Burnham V11 Installation and Operation Manual

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Commercial Boilers

8142604R14-1/10

www.burnhamcommercialcastiron.com

Price $5.00

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

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.

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 specied 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.

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 efciency.

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.

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

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 Ofce Directory ............................................................................................................................................65

Jacket Assembly .......................................................................................................................................................... 66

Bare Boiler Assembly ................................................................................................................................................... 70

Steam/Water Trim ......................................................................................................................................................... 74

WARRANTY ....................................................................................................................................................... REAR COVER

SECTION I - GENERAL INFORMATION

Figure 1: Dimensional Information

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

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 difculty 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

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

conned 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.

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 specic

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.

RAIN CAP

RIGHT

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 sufciently 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

90°

ELBOW

UP or DOWN

Figure 3b: Vents — Faults & Suggestions

Typical Vents that are used on Forced Draft Boilers, on Low Silhouette Buildings

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

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 sufciently

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 "Identication

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 afx 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: Afxing the Fiberglass Rope

u CT

C B

u CT

C B

u CT

C B

u CT

C B

u CT

V11 SECTION ARRANGEMENT

BOILER SECTION IDENTIFICATION CODE

PROPER ASSEMBLY OF JACKET AND PROPER ALIGNMENT OF PIPING WITH JACKET KNOCKOUTS.

u C

CT B

u C

CT B

u C

u CT

u Cn

u CT

u Cn

u CT

u Cn

u CT

u Cn

u CT

u Cn

Figure 8

C C B

C CT

CX CT

C CT CX

CT C B

u CT

C CT B

CT C B

u CT

C CT B

u C

u CX

u CT

u CX Cn

u C

u C Cn

u CX

u C Cn

u CX

u CT CXl u C

C CT CX

u CT CXl u C

IMPORTANT: THE SECTIONS MUST BE ASSEMBLED ACCORDING TO THE ARRANGEMENT LISTED BELOW TO ENSURE PROPER OPERATION.

CT B

CT C B

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

V1108 F CT

u CT

V1109 F CT C

V1110 F CT

u CT

V1111 F CT C

u CT

V1112 F CT C

V1113 F CT

V1114 F CT

V1115 F CT

uCT

V1116 F C

uCT

V1117 F C

uCT

V1118 F C

uCT

V1119 F C

u CT

V1120 F C

uCT

V1121 F C

uCT

V1122 F 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 specied 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 identied in Figure 9. (Unless specied 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.

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

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.

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.

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.

SECTION III - INSTALLATION INSTRUCTIONS

NOTE: Flue top insulation

not shown.

Figure 15: Bare Boiler Assembly

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)

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 contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Figure 18: Flue Cover Plate Attachment

B. INSTALL FLUE COVER PLATES over cleanout

openings on left side of boiler as shown in Figure 18.

WARNING

See Important Product Safety Information on Page 24 of this manual, regarding refractory ceramic

ber product warning.

tightening, a gap is still evident where the sections join, apply silastic along top and bottom edge of insulation board.

7. Repeat steps 3 through 6 for mounting remaining

ue cover plates.

C. MOUNT REAR OBSERVATION PORT

COVER, Refer to Figure 15.

1. Apply a ¼” bead of Silastic sealant along the groove on the inside face of the rear observation port cover.

2. Mount the rear observation port cover onto the rear section (with the word “Top” in the upright position) using the (4) 5/16”-18 X 1” cap screws and washers provided.

D. INSP ECT SEA LS

1. A visual inspection should be made of all sealed joints and repairs made if necessary. A darkened boiler room with a light source in the combustion space and canopy will aid this inspection.

E. INSTALL THE CERAMIC FIBER FIREWAL L

PLATES on the right side of the center sections

starting at the front and working toward the back, see Figure 15 and 19. Firewall plates are shipped in the canopy carton, see chart below for quantities required.

