Burnham V11 Installation and Operation Manual
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Commercial Boilers
8142604R14-1/10
www.burnhamcommercialcastiron.com
1
Price $5.00
2
IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be installed in accordance 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:
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 National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls
and safety devices.
E. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
B. The equipment shall be installed in accordance with the current Installation Code for Gas
Burning Appliances and Equipment, CSA B149, and applicable Provincial Regulations for
the class; which should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
CAUTION
NOTICE
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating
properly when the installation is complete. The warranty for this boiler is valid only if the boiler has been
installed, maintained and operated in accordance with these instructions.
3
DANGER
DO NOT store or use gasoline or other ammable 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 the proper order can cause personal injury or
death. Read and understand all instructions, including all those contained in component manufacturers
manuals which are provided with the appliance before installing, starting-up, operating, maintaining or
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance
for reference by owner and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled
and knowledgeable installer or service agency. All heating systems should be designed by competent
contractors and only persons knowledgeable in the layout and installation of hydronic heating systems
should attempt installation of any boiler. It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly when the installation is completed. Installation
is not complete unless a pressure relief valve is installed into the specied tapping located at the rear of
appliance - See Section III of this manual for details.
This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting. Do not
operate on oors where heat affected material is below.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to
assure that the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale.
The inside of combustion chamber should also be cleaned and inspected at the same time.
Have Burner and Controls must be checked at least once a year or as may be necessitated.
Do not operate unit with jumpered or absent controls or safety devices.
Do not operate unit if any control, switch, component, or device has been subject to water.
Return water cannot be lower than 135°F for prolonged periods of time. Operation under these conditions will
result in sustained condensing within the combustion chamber and potentially reduce boiler longevity.
In addition, the return water cannot be introduced into the boiler if it is more than 40°F less than the idle
boiler temperature. Continued operation under these conditions may result in premature boiler failure
through thermal shock.
Example: A boiler that has been idle for some time since the last heat demand cycle may have it’s boiler
water temperature reduced to 150°F. The return temperature from the next zone activation cannot be
less than 110°F.
If the above conditions exist, an RTC (or similar type of control system) system must be installed to
protect the boiler from sustained condensing operation and thermal shock. See separate RTC Manual,
P/N 8146382.
4
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which
can cause death or serious injury and which are known to the state of California to cause cancer, birth
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when
servicing or working nearby the appliance.
This boiler contains very hot water under high pressures. Do not unscrew any pipe ttings 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 servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
This appliance 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.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of the
heating season and should be inspected periodically throughout the heating season for any obstructions.
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without
service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in
cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent
damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil, natural and/or LP gas only. Do not use gasoline, crankcase
drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to
any solid fuel (i.e. wood, coal). All ammable debris, rags, paper, wood scraps, etc., should be kept clear
of the boiler at all times. Keep the boiler area clean and free of re hazards.
Always keep the oil supply valve shut off if the burner is shut down for an extended period of time.
Probe and oat type low water cutoff devices require annual inspection and maintenance. Refer to
instructions in Section V, Paragraph C for inspection and cleaning instructions.
NOTICE
All V11 Series cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler
and Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each V11
jacket, which indicates the boiler Maximum Allowable Working Pressure (MAWP). Each cast iron section is
permanently marked with the MAWP listed on the boiler’s ASME Data Label. Those values for the V11 are as
follows:
MAWP, Steam - 15 psi
MAWP, Water (USA) - 80 psi
MAWP, Water (Canada) - 50 psi
It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler
MAWP. Therefore, Burnham offers safety relief valves set at or below the MAWP of the boiler. See Table 1 for
available safety relief valve set pressures.
5
TABLE OF CONTENTS
SECTION I - GENERAL INFORMATION
Dimensional Information ............................................................................................................................................... 8
Ratings/Data .................................................................................................................................................................. 9
Locating the Unit . ........................................................................................................................................................ 10
Air Supply/Venting ....................................................................................................................................................... 11
SECTION II - CAST IRON BLOCK ASSEMBLY (Knockdown Only)
Assembly of Sections, Manual Draw-up ..................................................................................................................... 14
Assembly of Sections, Hydraulic Draw-up ................................................................................................................. 19
Hydrostatic Test ........................................................................................................................................................... 20
SECTION III - INSTALLATION INSTRUCTIONS
Knockdown
Canopy ......................................................................................................................................................................... 23
Flue Cover Plates ......................................................................................................................................................... 25
Rear Observation Port Cover ........................................................................................................................................ 25
Inspect All Boiler Seals ................................................................................................................................................ 25
Ceramic Fiber Firewall Plates ...................................................................................................................................... 25
Jacket Assembly .......................................................................................................................................................... 26
