For service & repairs to the heating plant, call your heating contractor. When seeking information on the boiler, provide
series and size designation shown on the rating plate.
Type
Boiler Number
Heating Contractor
Address
Form
8142501
.
No. 52009N-8194-1725f
AMERICA'S BOILER COMPANY
Firing Type System
Phone No.
Burnham Corporation
Lancaster,
PA
1
7604-3079
OUTPUT-
620,000
to
BTU/HR
SORT OUT ALL CARTONS, BUNDLES, AND SECTIONS and check against Shipping Schedule
Chart below
you ordered.
to
be certain that you have all the material required to assemble the Boiler
SHIPPING SCHEDULE CHART
NOTES:*Not furnished with Gordon & Piatt
VNot.required when sections are factory assembled
OPTIONAL EQUIPMENT
#548
Heater - Quantity as ordered
Heater opening cover plate-Quantity as ardered
Additional Controls-Type and quantity as ordered
R8
and
R10
gas or gas/oiI burners since these burners are furnished with steel mounting plates
IMPORTANT INFORMATION
PLEASE READ THIS PAGE CAREFULLY
1.
READ THIS MANUAL AND BURNER INSTALLATION MANUAL CAREFULLY BEFORE INSTALL
ING, OPERATING, OR SEBVICING THIS UNIT.
TO BURNHAM AND ASK FOR FORM NO.
2.
ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL
PLUMBING, HEATING AND ELECTRICAL C0DE.S AND THE REGULATIONS OF THE SERVING
UTILITIES.
ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY
3.
PERSONS KNOWLEDGEABLE IN THE LAYOUT AND INSTALLATION
SYSTEMS SHOULD ATTEMPT INSTALLATION OF ANY BOILER.
4.
THE BOILER MUST BE PROPERLY VENTED IN ACCORDANCE WITH NATIONAL FUEL GAS
CODE AND LOCAL CODES. SERIOUS PROPERTY DAMAGE
NOT PROPERLY VENTED.
5.
READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESS-,
ORY DEVICES. THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO
/
\
THE RECOMMENDATIONS OF THE MANUFACTURER.
6.
IT IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS
ARE CORRECTLY INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION
COMPLETED.
52003
IF
YOU DO NOT HAVE A BURNER MANUAL, WRITE
(Part
#814502).
0 F HYDRONIC HEATING
COULD RESULT IF THE BOILER
IS
IS
7.
FOR OPTIMUM PERFORMANCE FROM THIS UNIT SEIRVECE AS SPE(C1FIED IN SECTION V OF
THIS MANUAL.
8.
IN ALL CASES, CLEARANCES BETWEEN BOILER AND/OR SMOKE PIPE SURFACES AND COMBUSTIBLE MATERIALS MUST COMPLY WITH NATIONAL FUEL GAS CODE ANSI
DATED
ALL FLAMMABLE DEBRIS, RAGS, PAPER, WOOD SCRAPS, ETC., SHOULD BE KEPT CLEAR OF
9.
THE BOILER AT ALL TIMES. KEEP THE BOILER AREA CLEAN AND FREE OF FIRE HAZARDS.
10.
PROBE AND FLOAT TYPE LOW WATER CUTOFF DEVICES REQUIRE ANNUAL INSPBCTION AND
MAINTENANCE. REFER TO SECTION V ITEM
ING INSTRUCTIONS.
HIGH WATER TEMPERATURES INCREASE THE RISK OF BURNS OR SCALDING INJURY. INSTALL
AUTOM-4TIC MIXING VALVE AT THE TANKLESS HEATER OUTLET TO AVOID EXCESSIVELY HOT
WATER AT THE FIXWRES AS SHOWN IN FIGURE
1988
OR CURRENT EDITION AND, FOR OIL, NFPA
@
26.
211.
FOR STEP BY STEP INSPECTION AND CLEAN-
2223.1
(NFPA
54)
AN
TABLE OF CONTENTS
.
SECTION I
Ratings . Data
Setting the Unit
Air Supply/Venting
Tankless Heater Piping
Steam Trim
Water Trim
Burner Installation
SECTION IV . OPERATING INSTRUCTIONS
Filling System
Adjusting Controls
Adjusting Burner
Testing Controls
Initial Cleaning, Steam Boilers
Initial Cleaning, Water Boilers
Boiler Water Treatment
pH or Alkalinity Test
Warnings about Frequent Water Addition
Cleaning Boiler Heating Surfaces
Maintenance of Low Water Cutoff Devices
Checking Burner & Controls
Lubrication
General Maintenance Considerations
Attention to Boiler while not in Operation
.SECTION VI . REPAIR PARTS
Regional Office Directory
Bare Boiler Assembly
Steam/Water Trim
Jacket Assembly
I=B=R net ratings shown are based on piping and pickup allowances which vary from
water.