Boiler Model

V1104/1105 1 0

V1106/1107 1 1

V1108/1109 1 2

V1110/1111 2 3

V1112/1113 1 4

V1114/1123 1 5

Front

Firewall Plate

Common

Firewall Plate

1. Locate the cover plates, carriage bolts, nuts and washers in the boiler assembly carton(s).

2. Remove insulation from two 3/8" diameter holes in

ue cover plates using a 3/8" drill bit which can be

rotated through insulation by hand.

3. Hook ue cover 'J' bolts over attachment lugs.

4. With one hand, hold top 'J' bolt between your index

and middle ngers. With the other hand, hold ue

plate on a slight inward angle, align top hole with end of 'J' bolt and force it through as far as possible. Repeat similar process for bottom 'J' bolt.

5. Holding threaded end of top 'J' bolt, pull outward

and at the same time push ue cover plate against castings. Place one nger across 'J' bolt at base of ue cover plate hole. Place 5/16" washer, split lock

washer and brass nut on end of 'J' bolt. Hand tighten only. Repeat similar process for bottom 'J' bolt.

6. Push upward on bottom edge of ue cover plate to

eliminate sag in hardware. Tighten brass nuts with a deep socket or wrench until insulation on cover plate provides an adequate seal to casting. If after

1. There are two different types of rewall plates identied as "Front" and "Common". All builds start with one (1) "front" rewall plate and "common" rewall plates are added as the boiler

grows in size.

IMPORTANT

Models V1104 and V1106 Only. Cut-off 3/4" of

excess material from rear edge of rewall plate to

eliminate interference with rear target wall.

Model V1104: Remove excess from front rewall

plate.

Model V1106: Remove excess from common

rewall plate.

2. Firewall plates have two (2) notches located along the bottom edge which interlock with lugs cast on each center section, making them self positioning.

The "front" rewall plate must be positioned as far

forward as possible.

Figure 19: Firewall Plates

3. Install rewall plates using silastic (provided) on each upper and lower edge of rewall plate where

plate rests against section. Apply a minimum bead of 1/2" diameter to all contact points to form a good bond to the casting.

F. JACKET ASSEMBLY

FOR V1104 thru 1112 JACKET ASSEMBLY

DRAWING, SEE FIGURE 20.

FOR V1113 thru 1123 JACKET ASSEMBLY

DRAWING, SEE FIGURE 21.

1. Open jacket carton(s) and jacket hardware package. Unless otherwise stated, all jacket components are fastened with #8 x 1/2" hex head sheet metal screws. Do not drive sheet metal screws tight until jacket assembly is complete.

2. Remove square knockout from jacket rear panel. To remove knockout, use a single hacksaw blade with handle or aviation snips to cut metal tabs between slotted holes.

3. Attach jacket front panel to front section and jacket rear panel to back section using the eight (8) #10 self tapping screws. Tighten these screws securely.

4. JACKET INTERMEDIATE PANEL ATTACHMENT - required on V1113 thru 1123 jacket assemblies only.

Use two (2) sheet metal screws each to secure jacket

intermediate panels to brackets previously attached during the section assembly process. Tighten these screws securely. For bracket attachment refer to Section II, Paragraph B, Step m, item i.

5. Each jacket channel has a three (3) digit

identication number stamped on the bottom ange.

The last two (2) digits identify their nominal length. Refer to single and multiple channel usage charts, See Figures 22 and 23.

a. Attach each jacket 'J' channel to one of the jacket

'U' channels of equal length (last two digits match) as shown in the exploded jacket detail on each of the jacket assembly drawings.

b. A support bracket with adjustable leg is required

on 'J'/'U' channel assemblies 46" and longer. Attach each support bracket with three (3) sheet metal screws and thread adjustable support leg (1/4" cap screw) into bottom of support bracket approximately 1" as shown in exploded jacket detail.