Burner Mounting Plate / Burner Adapter Plate ........................................................................................................... 30
Steam Trim .................................................................................................................................................................. 31
Water Trim . .................................................................................................................................................................. 33
Burner Installation ....................................................................................................................................................... 33
Package Boilers
Preparation for Installation ........................................................................................................................................... 33
Common Installation Requirements
Boiler Piping - Heating Applications .......................................................................................................................... 34
Boiler Piping - Steam Applications .............................................................................................................................. 42
Boiler Piping - Domestic Hot Water (DHW) Applications .......................................................................................... 44
Tankless Heater Piping ................................................................................................................................................ 45
Electric Wiring .............................................................................................................................................................. 46
SECTION IV - OPERATING INSTRUCTIONS
Filling System ............................................................................................................................................................... 50
Adjusting Controls ....................................................................................................................................................... 50
Adjusting Burner ......................................................................................................................................................... 51
Test Controls ................................................................................................................................................................ 51
Initial Cleaning, Steam Boilers .................................................................................................................................... 51
Initial Cleaning, Water Boilers ....................................................................................................................................52
Frequent Water Addition .............................................................................................................................................. 53
Oxygen Corrosion ........................................................................................................................................................ 53
SECTION V - SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces ............................................................................................................................... 54
Maintenance of Low Water Cutoff Devices ................................................................................................................ 55
Checking Burner & Controls ........................................................................................................................................ 56
Lubrication ................................................................................................................................................................... 56
General Maintenance Considerations ........................................................................................................................... 56
Attention to Boiler While Not in Operation ................................................................................................................. 56
6
TABLE OF CONTENTS - Continued
SECTION VI - BURNER SPECIFICATIONS
Beckett Burners (Table VI) ...........................................................................................................................................57
Power Flame Burners (Table VII) ................................................................................................................................58
Webster Burners (Table VIII) .......................................................................................................................................61
Carlin Burners (Table IX) .............................................................................................................................................64
SECTION VII - REPAIR PART
Regional Ofce Directory ............................................................................................................................................65
Jacket Assembly .......................................................................................................................................................... 66
Bare Boiler Assembly ................................................................................................................................................... 70
Steam/Water Trim ......................................................................................................................................................... 74
WARRANTY ....................................................................................................................................................... REAR COVER
7
SECTION I - GENERAL INFORMATION
Figure 1: Dimensional Information
8
TABLE I – RATINGS/DATA
(1)
NET I=B=R RATING
(2)
I=B=R
BURNER
INPUT
HEATING
SURFACE
(SQ. FT.)
I=B=R
BOILER MODEL
BOILER HORSEPOWER
V1104 19.9 667 2083 500 580 5.8 837 64.6 74.4 7.9 0.35 59 72 2596 2704 8
V1105 25.6 857 2679 643 745 7.4 1068 83.5 96.2 10.6 0.36 68 84 3076 3210 8
V1106 31.9 1069 3342 802 930 9.2 1328 102.4 118.0 13.2 0.37 77 96 3561 3720 8
V1107 38.3 1281 4013 963 1114 11.0 1588 121.3 198.8 15.9 0.42 87 108 4050 4225 10
V1108 45.3 1517 4829 1159 1319 13.0 1876 140.2 161.6 18.5 0.42 96 120 4533 4733 10
V1109 51.7 1729 5563 1335 1503 14.8 2136 159.1 183.4 21.1 0.39 105 132 5022 5247 10
V1110 58.0 1941 6279 1507 1688 16.6 2396 177.0 204.2 23.8 0.42 115 144 5515 5757 12
V1111 64.3 2154 6967 1672 1873 18.4 2656 195.9 226.0 26.5 0.40 124 156 5997 6263 12
V1112 69.7 2334 7550 1812 2030 20.0 2887 214.8 247.8 29.1 0.42 133 169 6482 6782 12
V1113 74.8 2503 8096 1943 2177 21.5 3103 233.7 296.6 31.8 0.40 143 181 6962 7279 12
GROSS OUTPUT MBH
SQ. FT. STEAM
MBH STEAM
MBH WATER
OIL (GPH)
STEAM
GAS (MBH)
WATER
NET FIREBOX VOLUME
(3)
(CU. FT.)
PRESSURE IN FIREBOX
(INCHES WTR. COLUMN)
WATER
CONTENT
(GALLONS)
STEAM
WATER
BOILER
WEIGHT
W / WATER
(LBS.)
STEAM
WATER
I=B=R VENT DIA. (INCHES)
V1114 81.6 2730 8833 2120 2374 23.5 3392 252.6 291.4 34.4 0.38 152 193 7450 7792 14
V1115 88.3 2957 9567 2296 2571 25.5 3680 271.5 313.2 37.1 0.36 161 205 7942 8309 14
V1116 93.4 3126 10113 2427 2718 27.0 3897 290.4 335.0 39.7 0.38 171 217 8432 8816 14
V1117 100.2 3353 10846 2603 2916 29.0 4186 309.3 356.8 42.4 0.41 180 229 8916 9325 14
V1118 106.9 3580 11583 27780 3113 31.0 4474 328.7 377.6 45.0 0.39 189 241 9397 9831 16
V1119 111.7 3739 12096 2903 3251 32.5 4691 346.1 399.4 47.7 0.38 199 253 9889 10338 16
V1120 118.2 3957 12800 3072 3441 34.5 4979 365.0 421.2 50.3 0.38 208 265 10371 10845 16
V1121 124.7 4174 13504 3241 3630 36.5 5268 383.9 443.0 53.0 0.40 217 277 10861 11360 16
V1122 129.5 4334 14021 3365 3769 38.0 5485 402.8 464.8 55.6 0.41 227 290 11347 11872 18
V1123 136.0 4551 14721 3533 3957 40.0 5733 421.7 486.6 58.3 0.43 236 302 11831 12381 18
(1 ) S UFF IX " S" IND ICA T ES STE AM B OI L ER, "W " I N DIC ATE S
WA TER BO I LER . S UFF I X " G" IND I CAT ES GAS – FIR ED, "O "
IN DIC ATE S OI L–F IRE D , " GO" IN D ICA TES CO M BIN ATI ON
GA S–O IL F IRE D.
