 13C. Installation of the relief valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

WARNING

Safety valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area

where freez ing could occur. Do not install any shut-off valves, plugs or caps.

7.On units without a heater opening, install the well into the ¾” NPT tapping "A" located on the front of the boiler in the upper left corner. See Figures 1A and 5. Tighten the well and insert the control’s bulb into the well. Secure control to well with set screw.

WARNING

Aquastat bulb must be fully inserted into the well.

8.On units with a heater opening, install the well in the ½" NPT or ¾” NPT tapping on the tankless heater plate or cover plate. See Figures 1B, 1C and 5. Tighten the well and insert the control’s bulb into the well. Secure control to well with set screw.

9.Connect Field Wiring.

a.Water boilers without tankless heater and with front tankless heater. Connect the field wiring from the circulator to the aquastat control and from the control to the burner disconnect J-box or directly to the burner J-box. Make the wiring connections as shown on Figures 22, 23A and 23D.

b.Water boilers with rear tankless heater. Connect the field wiring from a standard junction box or burner disconnect J-box to the circulator, aquastat control and burner. Make the wiring connections as shown on Figure 23B.

NOTE:

•Do not remove (cut) "T-T" jumper on R7184P Primary Control for application 9a or 9b above.

c.Refer to Paragraph S for details on use of burner disconnect junction box provided with all knockdown boiler builds.

P.INSTALL TRIM AND CONTROLS WITH CARLIN 102CRD BURNER.

Follow instructions in Paragraph N, Steps 1 through 7. Steam Boilers Only (see Figures 1D and 5).

8.Connect Field Wiring

a.Steam Boiler with Hydrolevel CG450 LWCO, Carlin Burner.

Connect the field wiring to the pressure limit, the LWCO, R8239C Control Center and the burner disconnect J-box or directly to burner J-box on burners less disconnect harness (power cord).

If equipped with tankless heater, connect field wiring from the aquastat control to the R8239C Control Center’s “R-G” terminals. Make the wiring connections as shown in Figure 19A.

b.Steam Boiler with McDonnell & Miller PS-801 or McDonnell & Miller 67 LWCO, Carlin Burner.

Connect the field wiring to the LWCO, the pressure limit and the burner disconnect J-box. If equipped with tankless heater, connect field wiring from the aquastat control to the oil burner primary control’s “T-T” Terminals. Make the wiring connections as shown in Figures 20A, and 21A.

c.Refer to Paragraph S for details on use of burner disconnect junction box provided with all knockdown boiler builds.

Water boilers Only (see Figures 1A, 1B, 1C and 5). Follow instructions in Paragraph O, Steps 1 through 7

9.Connect Field Wiring

a.Water boilers without tankless heater and with front tankless heater. Connect the field wiring from the circulator to the aquastat control and from the control to the burner disconnect J-box or directly to oil burner primary control on burners less disconnect harness (power cord). Make the wiring connections as shown on Figures 22A and 23B .

b.Water boilers with rear tankless heater. Connect the field wiring from a standard junction box or burner disconnect J-box to the circulator, aquastat control and burner. Make the wiring connections as shown on Figure 23E.

c.Refer to Paragraph S for details on use of burner disconnect junction box provided with all knockdown boiler builds.