6. Channel Attachment - V1104 thru 1112 Jacket Assembly (refer to single channel usage chart, Figure 22).

a. Attach each 'J'/'U' channel assembly to the

bottom of the front and rear jacket panels using four (4) sheet metal screws.

b. On 'J'/'U' channel assemblies with support

bracket, adjust support leg (1/4" cap screw)

down until leg touches oor, then add 1/2 to 1

full additional turn.

c. Attach each remaining 'U' channel to the top of

the front and rear jacket panels ('U' side down) using (2) sheet metal screws.

7. Channel Attachment - V1113 thru 1123 Jacket Assembly (refer to multiple channel usage chart, Figure 23).

a. Attach the appropriate length 'J'/'U' channel

assembly to the bottom of the front and intermediate jacket panels using four (4) sheet metal screws. Repeat for opposite side.

b. Attach remaining 'J'/'U' channel assemblies

between the bottom of intermediate and rear jacket panels on each side in the same manner.

c. On 'J'/'U' channel assemblies with support

bracket, adjust support leg (1/4" cap screw)

down until leg touches oor, then add 1/2 to 1

full additional turn.

d. Using two (2) sheet metal screws each, attach the

remaining 'U' channels ('U' side down) between the tops of the front, intermediate and rear jacket panels according to channel length.

8. Position the loose piece of 1" thick x 36" wide

berglass insulation, provided in the canopy carton,

against left side 'U' channel(s), across top of canopy and down over right side between canopy and supply piping. Remove insulation from collar on

top ue outlet damper assembly, if so equipped.

9. Jacket Top Panel Attachment

a. On the top ue outlet damper assembly, remove

octagon shaped knockout. To remove knockout,

Figure 20: V11 Series Jacket Assembly (Boiler Models V1104 Thru V1112)

Figure 21: V11 Series Jacket Assembly (Boiler Models V1113 Thru V1123)

SINGLE CHANNEL USAGE

Boiler Size

Channel No.

(4 Req'd.)

V1104 U26 J26

V1105 U32 J32

V1106 U38 J38

V1107 U44 J44

V1108 U50 J50

V1109 U56 J56

V1110 U63 J63

V1111 U69 J69

V1112 U75 J75

'U'

'J'

Channel No.

(2 Req'd.)

Figure 22: Single Channel Usage Chart

MULTIPLE CHANNEL USAGE

Boiler

Size

V1113 U46 J46 U34 J34

V1114 U46 J46 U40 J40

V1115 U46 J46 U46 J46

V1116 U52 J52 U46 J46

V1117 U52 J52 U52 J52

V1118 U52 J52 U58 J58

V1119 U65 J65 U58 J58

V1120 U65 J65 U58 J58

V1121 U65 J65 U65 J65

V1122 U65 J65 U71 J71

V1123 U65 J65 U77 J77

Front 'U'

Channel No.

(4 Req'd.)

Front 'J'

Channel No.

(2 Req'd.)

Rear 'U'

Channel No.

(4 Req'd.)

Rear 'J'

Channel No.

(2 Req'd.)

Figure 23: Multiple Channel Usage Chart

LEFT SIDE USAGE CHART

MULTIPLE SIDE PANELS (FRONT TO REAR)