(2 ) I =B= R N E T R ATI NGS SH O WN ARE BA S ED ON P IP I NG AND
PI CKU P A L LOW ANC ES W HIC H V ARY FRO M 1 .33 3 TO 1. 288
FO R S TEA M AN D 1 .15 FOR WA TER .
CO NSU LT M ANU FAC TUR E R F OR INS T ALL ATI ONS HAV ING
UN USU AL P IPI NG AND PIC KUP RE Q UIREMENTS, SUCH
AS INTERMITTENT SYSTEM OPERATION, EXTENSIVE PIPING
SYSTEMS, ETC.
THE I=B=R BURNER CAPACITY IN GPH IS BASED ON OIL HAVING
A HEAT VALUE OF 140,000 BTU PER GALLON.
(3 ) B OIL ER R AT I NGS AR E B A SED ON 13 . 0% CO2 (OIL) AND
10.0% CO2 (NATURAL GAS) AND + .10" WATER COLUMN
PRESSURE AT BOILER F L UE OUT LET .
RA TIN GS S HOW N A BOV E AP PLY AT ALT ITU DES UP
TO 10 00 F EET ON OI L AN D 2 000 FEE T O N G A S. FOR
AL TIT UDE S AB OVE TH O SE IND ICA T ED, TH E R A TIN GS
SH OUL D B E RE DUC ED A T T HE RAT E OF 4% FO R EA CH
10 00 FEE T AB OVE SE A LE VEL .
SAFETY (RELIEF) VALVE SET PRESSURE:
USA BOILER CANADIAN BOILER
STEAM - 15 PSI STEAM - 15 PSI
WATER - 50 PSI WATER - 50 PSI
OPTIONAL WATER - 30 PSI OPTIONAL WATER - 30 PSI
- 80 PSI
9
SECTION I - GENERAL INFORMATION (continued)
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A. IN SPECT SH IPMENT carefully for any signs of
damage.
1. ALL EQUIP MENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated Boiler to the carrier in good
condition.
2. ANY CLAIM S for damage or shortage in shipment
must be led 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 the
receipt of goods.
B. LOCATE THE UNIT
NOTICE
Recommended clearance for service may be
reduced to minimum clearance to combustible
material. However, increased service and
maintenance difculty will result.
1. RECOMMENDED SERVICE CLEARANCE
- Locate the unit in the boiler room so as to
provide ease of venting and adequate clearance
for maintenance, serviceability, and installation of
piping. Refer to Figure 1 for boiler dimensional
data.
FRO NT --- Provide 54" service clearance for
removal, maintenance, and servicing of burner and
controls.
REAR --- Provide a minimum service clearance
from the boiler jacket for access to pressure relief
door, ame observation port, rear ue damper and
vent piping, relief valve, and boiler return piping.
See following chart.
LEFT SIDE --- Provide a minimum clearance from
the boiler jacket of 36" for cleaning of ueways.
RIGHT SIDE --- Less Tankless Heater - Provide a
minimum clearance from boiler jacket of 12".
With Tankless Heater - Provide a minimum
clearance from the boiler jacket of 35" for
installation and removal of tankless heater(s).
TOP --- Provide a minimum clearance from the
boiler jacket of 24".
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table II.
3. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
Table II: Minimum Installation Clearances To
Combustible Materials (Inches)
Boilers with Top Flue Outlet
Boilers with Rear Flue Outlet
A B C D E
Above Front Rear Sides Vent Connector
6 24 6 6 18
* See Table III for recommended service clearance
to access rear of boiler.
Table III: Recommended Rear Service Clearance
10
Figure 2: Boiler Foundation
WARNING
Boiler is suitable for installation on combustible
oor. Do not install boiler on carpeting.
Floor construction should have adequate load
bearing characteristics to bear the weight of
the boiler lled with water (see Table 1). A
boiler foundation similar to the one shown in
Figure 2 is recommended if the boiler room
oor is weak or uneven or if a water condition exists.
4. PROVIDE AIR SUPPLY AND
VENTILATION to accommodate proper
combustion.
WARNING
Failure to supply adequate air to the boiler will
result in unsafe boiler operation.
For commercial and industrial equipment,
permanent facilities for supplying an ample amount
of outside air shall be provided in accordance with
the following.
For boiler rooms adjacent to outside walls, and
where combustion air is provided by natural
ventilation from the outside, there shall be a
permanent air supply inlet having a total free area of
not less than 1 sq. in. per 4,000 Btu per hr. (35 sq.
in. per gal. per hr.) (5.5 cm2 per kw.) of total input
rating of the burner or burners and in no case less
than 35 sq. in. (0.425 m2).