Consult manufacturer for installations having unusual piping and
pickup requirements, such as intermittent system operation, extensive piping systems, etc.
Net ratings for water, square feet, are based on
water temperature in system.
For higher water temperatures, select boiler on basis of
Net Ratings, MBH.
The I=B=R burner capacity in GPH is based on oil having a heat
Minimum gas pressure required at std. gas train inlet for maxi-
(3)
mum burner input based on
gas.
Boiler ratings are based on
(4)
sure at boiler flue outlet.
MAXIMUM ALLOWABLE WORKING PRESSURE
STEAM
WATER
OPTIONAL SPECIAL ORDER
Ratings shown above apply at altitudes up to
2000
feet on gas. For altitudes above those indicated, the ratings
should be reduced at the rate of
sea level.
Net
:irebo:
4olum1
(ft.3
8.5
11.1
13.7
16.3
18.9
21.5
24.1
26.8
29.4
32.0
34.6
37.2
39.8
42.4
45.0
47.6
50.2
52.8
-
(USA)
-
-
Water
Eonten
)
(I
-
Full
br.)
58
-700
918
937
1056
1174
1293
1412
1530
1649
I768
1886
2005
2
123
2242
236
2479
2598
1000
Btu/cu. ft.
121/q%
15
PSI STEAM
50
PSI
COZ,
4%
1
1
+.lo
(CANADA)
WATER
-
70
for each
er
Weight
full
of
Water
(1,bs.)
233
1
2800
32i8
3687
4106
4574
5043
5512
5980
6399
6858
7335
7755
8223
8742
9161
9629
10098
0.60
specify gravity
water column pres-
-
15
PSI
-
50
PSI
PSI
1000
feet on oil and
1000
=B
=R
Vent
liarnetel
inehes]
feet above
SECTION
I
-
GENERAL INFORMATION
(
CONTINUED
)
@
INSPECT SHIPMENT carefully for any signs
.
damage.
4.
ALL EQUIPMENT is carefully manufactured, inspect-
ed and packed. Our responsibility ceases upon delivery
of crated Boiler to the carrier in good condition.
B. ANY CLAIM'S for damage or shortage in shipment
must be filed immediately against the carrier by the
consignee. No claims for variances from, or shortage
in orders, will be allowed by the manufacturer unless
presented within sixty (60) days after receipt of
goods.
@
BOILER INSTALLATION - Must conform to the
authority having jurisdiction, or in the absence of such
-
:
-
1967 (Re-
Above or Top
-
6 Inches
requirements to
USA
-
Installation of oil burning equipment, AN'SIINFPA 31.
CANADA
Oil Fired Steam and Hot Water Boilers for 'Commercial
and Industrial use, ,CSA Standard B140.7.2
affirmed 1991)
MINIMUM INSTALLATION CLEARANCES TO COMBUSTIBLE MATERIAL:
-
Front
Sides
Rear
24 Inches
-
6 Inches Vent Connector Pipe - 18 Inches
-
6 Inches
of
IF BOILER
A
WATXR COWDIIIOR mIST8. A BOILER WUHDATIOR
ROW
PICOR IS WEAK
OR
UHEVEW
Fig.
OR
IF
2
VOTE:
Listed clearances comply with American National Standard ANSIINFPA 31, Installation of oil ,burning
equipment.
Listed clearances can not be reduced for alcove or
closet installations.
For reduced clearances to combustible material, protection must be provided as described in the above
31
ANSIINFPA
A. SERVICE 'CLEARANCE
er room so as to provide ease of venting and adequate
clearance for maintenance, serviceability, and installation of piping. Allow a minimum clearance of
at front and back of boiler for burner service and access to pressure relief
on each side of the unit for cleaning of flues and for
tankless water heater installation. 'Refer
for boiler dimensional data.
B. PROVIDE ADEQUATE FOUNDATION for the unit.
ON CARPETING. 'Boiler is suitable for installation
on combustible floors.
2. Floor construction should have adequate load bearing characteristics to bear the weight of the boiler
filled with water (see Table 1). A boiler foundation
similar to the one shown in Figure 2 is recommended if the boiler room floor is weak or uneven or if
a water condition exists.
standard.