Panel No.1Panel No.2Panel No.3Auxiliary Boiler Size

Single

Left Side

Panel

V1104 SLS24 --- --- --- --- ---

V1105 SLS30 --- --- --- --- ---

V1106 SLS36 --- --- --- --- ---

V1107 --- FLS27 RLS15 --- --- ---

V1108 --- FLS27 RLS21 --- --- ---

V1109 --- FLS27 FLS27 --- --- ---

V1110 --- FLS27 RLS33 --- --- ---

V1111 --- FLS39 RLS27 --- --- ---

V1112 --- FLS39 RLS33 --- --- ---

V1113 --- FLS27 RLS17 FLS17 --- RLS15

V1114 --- FLS27 RLS17 FLS17 --- RLS21

V1115 --- FLS27 RLS17 FLS17 --- RLS27

V1116 --- FLS33 RLS17 FLS29 --- RSL15

V1117 --- FLS33 RSL17 FLS29 --- RLS21

V1118 --- FLS33 RLS17 FLS29 --- RLS27

V1119 --- FLS33 RLS29 FLS29 --- RLS21

V1120 --- FLS33 RLS29 FLS29 --- RLS27

V1121 --- FLS33 RLS29 FLS29 --- RLS33

V1122 --- FLS33 RLS29 FLS29 ALS24 RLS15

V1123 --- FLS33 RLS29 FLS29 ALS24 RLS21

Forward

Left Side

Panel

Rearward

Left side

Panel

Forward Left side

Panel

Auxiliary

Left Side

Panel

Panel No. 4

Rearward

Left Side

Panel

Figure 24: Left Side Panel Usage Chart

RIGHT SIDE USAGE CHART

MULTIPLE SIDE PANELS (FRONT TO REAR)

Single

Panel No.1Panel No.2Panel No.3Auxiliary

Right

Boiler

Side

Panel

Forward

Right Side

Heater

Panel

Size

Heater

V1104 SRH24 --- --- --- --- ---

V1105 SRH30 --- --- --- --- ---

V1106 SRH36 --- --- --- --- ---

V1107 --- FRH27 RRH15 --- --- ---

V1108 --- FRH27 RRH21 --- --- ---

V1109 --- FRH27 FRH27 --- --- ---

V1110 --- FRH27 RRH33 --- --- ---

V1111 --- FRH39 RRH27 --- --- ---

V1112 --- FRH39 RRH33 --- --- ---

V1113 --- FRH27 RRH17 FRH17 --- RRH15

V1114 --- FRH27 RRH17 FRH17 --- RRH21

V1115 --- FRH27 RRH17 FRH17 --- RRH27

V1116 --- FRH33 RRH17 FRH29 --- RRH15

V1117 --- FRH33 RRH17 FRH29 --- RRH21

V1118 --- FRH33 RRH17 FRH29 --- RRH27

V1119 --- FRH33 RRH29 FRH29 --- RRH21

V1120 --- FRH33 RRH29 FRH29 --- RRH27

V1121 --- FRH33 RRH29 FRH29 --- RRH33

V1122 --- FRH33 RRH29 FRH29 ARH24 RRH15

V1123 --- FRH33 RRH29 FRH29 ARH24 RRH21

Rearward

Right Side

Heater

Panel

Forward

Right Side

Heater

Panel

Auxiliary

Right Side

Figure 25: Right Side Panel Usage Chart

use a single hacksaw blade with handle or aviation snips to cut metal tabs between slotted holes.

b. Remove knockout(s) for necessary supply piping

in a similar manner.

c. Attach jacket top panel(s) to the front panel, rear

panel and upper 'U' channels with sheet metal screws. Secure seam on two piece top panel (V1113-1123) with sheet metal screws.

10. Install Jacket Side Panels a. Snap black thumb hole bushings into all side

panel holes.

b. Use left side panel and right side panel usage

charts to determine correct positions of side

panels. The ve (5) digit panel identication

numbers shown in the charts are also stamped along the bottom edge of each panel. Refer to Figures 24 and 25.

c. Forward and auxiliary panels have reverse bend

anges on one side of panel. These panels must

be installed prior to rearward panels.

d. If boiler is equipped with tankless heaters they

should be installed at this time if they were not installed for hydrostatic test outlined on Page 20.

e. Install left side panels into position by inserting

top of panel into upper 'U' channel, pushing bottom of panel in toward boiler, and sliding panel down into bottom 'J' channel.

f. Remove the knockouts necessary for tankless

heater operation on right side panels.

g. Install right side panels.

Panel

Heater

Panel

Panel No. 4

Rearward

Right Side

Heater

Panel

11. Combination Label and Burnham Logo Plate applied by manufacturer. If loose or peeling, apply pressure to reset adhesive.