For boiler rooms not adjacent to outside walls,
the combustion air shall be supplied in a manner
acceptable to the authority having jurisdiction.
a. In the absence of local requirements, the
conned space shall be provided with two
permanent openings, one in or near the top of
the room and one near the bottom. The openings
shall communicate by means of ducts, with the
outdoors or to such spaces (crawl or attic) that
communicate with the outdoors.
i. Where communicating by means of vertical
ducts, each opening shall have a free area of
not less than 1 sq. in. per 4,000 Btuh (35 sq.
in. per gph.) (5.5 cm2 per kw) of total input
rating of all appliances in the enclosure.
ii. If horizontal ducts are used, each opening
shall have a free area of not less than 1 sq.
in. per 2,000 Btuh (70 sq. in. per gph.) (11
cm2 per kw) of total input of all appliances
in the enclosure.
5. CHIMNEY OR VENT
NOTICE
When a V11 gas red boiler is connected to
a venting system that is designed so that it
will operate under a negative pressure, the
use of Type C, B, or other manufactured vent
systems designed for negative pressure is
acceptable.
When a V11 oil red or combination gas/oil
red boiler is connected to a venting system
that is designed so that it will operate under
a negative pressure, the use of Type C, L or
other manufactured vent systems designed
for negative pressure is acceptable.
Unlined masonry chimneys are not acceptable. Lined masonry chimneys are acceptable
with the appropriate vent connectors using
materials described above.
11
WARNING
When a V11 gas red boiler is connected to
a venting system that is designed so that
it will operate under a positive pressure,
manufactured vent systems, designed and
approved for positive pressure application per
UL1738, must be used (for example, Van-Packer
model CS, Protech Model FasNSeal / FasNSeal
W2, Heatfab Saf-T-Vent or equivalent).
When a V11 oil red or combination gas/oil
red boiler is connected to a venting system
that is designed so that it will operate under a positive pressure, manufactured vent
systems, designed and approved for positive pressure application, must be used (for
example, Selkirk Metalbestos Model PS / IPS,
Van-Packer Model ES or equivalent).
The V11 Series boiler is designed for forced draft
ring and may be used with a conventional natural
draft stack (15’ minimum height) or a stub vent,
sometimes called a diesel stack (see Figure 3a). See
Table I for the proper vent outlet size. For low
silhouette vent terminations, see Figure 3b. 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 damper, which should be adjusted to
maintain a positive pressure of 0.1” W.C. in the vent
connector box during burner high re operation (see
breeching pressure sensing port in Figure 1).
Figure 3a: Typical Arangement For Stub Vent
If the venting system is designed for positive or forced
draft venting, the boiler, vent connector and stack will
operate under positive pressure. Gas tight vent systems
designed for pressure systems must be used to prevent
ue by-product leakage. The vent height is usually
limited to prevent negative draft, typically three (3)
feet above the roof line (see Figure 3a). The damper
shall be adjusted to maintain a positive pressure of 0.1”
W.C. in the vent connector box during burner high re
operation (see breeching pressure sensing port in Figure
1).
If the venting system is designed for negative pressure
(natural draft), the boiler still operates with positive
pressure in the chamber and up to the xed damper on
the ue collar. However, if the venting system is larger
than what is required, the stack will provide a surplus
draft (or negative pressure) that may require the use of
a barometric damper to maintain the positive 0.1” W.C.
pressure at the ue outlet. Multiple forced draft boiler
stacks should always be designed as negative to ensure
the products of combustion do not exit a boiler that is
not ring.
WARNING
Venting instructions are recommendations only. Consult a venting expert on the design of a specic
vent system for your application. The ASHRAE Venting Guide and The National Fuel Gas Code, NFPA 54
should be considered in all venting systems.
Conventional vent material may not e suitable for the application. Flue gases can leak carbon monoxide
from the joints on these materials and can result in severe personal injury or death.
Installations having long horizontal runs or an excessive amount of tees or elbows will restrict the ow
of combustion gases and can result in condensation, ue gas leakage of carbon monoxide, resulting in
severe personal injury or death.
12
A
B
C
RAIN CAP
RIGHT
D
WRONG
VENT SIZING - Area must be the same as or greater than the boiler breeching (Smoke Outlet). A barometric damper may be required on
installations with a high draft condition.
1. If improper vent is suspected, remove pipe at breeching and operate boiler. This will determine if excessive down draft,
blocked or restricted ue, etc. is causing the problem.
2. If using type shown in A above, be sure cap is raised sufciently above main pipe to allow ue gases to vent unimpeded.
3. A popular type cap is shown in B.
4. The tee is frequently used as shown in C.
5. D and E should not be used due to possible uctuations in back pressure.
"A" CAP
RIGHT
WRONG
FAULTY BOILER BURNER OPERATION
TEE TYPE
RIGHT
E
90°
ELBOW
UP or DOWN
Figure 3b: Vents — Faults & Suggestions
Typical Vents that are used on Forced Draft Boilers, on Low Silhouette Buildings
13
SECTION II - CAST IRON BLOCK ASSEMBLY
A. FACTORY ASSEMBLED SECTIONS - The
assemblage should be set in the proper location as
outlined in Section I. Lifting arrangement and weights
are given in Figure 4.
THEN THE DRAW-UP ROD NUTS SHOULD BE
LOOSENED UNTIL FINGER TIGHT AND THEN
TIGHTENED ½ TURN WITH A WRENCH. Now
proceed to Paragraph C of this section, “HYDROSTATIC TEST”.
B. FIELD ASSEMBLED SECTIONS - If the boiler
was ordered to be eld assembled, follow the assembly
procedure outlined on the following pages.