-
Locate the unit in the boil-
door/flame observation port and
to
Figure
3
feet
1
TYPICAL ARRANGEMENT
FOR STUB VENT
Fig.
3
@
PROVIDE AIR SUPPLY AND VENTILATION to
accomodate proper combustion.
A permanent opening or duct should be provided so that
4,000
the boiler input will not exceed
area.
@
CHIMNEY OR VENT
The PF-5 is designed for forced draft firing and may be
a
used with
conventional natural draft stack or a stub
Btuhlin of free
vent (see Figure
Draft controls are not normally required, although they
may be used on installations where a natural draft stack
is used or on multiple boiler installations with a common
stack. The boiler is provided with a breeching
which should be adjusted to maintain a slightly positidt
pressure in the vent connector box (up to
ing burner operation.
3).
See Table I for the proper vent size.
0.1"
W.C.) dur-
dampey-
SECTION
II
-
CAST IRON BLOCK ASSEMBLY
FOUR LEG SLING
('MIN.
34"
DIA.
REQUIRED
CABLE)
LIFTING INSTRUCTIONS
Fig.
4
@
FACTORY ASSEMBLED SECTIONS - The assemblage should be set in the proper location as outlined in
9ection
Figure
The tie-rod nuts should then be loosened until finger
tight. Now proceed to part
STATIC TEST".
@
sembly procedure outlined on the following pages.
A. Assembly of Sections (Manual Draw-Up)
DRAULIC DRAW-UP EQUIPMENT, NEVER
B'LE MORE THAN ONE SECTION AT A TIME.
(
I.
Lifting arrangement and weights are given in
4.
@
of this section "HYDRO-
FIELD ASSEMBLED SECTIONS - Follow the as-
WHEN ASSEMBLING 'SECTION'S WITHOUT HY-
ASSEM-
1.
Place the rear section in its approximate final position, as outlined in Section I and support it with a
suitable prop. See Figure
2.
Open the Boiler Assembly Carton(s)
3. Clean nipples and nipple ports ,thoroughly with
a degreasing solvent and apply nipple lubricant provided.
5.
.
POSITIONING OF BACK SECTION
Fig.
5
4.
Drive nipples squarely into section using block of
wood and hammer, or preferably an aluminum
headed hammer, if available.
5.
A special n'ipple setting gauge is provided for the
nipples. Gauge nipple in both directions to insure
that it is driven to the proper depth into the nipple
opening. Cut-out in gauge must rest on nipple, with
legs of gauge touching finished face of section,
when nipple is properly driven. See 'Figure
NIPPLE'S MUST BE DRIVEN AS DTRECTED'TO
INSURE TXHT JOINTS. M
LEAKS ARE CAUSED BY TILTED OR COCKED
NIPPLES.
6.
THIS IS A FORCED DRAFT FIRED BOILER
SEALANT MUST BE APPLIED WHERE SPECIFIED FOR PROPER AND SAFE PERFORMANCE. THE BURNHAM CORPORATION HAS
APPROVED A SECTION JOINT SEALANT
LASTIC) MANUFACTURED BY DOW-CORN-
\
ING UNDER THE PRODUCT NUMBERS OF
732-RTV, 732-BLll AND 781. ALL THREE NUMBERS ARE THE SAME MATERIAL.
0
B T NIPP'LE
6.
&
(SI-
SETTING OF NIPPLES
Fig.
6
The grooves in the ground joint along the edge of
the section should be cleaned with a wire brush.
a
Then using
apply
'/a"
cartridge of sealant in a caulking gun,
bead of Silastic to one side of each joint.
to be mated. Touch up any missed spots before
draw-up. Touch-up after draw-up has no value. See
Figure
7.
SECTIONS MUST BE DRAWN-UP TIGHT
WTTHIN FOUR HOURS OF TWE TIME WHEN
STLASTIC I'S FIRST APPLIED. 'SILASTIC
CURES IN FOUR HOURS AND WILL NOT
FLOW INTO SEAL GROOVES AFTER FOUR
HOURS FROM APPLICATION, REGARDLESS
OF THE PRESSURE APPLI'ED.
7.
From arrangement of sections chart (see Figure
8)
select next section according to code letters on
section.
SECTIONS MUST BE ASSEMBLED IN PROPER
ORDER.
Clean .nipple ports and place section on nipples in
rear section. 'To facilitate assembly, it is advisable
to enter the upper nipple first in its port, then enter
the lower nipples in their respective ports.