12. Place the rating label (from Instruction envelope)

over the top of front panel label that identies the

proper location.

13. On steam boilers, attach lowest permissible water level plate (from steam trim carton) to the front panel using sheet metal screws.

14. Tighten all sheet metal screws to complete jacket assembly.

G. MOUNT BURNER MOUNTING PLATE, refer to

Figures 15 and 26.

1. Install ten (10) 5/16" x 2" long tap-end studs with the short length of threads into the boiler front section.

2. With the use of silastic, secure the 3/16" diameter rope gasket to the groove along the mounting plate opening in the front section.

3. Place burner mounting plate over studs and secure

with 5/16" at washer, lock washers and brass nuts.

H. MOUNT BURNER ADAPTER PLATE TO

BURNER MOUNTING PLATE, refer to Figures 26

and 27.

Figure 26: Burner Mounting Plate and Burner

Adapter Plate

Figure 27: Burner Mounting Plate/Burner Adapter Plate Options

ALSO, REFER TO BURNER INSTALLATION

IM TNATROP

MANUAL FOR INSTRUCTIONS SPECIFIC TO EACH BURNER.

1. In most cases the burner adapter plate carton for

the specied burner will be provided by Burnham.

Power Flame V1122 and V1123 burners require special adapters that will be provided with the burner.

2. If adapter is provided by Burnham, open carton and remove contents. Apply four (4) small dabs of silastic on rear surface of adapter plate to temporarily hold gasket in place. Hold adapter plate in position against burner mounting plate, align holes and secure with four (4) 3/8" lock washers and 3/8" - 16 x 7/8" lg. cap screws.

3. If adapter is furnished with burner, follow manufacturer's instructions using gasket material and hardware provided with burner.

a. Power Flame burners for the V1122 and V1123

are furnished with special adapter plates.

b. All other burners connect directly to the adapter

plate supplied by Burnham.

4. USE A HOLE SAW OR KNIFE TO CUT BURNER MOUNTING PLATE INSULATION TO MATCH HOLE SIZE ON BURNER ADAPTER PLATE. After cutting, remove any and all loose pieces of insulation which may become lodged or interfere with the head of a burner air tube after insertion.

5. Conrm that hole in insulation ts snugly around

burner blast tube. If hole is oversized, remove burner mounting plate (with burner attached) from

boiler. Use additional berglass rope gasket provided with burner to ll in any space between

insulation and blast tube. If additional rope gasket

is not provided with the burner, use 3/8” berglass

rope rated for 2300°F (provided by others).

Reinstall burner mounting plate when nished.

CAUTION

Failure to properly ll all gaps between the

insulation and burner blast tube may result in damage to the burner.

6. For boilers without tankless heaters, proceed to Paragraph I (Install Steam Trim) or J (Install Water Trim).

7. For boilers with tankless heaters, install the tankless heater manifolds according to Figure 28.

Water heater manifolds must be removable to allow for

heater repair and replacement, also for the removal of jacket right side panels for boiler repair and inspection.

Therefore, the recommended use and placement of shut off valves and unions on all manifold assemblies is crucial to providing easy access for future servicing.

I. STEAM BOILERS - INSTALL STEAM TRIM

Items for steam trim are located in the steam trim

carton (except for the separately ordered low cutoff and tankless heater control). Table IV and Figure 29 show the proper tappings for each item.

1. Install the gauge glass set.

2. Install the low water cutoff. When using two LWCO's on a V11 steam boiler, a probe type LWCO

cannot be used in conjunction with a oat type. See Figure 39 for illustration of two oat LWCO's. Also

follow manufacturers instructions furnished with control.

3. Install the Pressuretrol to the boiler using the 1/4" x 90° (1-7/8" x 4") siphon and the 3/4" NPT x 1/4" FPT hex bushing.