1. ASSEMBLY OF SECTIONS (MANUAL
DRAW-UP)
These sections are designed to be drawn together
one section at a time using the 11" long draw-up
rods (provided) and ordinary hand tools.
Tools required:
(1) ¾" Drive Ratchet
(1) 1¼" Socket
(1) 1¼" Combination or Open End Wrench
(1) Can Thread Cutting Oil or Grease
WHE N ASSEM BLING S ECTIONS WITHOU T
HYDRAULIC DRAW-UP EQUIPMENT,
NEVER ASSEMBLE MORE THAN ONE
SECTION AT A TIME.
a. Place the rear section in its approximate nal
position, as outlined in Section I and support it
with a suitable prop. See Figure 5.
Figure 5: Positioning of Back Section
Figure 4: Lifting Instruction
14
b. On sizes 1104 thru 1106 only - Open target wall
carton, apply silastic to back of target wall and
secure target wall to rear section.
c. Clean the groove in the ground joint along the
edge of the section with the wire brush.
d. Open the Boiler Assembly Carton(s) and remove
the bottle of adhesive. Using the dauber supplied
in the bottle, apply the adhesive to the groove.
Be sure to use enough adhesive to sufciently
coat the entire groove surface. If so desired,
a multi-purpose spray adhesive (supplied by
others) may be used instead. HOWEVER,
GREAT CARE MUST BE TAKEN TO
ENSURE THAT THE ADHESIVE DOES
NOT COME IN CONTACT WITH THE
NIPPLES OR NIPPLE PORTS.
e. While the adhesive is becoming tacky, clean the
nipples and nipple ports thoroughly with a degreasing solvent. Use the Loctite #592 supplied
to lubricate the nipples and nipple ports. Apply
the lubricant to the nipples and nipple ports,
then use a brush to disperse it evenly around the
nipples and nipple ports. Use approximately 25
ml of Loctite #592 per ueway [(1) 7" and (2) 3"
nipples and their (6) corresponding nipple ports].
f. Drive nipples squarely into section using
block of wood and hammer, or preferably, an
aluminum head hammer. Burnham offers a
polyethylene block for setting the nipples (part
no. 8052601). Place block over entire nipple
edge and hit the wood with the hammer.
end of the groove is reached, cut off the excess
rope. Push the length of the excess rope into
the groove at the top corner of the section face
end of the groove is reached, cut off the excess
rope. Push the length of the excess rope into
the groove at the top corner of the section face
(opposite of the 7" nipple port). Cut off and
discard any remaining rope after groove is lled.
See Figure 7.
i. From the "Section Arrangement" chart, select
the next section according to the "Identication
Code" at the top of the chart. See Figure 8.
WARNING
Nipples must be driven in evenly and to the
proper depth to assure tight joints. Most
nipple leaks are caused by tilted or cocked
nipples.
DO NOT use steel/iron head hammer to
drive nipples without using a wood block.
Nipple damage may result.
g. A special nipple setting gauge is provided for the
nipples. Gauge nipple at 90° angles to insure
that it is driven to the proper depth into the
nipple opening (nipple port). Cut-out in gauge
must rest on nipple, with the legs of the gauge
touching nished face of section, when nipple is
properly driven. See Figure 6.
h. Remove a 127" length of berglass rope from
the assembly carton. Starting with the area
around the upper 7" nipple port, rmly press
the rope into the groove, so that the adhesive
holds it in place. (If more than 25 minutes have
passed since the adhesive was applied, it may be
necessary to reapply.) Continue to afx the rope
to the groove in this fashion around the perimeter
of the section. Make sure that the rope does not
droop or hang outside of the groove. When the
Figure 6: Setting of Nipples
Figure 7: Afxing the Fiberglass Rope
15
B
u CT
C B
u CT
B
u CT
C
u CT
C B
u CT
C
u CT
B
u CT
C
u CT
CX
u CT
C B
u CT
C
u CT
CX
u CT
B
u CT
C
u CT
CX
u CT
C
u CT
C B
u CT
C
u CT
CX
u CT
C
u CT
V11 SECTION ARRANGEMENT
BOILER SECTION IDENTIFICATION CODE
PROPER ASSEMBLY OF JACKET AND PROPER ALIGNMENT OF PIPING WITH JACKET KNOCKOUTS.
B
u C
B
CT B
CT
uC
uC
u C
CT B
u C
CT
u C
C
u CT
CX
u CT
C
u CT
CX
u CT
CX
u CT
C
u CT
CX
u CT
C
u Cn
C
u CT
C
u Cn
C
u CT
C
u Cn
CX
u CT
C
u Cn
CX
u CT
C
u Cn
Figure 8
C
C
CX
C C B
C CT
C CT
CX CT
CX CT
Cn
Cn
Cn
C
C
C
C CT CX
C CT CX
C CT CX
C CT CX
CT C B
u CT
u CT
C CT B
CT C B
u CT
C CT B
C
u C
u C
CT
u CX
CX
u CT
C
CX
u CT
C
u CX Cn
CT
u C
u C Cn
CT
u CX
u C Cn
CT
u CX
u CT CXl u C
u CT CXl u C
u CT CXl u C
u CT CXl u C
u CT CXl u C
u CT CXl u C
C CT CX
u CT CXl u C
u CT CXl u C
IMPORTANT: THE SECTIONS MUST BE ASSEMBLED ACCORDING TO THE ARRANGEMENT LISTED BELOW TO ENSURE PROPER OPERATION.