Drive section in place with a heavy block of wood,
striking blows as squarely as
%"
Insert the three
draw-up rods through the nipple
possible over nipples.
ports in the intermediate section extending them
through the tapped holes in the rear section.
Place a 12" lg. steel channel on each end of the
upper draw-up rod and an
8%" lg. steel channel on
each end of the lower draw-up rods along with nuts
and washers. These items are all located in the
9
Draw-Up Kit. See Figures
and 10.
Be sure to apply the sealant to the groove in the
ground joints between adjacent sections as the boiler operates with a positive pressure ,in the fireboxf
and products of combustion will escape between
sections unless the sections are properly sealed. The
sealant should be applied before each section is phced on the assemblage.
I
AVOID DAMAGE TO THE DRAW ROD
THREADS WHILE DRAWING UP SECTIONS.
APPLY OIL OR GREASE FREELY 'TO TIE ROD
THREADS WHILE ASSEMBLING SECTIONS
TO PREVENT STRIPPING OF THREADS ON
ROD.
DRAW UP SECTION SLOWLY AND EVENLY,
tightening each draw-up rod a little at a time so
that sections are equally spaced, starting with
lower draw-up rods.
KEEP NIPPLES ALIGNED WITH NIPPLE
PORTS. If necessary, tap nipples lightly with a
blunt tool or rod to keep nipples from cocking while
sections are being drawn up. DO NOT DRAW UP
SECTION WHEN
NIPP-LES ARE COCKED. Continue tightening draw-up rods equally, periodically
bumping the section with the heavy block of wood
to relieve tensi'on on the draw-up rods, until sections meet iron-to-iron on the ground surfaces.
CONTINUE ASSEMBLING SECTIONS IN
THEIR RESPECTIVE ORDER. Be certain that
all sections are drawn up iron-to-iron at all three
nipple ports.
APPLICATION
Fig.
OF
7
SEALANT
On long boiler assemblies, it may be necessary to
draw-up a partial block if the entire boiler is not
ready to be drawn-up tight within four hours of
the first application of Silastic. If the block assembly time extends overnight, the partial block
completed must be drawn-up tight before leaving
the boiler overnight. If a joint springs out, it must
be re-drawn tight within four hours of first application of Silastic to the joint.
13.
Tie rods must be installed in lugs immediately after
draw-up is complete.
a. Insert tie rods through the lugs on the front
back sections. Place regular steel nuts & flat
washers on both ends of rods and tighten finger
tight.
Do not overtighten tie rods. Steel nuts should be
finger tight only to prevent section damage due to
thermal expansion.
b. Remove draw rod assembly from the sections and
remove the draw rod couplings from the tie rods.
&
i.
If
a
joint springs apart it must be re-drawn tight
within four hours of the time of application of the
silastic to that joint.
A
RRANGEMENT OF SECTION3
?he sections must be assemble according to the arronpemont listed in figure blow
to insure proper operation and proper alignment of pipiG with jacket knockouts.
--
FX-FRONT SECTION WITH 4'* TOP TAPPING C-CENTER SECTION CX
CT
-
r
CENTER SECTION W/T.W.H. OPENING
--
SECTION ARRANGEMENT
CODE LETTERS
BX - BACK SECTION WITH
-
CENTER SECTION W/4"TOP TAPPING
4"
TOP TAPP ING
PULL - UP ASSEMBLY
Fig.
9
NOTE: . For boilers less tmklns water hooters replace
I
the
"CT"
~utions with p'~s* sections..
Fig.
8
CHANNEL BLOCK IN POSITION
Fig.
10
SECTION ASSEMBLEDGE
Fig.
11
14.
Excess length of tie rods must be sawed off so they
will not extend beyond end sections. Rods should
project equally
the jacket.
See Figure
blage. Illustration shows boiler equipped with sections for built-in water heater.
B. Assembly of Sections (Hydraulic Draw-Up)
The entire assemblage may be drawn up at one time
using hydraulic draw-up equipment providing the
eration is completed within four hours after application of the sealant.
"Hydraulic Draw-Up Equipment" is available through
Burnham by ordering part number
1.
Repeat steps 1 through 9 under "Assembly of Sec-
tions (Manual Draw-Up)
2.
Continue driving sections in place (in their respective order) until all sections are in the assemblage.
Ground surfaces between adjoining sections should
be spaced
%"
will limit number of sections that can be drawn
up in one unit and could indicate cocked nipples.