4. The Pressuretrol must be accurately leveled for proper operation. It is level when the leveling indicator hangs freely with its pointer directly over the index mark inside the back of the case. Level the controller by carefully bending the steam trap (siphon loop).

5. Install drain valve supplied by others in tapping B using the appropriate bushing

6. Install the steam gauge using the 1/2" NPT x 1/4" FPT hex bushing.

7. Install the safety valve to the back section as shown in Figure 43. The safety valve is installed in the tee provided for blowoff piping.

NOTICE

The L404 Pressure Limit contains mercury in a sealed tube. Do not place limit in the trash at the end of its useful life. If this limit is replacing a limit that contains mercury in a sealed tube, do not place your old limit in the trash. Contact your local waste management authority for instructions regarding recycling and the proper disposal of this limit, or of an old limit containing mercury in a sealed tube.

If you have questions, call Honeywell Inc. at

1-800-468-1502

WARNING

Safety valve discharge piping must be piped

to within six (6) inches of oor or to oor drain

to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps in discharge piping.

Figure 28: Minimum Piping Recommendations for V11 Series Tankless Heater Manifolds

Figure 29: Purpose of Tappings

Table IV: Purpose of Tappings

TAPPING SIZE STEAM BOILER WATER BOILER

A 4" Supply Supply B 3" Return Return C 3" Safety Valve Relief Valve

D 1½" Crown Inspection / Washout * Crown Inspection / Washout * E1 1" Float L.W.C.O. Float L.W.C.O. E2 1" Float L.W.C.O. Float L.W.C.O.

F1 1"

F2 1"

G ¾" ----- Probe L.W.C.O.

H ¾" ----- Auxiliary Probe L.W.C.O.

J ¾" Firing Rate Pressure Control Firing Rate Temperature Control

K1 ¾"

K2 ¾"

L ½" Gauge Glass Not Used - Plug M ½" Steam Gauge (Bush to ¼") Temperature/Pressure Gauge N ¾" ----- Auxiliary Tapping * P ¾" Low Fire Hold Control Low Fire Hold Control

* Special Order Only

Upper Auxiliary Float

L.W.C.O. Connection *

Lower Auxiliary Float L.W.C.O. Connection

Operating Pressure

Limit Control

High Pressure Limit Control/

Manual Reset

-----

Operating Temperature

Limit Control

High Temperature Limit Control/

Manual Reset

8. For boilers with tankless heaters, install the operating control in an unused tapping through one of the heater plates.

9. Plug extra tappings.

J. WATER BOILERS - INSTALL WATER TRIM

Items for water trim are located in the water trim carton

(except for the separately ordered low water cutoff and tankless heater control). Table IV and Figure 29 show the proper tappings for each item.

1. Install the temperature pressure gauge.

2. Install the low water cutoff. Follow manufacturers instructions furnished with controls.

3. Install the immersion well and mount the aquastat onto the well.

4. Install the drain valve supplied by others in tapping B using the appropriate bushing.

5. Install the pressure relief valve as shown in Figure 44.

6. Plug extra tappings.

K. BURNER INSTALLATION

Refer to burner manufacturer's installation manual

for proper installation, fuel piping, wiring, burner adjustment and service instruction.

L. PACKAGED BOILER

1. The packaged boiler comes on its own shipping skid (see Figure 30) and the assembled block is hydrostatically tested at the factory. Once the boiler

is in its nal position, perform another hydrostatic

test at 1½ times the working pressure of the boiler. The shipping skid can be used as a housekeeping pad unless local codes say otherwise. All controls are pre-wired down to the burner. If burner is equipped with a lead lag panel, lead lag controls will be shipped loose for header mounting. The power can be supplied to the burner if equipped with a control panel. If burner has no panel, the power is supplied to the J-box on the front jacket.

2. SUPPLY CONNECTIONS - Removal of top jacket is not required to connect the supply riser(s),

however one may nd it easier. Refer to Figure(s) 31

and/or 32 for water boilers and Figure 37 for steam boilers.