B
CT B
CT C B
uC
uC
uC
F = FRONT SECTION WITH 4" SUPPLY TAPPING C = CENTER SECTION
B = BACK SECTION WITH 4" SUPPLY TAPPING CX = CENTER SECTION WITH 4" SUPPLY TAPPING
CT = CENTER SECTION WITH TANKLESS HEATER OPENING
V1104 F CT
V1105 F CT
V1106 F CT
u CT
V1107 F CT C
CT
uC
V1108 F CT
u CT
V1109 F CT C
CT
uC
V1110 F CT
u CT
V1111 F CT C
u CT
V1112 F CT C
CT
uC
V1113 F CT
16
CT
uC
V1114 F CT
CT
uC
V1115 F CT
C
uCT
V1116 F C
C
uCT
V1117 F C
C
uCT
V1118 F C
C
uCT
V1119 F C
C
u CT
V1120 F C
C
uCT
V1121 F C
C
uCT
V1122 F C
C
uCT
V1123 F C
NOTES: 1. Chart depicts steam boiler with maximum number of 'CT' Sections.
2. (u) Denotes location of Center Section to which Canopy 'J' Bolts are attached to lugs on the casting. If a lug is broken or missing, casting
must be relocated to an alternate location in the assembly.
3. (l) Denotes location of Single 'CX' Center Section required on water boilers.
4. (n) Denotes location of 'C' Center Section to which jacket support brackets must be attached during block assembly, see Figure 10 for
bracket details.
5. For boilers less tankless water heaters, replace the 'CT' Sections with 'C' Sections.
NOTICE
The sections must be assembled according to the
arrangement shown to ensure proper operation,
proper assembly of canopy, jacket and alignment
of piping and tankless heaters with jacket
knockouts. Start with the back section and work
towards the front.
Use a brush to clean the groove in the face of
the next section. Then, using a cartridge of RTV
6500 or RTV 736 sealant in a caulking gun, ll
the groove in this section with the silastic sealant.
Touch-up any missed spots before draw-up.
Touch-up after draw-up has no value.
WARNING
This is a forced draft red boiler and sealant must
be applied where specied for proper and safe
performance. Burnham Commercial has approved
section joint sealants (silastics) manufactured
by Dow-Corning under the product number RTV
736, and Sil-Bond under the product number RTV
6500.
Figure 9: Connection Inspection Locations and
Manual Draw-Up Tie Rod Pattern
CAUTION
WARNING
Sections must be drawn-up tight immediately
after properly applying sealant for best results.
Although sections may be joined within two
(2) hours of applying sealant, humidity and
temperature affect cure time. If a "thick skin"
has been formed on the sealant bead, remove
and re-apply sealant.
Sealant must be properly applied to ALL boiler
joints. Failure to properly seal the boiler joints
will result in combustion gas leaks through the
joint. DO NOT operate boiler with combustion
gas leaks.
j. Clean and lubricate nipple ports on next section
to be assembled and place on nipples previously
installed in rear section. To facilitate assembly,
it is advisable to enter the upper nipple rst in
its port. Then enter the lower nipples in their
respective ports. If necessary, place a lifting bar
(crowbar) under the center of the section and
lift the nipple port onto the upper nipple. Drive
section in place with a heavy block of wood,
striking blows as squarely as possible over nipple
ports.
k. Large draw-up rod lugs with dual holes are cast in
the four corners of each casting. STARTING WITH
THE UPPER HOLES, in s tall fo ur 3/4" x 11"
lo ng dra w -up ro ds along with washers and nuts
(see Figure 9).
To avoid damage to the draw-up rod threads while
drawing up sections, apply oil or other lubricant
to tie rod threads while assembling sections to
prevent stripping of threads on rod and to make
assembling easier.
l. DRAW UP SECTION SLOWLY AND
EVENLY using an alternating pattern starting
with the upper right lug (closest to the 7" port)
and proceeding to the lower left , lower right
and nishing with upper left lug. When you
start, grind surfaces between adjoining sections
should be approximately 3/8” apart. Use
three (3) or four (4) passes at tightening the
four (4) draw-up rods a little at a time so that
sections are pulled up evenly. During the last
pass, pay close attention to the silastic sealant
as it squeezes when the sections come in close
contact. The silastic sealant should continue
to squeeze out wafer thin until the sections are
connected metal to metal. If the silastic has
stopped squeezing out from the connection and
the sections still do not appear to be drawn metal
to metal, use a feeler gauge to measure any gaps
at the locations identied in Figure 9. (Unless
specied otherwise, gaps should be measured at
these locations on both sides of the sections). A
maximum gap of .025" is acceptable. Measure
gaps at the outer edge of the connection only,
making sure not to puncture the gasket created
by the silastic and rope.
17
WARNING
IMPORTANT
When tightening the draw-up nuts, DO NOT
EXCEED 165 FT - LB. OF TORQUE. If the maximum
torque limit has been reached and a gap greater
than .025" still exists between the sections,
consult the sales representative.