Be sure to apply the sealant to the groove in the
ground joints between adjacent sections as the boiler operates with a positive pressure
and products of combustion will escape between
sections unless the secti'ons are properly sealed. The
sealant should be applied before each section is
placed on the assemblage.
On long boiler assemblies, it may be necessary to
draw-up a partial block if the entire boiler is not
ready to be drawn-up tight within four hours of
the first application of Silastic.
sembly time extends overnight, the partial block
completed must be drawn-up tight before leaving
the boiler overnight. If a joint springs out, it must
be re-drawn tight within four hours of first application of Silastic to the joint.
3.
Insert the three
appropriate) through the tapped holes in the rear
section extending them through the tapped holes
in the front section. Be sure to screw draw-up rods
illto couplings far enough to prevent stripping
threads.
4.
Place a
upper draw-up rod and an
each end of the lower draw-up rods.
and washers on one end of the draw-up rods and
hydraulic rams, washers
on the other. See Figure
at
each end to insure proper fit of
11
for complete boiler section assem-
6196008.
."
%"
to
%"
apart.
%"
draw-up rods (and couplings if
12"
lg. steel channel on each end of the
Spacing of more than
'in the firebox
If the block as-
8%"
lg. steel channel
Install
and
draw-up
rod
12.
op-
on
nuts
the
elampe
5.
Draw-up Sections.
READ THE STATEMENTS BELOW BEFORE ATTEMPTING TO USE HYDRAULIC EQUIPMENT.
-
RELEASE PRESSURE IN RAM PUMPS BEFORE ATTEMPTING TO REMOVE CLAMPS.
-
DO NOT STAND IN LINE WITH DRAW-UP
RODS AT EITHER END WHEN HYDRAULIC
PRESSURE IS BEING APPLIED.
TY MEASURE, ENDS OF DRAW-UP RODS
SHOULD BE COVERED WHILE SECTIONS
ARE BEING DRAWN IN CASE RODS SHOULD
SNAP WHILE UNDER TENSION.
-
DO NOT OPERATE RAM AGAINST DRAW-UP
COUPLING.
-
DO NOT OPERATE PUMP AFTER RAM HAS
REACHED 'STROKE LIMIT.
Use hydraulic rams to draw up sections by applying
pressure alternately on the draw-up rods. When
rams reach stroke limit, release pressure in ram
pumps and then move clamps to new position.
KEEP NIPPLES ALIGNED WITH NIPPLE
PORTS. If necessary, tap nipples tightly with a
blunt tool or rod to keep nipples from cocking while
sections are being
SECTION WHEN NIPPLES ARE COCKED. Continue tightening draw-up rods equally, periodically
bumping the section with the heavy block of wood
to relieve tension .on the draw-up rods, until sections meet iron-to-iron on the ground surfaces.
6.
.Continue to draw-up until all sections make contact
at the ground joints.
7.
Repeat steps
tions (Manual Draw-Up)
drawn up. DO NOT DRAW UP
13
and
14
under "Assembly of Sec-
."
AS A 'SAFE-
Rods should be approximately centered in openings
so that rods and couplings (when used) do njot drag
on pipe thread in end section tappings.
:L
CHANNEL BLOCK
7
BLOCK
HYDRAULIC DRAW-UP
Fig.
@
HYDROSTATIC TEST - After the boiler sections
have been assembled, it is essential that the boiler be hydrostatically tested before platework, jacket, or piping is
installed. D.
Tankless Heater Installation
If boiler is ordered with tankless heaters, install heaters with the gaskets provided. Table
gives the maximum number of heater permissible per
assemblage and the heater ratings.
Plug all boiler tappings and fill entirely
water. To protect and safeguard the accuracy of steam
or water gauge supplied, DO NOT INSTALL GAUGE
UNTIL AFTER TESTING OF BOILER.
I1
on page
with
25
cold
C. Testing pressure should be
E.
3''
--q
-
-
OF
SECTIONS
12
should not exceed
EXAMINE BOILER CAREFULLY, INSIDE AND
OUTSIDE, to insure against leaks from cocked nipples
or through concealed breakage caused in shipping and
handling. This precauti'on is for your protection and
will simplify handling of necessary replacements and
adjustment claims.
After making certain that there
boiler and remove plugs for boiler trim and other con-
nections.
DRAW UP
-3
REQ'D
PUMP AND
PUMP AND
50
pounds.
ROD CLAMP
RAM
at
least
are no leaks, drain
SET
10
pounds but
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