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Contents V8 Series USA Boilers Important Information Read CarefullyPage Table of Contents Dimensional Data see Figures 1A Thru 1D V82 thru V89 Water Boiler without Tankless Heater V83 thru V89 Water Boiler with Front Tankless Heater V83 thru V89 Water Boiler with Rear Tankless Heater V83 thru V89 Steam Boiler with or without Tankless Heater Section I PRE-INSTALLATION Page Do not allow any flueway blockage by gasket Section II Knockdown Boiler AssemblyRemoval of Bare Boiler from Skid Boiler Tapping Locations and Usage Knockdown Boilers Only Install Boiler JACKET. See Figure Knockdown Boiler Jacket AssemblyInstall Beckett OIL BURNER. See Figure Oil Burner Installation Beckett Burner ShownSteam Boilers Only Do not install burner without gasketInstall Carlin 102CRD OIL BURNER. See Figure Water Boilers Only Combustion Head AdjustmentInstall Carlin Elite EZ OIL BURNER. See Figure Installation/Removal of Drawer Assembly Nozzle Replacement Install probe type Low Water Cut-Off Lwco if so equipped Aquastat bulb must be fully inserted into the well Float-Type Low Water Cut-Off Pressure Limit InstallationInstall Trim and Controls with Carlin 102CRD Burner Burners Supplied by Burnham utilize Install Trim and Controls with Carlin Elite EZ BurnerInstall Trim and Controls with Riello Burner Page Do not drop boiler. Do not bump boiler jacket against floor Section III Packaged Boiler AssemblyRemove Crate Remove Boiler from SkidPage Page Steam or Water Boilers Inspect Nozzle and Electrodes Install Safety or Relief Valve in Tapping MEvaluate the Existing Water System Section IV Water Boiler Piping and TrimPage Recommended Water Piping for Circulator Zoned Heating System Page Page Evaluate the Existing Steam System Section V Steam Boiler Piping and TrimPage Section VI Tankless and Indirect Water Heater Piping GPM Connect Alliance Indirect Water Heater Piping as shown in B Alliance Water Heater Piping with V8 BoilerDo not exceed maximum allowable air intake length Section VII Venting and AIR Intake PipingGeneral Venting Guidelines Recommended Vent Pipe Arrangement and Chimney Requirements Seal all external joints with weatherproof caulk General Section Viii ElectricalBoiler Sequence of Operation with Probe Lwco Page Page Jumper Page Page Boiler Sequence of Operation with Float Lwco Page Page Boiler Sequence of Operation Page Page Boiler Sequence of Operation Page Page Boiler Sequence of Operation Page Page Single Pipe OIL Lines Section IX OIL PipingSINGLE-STAGE Units 3450 RPM TWO Pipe Systems TWO Pipe OIL LinesFill Heating System with Water Always Inspect Installation Before Starting BurnerSection X System START-UP Carlin Elite EZ Burners Adjust OIL Burner Before StartingBeckett Burners Carlin 102CRD BurnersStart OIL Burner Adjust OIL Burner While OPERATING. flame presentRiello Burners L1 and V1 Head Electrode Test Controls Check for Clean CUT OFF of BurnerCAD Cell Resistance When Sensing Flame Jumper must be removed after this check Aquastat Switching Action Within L8124C ControlAquastat Switching Action Within L8148A Controls Avoid Breathing Fiber Particulates and Dust Maintenance of LOW Water CUT- OFF Devices Section XI Maintenance and Service InstructionsPage Gal/Month V83 V85 V87 V89 V84 V86 V88 14½ Frequent Water AdditionPage Clean the Combustion Chamber Section XII Boiler CleaningClean the Flueways See Figure Clean TOP of Boiler Sections if cleaning from the topCleaning of Boiler Flueways OIL Primary Control Section Xiii Trouble ShootingCombustion Section XIV Repair Parts Bare Boiler Assembly Bare Boiler Assembly Bare Boiler Assembly 1BB Bare Boiler AssemblyJacket Assembly Page V83 Thru V89 Steam Boilers Trim and Controls V83 Thru V89 Steam Boilers Trim and Controls V82 Thru V89 Water Boilers Trim and Controls V82 Thru V89 Water Boilers Trim and Controls Beckett AFG Burner Beckett OIL Burner Part NOS. for V8 Series Boilers Beckett OIL Burner Part NOS. for V8 Series Boilers Carlin OIL Burner Part Numbers for V8 Series Boilers Burner Specifications When XV. LOW Water CUT OFF LwcoService Record Limited Warranty For Residential Cast Iron Steam Boilers
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