KEEP NIPPLES ALIGNED WITH NIPPLE
PORTS. If necessary, tap edge of 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
NIPPLES ARE COCKED. If the torque
required becomes excessive, periodically place a
heavy block of wood over each nipple port and
strike as squarely as possible with several blows
to relieve tension on the draw-up rods.
m. CONTINUE ASSEMBLING SECTIONS IN
THEIR RESPECTIVE ORDER alternating
the draw-up rods from the upper to lower set
of holes in draw-up lugs. Be certain that all
sections are drawn up IRON-TO-IRON at all
three (3) nipple ports.
BE SURE TO APPLY THE FIBERGLASS
ROPE AND SEALANT to the grooves in the
ground joints between adjacent sections as the
boiler operates with a positive pressure in the
rebox and products of combustion will escape
between sections unless they are properly sealed.
The rope and sealant should be applied before
each section is placed on the assembly.
JACKET SUPPORT BRACKETS must be attached
to the appropriate center section during the
assembly process on boiler sizes V1113 thru
V1123. Check "Section Arrangement" Chart for
location of center section to which jacket support
brackets must be attached (see Figure 8 on Page
16).
i. LOCATE JACKET INTERMEDIATE
PANEL MOUNTING BRACKETS NO.
1, NO. 2 AND NO. 3 IN JACKET
CARTON. Brackets are shipped at and
must be formed by hand, bend as shown in
Figure 10.
ii. WHEN APPROPRIATE SECTION is
being assembled to block, slide brackets
over draw-up rod lugs prior to inserting
draw-up rods, washers and nuts. To
prevent the brackets from turning during
the draw-up process, insert a large punch
or draw-up rod through second hole in each
Figure 10: Jacket Intermediate Panel
Mounting Brackets
(Required on Boiler Models V1113 thru V1123)
Figure 11: Bracket Placement
Figure 12: Bracket Attachment to Center Section
18
Figure 13: Hydraulic Draw-Up of Sections
bracket. Refer to Figures 11 and 12 for
proper location of each bracket and typical
attachment.
n. If a joint springs apart it must be re-drawn tight
within four (4) hours of the time of application of
Silastic to that joint.
o. EXCESS LENGTH OF DRAW-UP RODS
must not extend beyond front and rear sections to
ensure proper t of jacket, adjust accordingly.
p. AFTER ALL SECTIONS HAVE BEEN
DRAWN UP, THE DRAW-UP ROD NUTS
SHOULD BE LOOSENED UNTIL FINGER
TIGHT AND THEN TIGHTENED ½ TURN
WITH A WRENCH.
q. Now Proceed to Paragraph C of this section,
Hydrostatic Test.
2. ASSEMBLY OF SECTIONS (HYDRAULIC
DRAW-UP)
V1104 through V1112 Section Assemblies
The entire assemblage may be drawn-up at one time
using the hydraulic draw-up equipment providing
the operation is completed within four (4) hours
after application of the sealant.
V1113 through V1123 Section Assemblies
The total assemblage should be rst drawn-up into
two (2) sub-assemblies. Each sub-assembly may be
drawn-up at one time using the hydraulic draw-up
equipment providing the operation is completed
within four (4) hours after the application of the
sealant.
"Hydraulic Draw-Up Equipment" is available
through Burnham by ordering part number 6196008.
a. Repeat steps 1a through 1j under "Field
Assembled Sections (Manual Draw-Up)".
b. Continue driving sections in place (in their
respective order) until all sections are in the
assemblage. Ground surfaces between adjoining
sections should be spaced 1/4" to 3/8" apart.
Spacing of more than 3/8" will limit number of
sections that can be drawn up in one unit and
could indicate cocked nipples.
WARNING
Sealant must be properly applied to ALL grooves.
Failure to properly seal the boiler joints will result
in combustion gas leaks through the joint. DO
NOT operate boiler with combustion gas leaks.
The sealant should be applied before each section
is placed on the assembly.
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 (4)
hours of the rst application of the 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
(4) hours of rst application of Silastic to the
joint.
c. Insert the three 3/4" draw-up rods (and
couplings, if 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 into couplings far enough to
prevent stripping threads.
d. Place a 12" long steel channel on each end of the
upper draw-up rod and an 8½” long steel channel
on each end of the lower draw-up rods. Install
nuts and washers on one end of the draw-up rods
and the hydraulic rams, washers and draw-up rod
clamps on the other. See Figure 13.
e. Draw-Up Sections
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.
19
CAUTION
Do not apply pressure directly on threaded
tappings on front and rear sections with draw-up
channels during assembly procedures.
Rods should be approximately centered in
openings so that rods and couplings (when
used) do not drag on pipe thread in end section
tappings.
WARNING
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. As a safety measure, ends of drawup 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.
f. Continue to draw-up until all sections make
contact at the ground joints.
g. After all sections have been drawn up, but before
removing the hydraulic rams and draw-up rods,
the 11" long tie-rods must be installed.
Large draw-up rod lugs with dual holes are cast
in the four (4) corners of each casting. Starting
with the upper holes in the back section, install
four (4) ¾" x 11" long tie rods along with
washers and nuts. Continue installing the tie
rods alternating from the upper to lower set
of holes in draw-up lugs until front section is
secured. Be certain that all sections are drawn up
iron to iron at all three nipple ports.
IMPORTANT
Jacket Support Brackets must be attached to the
appropriate center section during this process.
Check "Section Arrangement" chart for location
of center section to which jacket support brackets
must be attached (see Figure 8).
i. LOCATE JACKET INTERMEDIATE
PANEL MOUNTING BRACKETS
NO. 1, NO. 2, AND NO. 3 IN JACKET
CARTON. Brackets are shipped at and
must be formed by hand, bend as shown in
Figure 10.
Figure 14: Boiler Section Assemblage
Brackets are shipped at and must be formed
by hand, bend as shown in Figure 10.
ii. Slide brackets over draw-up rod lugs prior
to inserting the 11" long tie rods, washers
and nuts. Refer to Figures 11 and 12 for
proper location of each bracket and typical
attachment method.
h. Excess length of draw-up rods must not extend
beyond front and rear section to ensure proper t
of jacket, adjust accordingly. TIGHTEN ALL
TIE ROD NUTS UNTIL FINGER TIGHT.
THEN TIGHTEN THEM AN ADDITIONAL
½ TURN WITH A WRENCH.
C. HYDROSTATIC TEST - After the boiler sections
have been assembled, it is essential that the boiler be
hydrostatically tested before the canopy, ue cover
plates, jacket, or piping is installed.
1. Tankless Heater Installation
If boiler is ordered with tankless heaters, install
heaters with the gaskets provided. Table V gives
the maximum number of heaters permissible per
assemblage and the heater ratings.
2. Plug all boiler tappings and ll entirely with cold
water.
CAUTION
DO NOT install gauge until after hydrostatic
testing the boiler. Gauge failure may result.
3. All completed boilers shall satisfactorily pass the
prescribed hydrostatic test.
a. STEAM BOILERS: The assembled boiler shall
be subjected to a hydrostatic test of not less than
45 psig.
20
b. HOT WATER BOILERS: The assembled boiler
shall be subjected to a hydrostatic test of not less
than 1½ times the maximum allowable working
pressure, as established by the relief valve
provided with the boiler. For example, a boiler
with a 50 psi relief valve must be subjected to a
test pressure of 75 psig to 85 psig.
WARNING
Failure to properly hydrotest all boilers at the
correct pressure may result in section assembly
failure in operations.
4. EXAMINE BOILER CAREFULLY, INSIDE AND
OUTSIDE, to insure against leaks from cocked
nipples or through concealed breakage caused in
shipping and handling. This precaution is for your
protection and will simplify handling of necessary
replacements and adjustment claims.
5. After making certain that there are no leaks, drain
boiler and remove plugs for boiler trim and other
connections.
21
SECTION III - INSTALLATION INSTRUCTIONS
NOTE: Flue top insulation
not shown.
Figure 15: Bare Boiler Assembly
22
SECTION III - INSTALLATION INSTRUCTIONS (continued)
A. CANO PY/FLUE OUTLET ASSEMB LY, Refer to
Figures 15, 16 and 17.
1. Open canopy carton.
2. Two piece canopies should be joined together using
the 1/8" x 1" wide self-adhesive ber gasket and
seventeen (17) #10 x 1/2" sheet metal screws.
3. Attach the canopy bracket to the front end cap of
canopy with four (4) #10 x 1/2" sheet metal screws.
4. Across the top of the front section and along the top
ledges running back each side of the sections, place
continuous 2" wide strips of cerafelt and overlap
joints at front corners. Cerafelt strip should extend
1/4" beyond raised ange on rear surface of back
section. Cut off excess.
5. Place the canopy on the sections.
6. Position rear ange (end with studs) of canopy ush
with raised ange on rear of back section.
7. Loosely attach the canopy bracket to the lug on the
front of the section assembly with 5/16" carriage
bolt, at washer and lock-nut.
8. Attach canopy hold down channels to center
sections with appropriate canopy 'J' bolts. Insert
threaded end through holes in channels and hook
'J' bolts on center section lugs (hooks should face
forward). Loosely secure canopy with 5/16" at
washers, lock washers and brass nuts.
9. Check to see if rear ange of canopy is still ush
with raised ange on back section. Tighten rear set
of canopy 'J' bolts only.
10. Open either the rear ue outlet carton (standard) or
top ue outlet carton (optional).
11. Attach the 1/8" x 1" wide self-adhesive ber gasket
to the surface of either the rear ue outlet damper
assembly or rear ue outlet cover that mounts
against the canopy and back section. Gasket must
be centered over all attachment holes. Do not
overlap corners, cut butt joints.
12. Attach either the rear ue outlet damper assembly or
rear outlet canopy cover to the canopy with the six
(6) 5/16" at wasters, lock-washers and brass nuts.
Attach the rear ue outlet damper assembly or cover
to the back section with the six (6) 5/16" at
washers and cap screws.
13. Tighten front canopy carriage bolt and remaining 'J'
bolts until canopy is secure.
14. Attach the 1/8" x 1" wide self-adhesive ber gasket
to the surfaces of either the top ue outlet damper
assembly or top outlet canopy cover that mounts
against the canopy. Gasket must be centered over
all attachment holes. Do not overlap corners, cut
butt joints.
15. Secure either the top ue outlet damper assembly or
top outlet canopy cover with #10 x 1/2" sheet metal
screws.
16. 1" thick piece of berglass insulation provided in
canopy carton will be installed during jacket
assembly, set aside until then.
Figure 16: Canopy with Rear Flue Outlet Damper
Assembly
Figure 17: Canopy with Top Flue Outlet Damper
Assembly (Rear Cover Removed)
23
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