3. RETURN CONNECTIONS - The boiler is secured to the shipping skid with U bolts and 3" shipping nipples. REMOVE THE BOLTS AND NIPPLES. Using 3" plugs and an appropriate pipe sealant,

Figure 30: Shipping Information

plug the unused return connections according to the minimum piping recommendations. Refer to Figure(s) 31 and/or 32 for water boilers and Figure 37 for steam boilers.

4. If the boiler burner unit was factory re tested, the

burner was adjusted to approximately 10% CO2

(gas) or 13% CO2 (oil) with an overre pressure as listed in the Burner Specications, Section VI of this

manual. Final adjustments should be made once the unit is installed and adjusted.

M. BOILER PIPING - HEATING APPLICATIONS

Connect supply and return piping to heating system (see

Figures 31 to 37). Flow direction for hot water boilers must be from the rear return out through the top front supply. Steam boilers can pipe return to the front as an alternate location. Some boiler sizes may require the use of additional supply and return tappings. Check Table IV, Figure 29 and applicable piping diagram for the boiler size you are installing.

WARNING

Failure to properly pipe boiler may result in improper, unsafe system operation and void manufacturer's warranty. DO NOT improperly pipe boiler.

NOTICE

All steam and hot water pipes must have clearances of at least ½" from all combustible construction.

Boiler

Number of

Number

* Width can vary with gas train conguration.

** Add 6½" to dimension C when equipped with optional top outlet.

*** Varies slightly with burner and gas train conguration.

Sections

V1104 4 71¼ 48 68 22 2438 V1105 5 77½ 48 68 25½ 2899 V1106 6 89½ 48 68 28¼ 3360 V1107 7 95½ 48 68 31¾ 3806 V1108 8 101¾ 48 68 35 4254 V1109 9 108 48 68 38½ 4689 V1110 10 114 48 68 41½ 5129 V1111 11 120 48 68 44½ 5597 V1112 12 130¼ 48 68 47½ 6029 V1113 13 136½ 48 68 50¾ 6537 V1114 14 142½ 48 68 53¾ 6880 V1115 15 148½ 48 68 56¾ 7408 V1116 16 154¾ 48½ 70 59¾ 7835 V1117 17 161 48½ 70 63 8265 V1118 18 167 48½ 70 67 8691 V1119 19 173 48½ 70 70 9140 V1120 20 179¼ 48½ 70 73 9567 V1121 21 185½ 48½ 70 76¼ 10005 V1122 22 197½ 48½ 70 79¼ 10429 V1123 23 203½ 48½ 70 82¼ 10859

1. Do not tilt. Exercise caution when lifting to avoid damage.

2. This boiler can be lifted by fork tuck. Do not truck from front.

3. When lifting from rear, forks must extend from beyond center of gravity and second skid cross bar.

4. When lifting from side, forks must extend to opposite skid rail and straddle center of gravity.

5. Cablespreader is to prevent jacket damage. Spreader width should equal B (width of skid) + 12". Adjust cable lengths to lift at approximate center of gravity per chart.

Length A Width B *

Height

C **

Approx.

Center of

Gravity D ***

WARNING

A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation.

1. HOT WATER HEATING - This boiler must be installed in strict accordance with this installation manual Deviations from these installation instructions may void manufacturer’s warranty. Also consult I=B=R Installation and Piping Guides.

WARNING

Continued boiler operation for prolonged periods of time under conditions when temperature differential across the system exceeds 40°F and/ or, return water temperature stays below 135°F,

may result in premature boiler failure due to ue

gas condensation and/or thermal shock.

a. If the boiler is used in connection with

refrigeration systems, boiler must be installed with chilled medium piped in parallel with heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure

40.

b. If the boiler is connected to heating coils

located in air handling units where they may be exposed to refrigerated air, boiler piping must

be equipped with ow control valves to prevent

gravity circulation of boiler water during cooling

system operation.

Approx.

Shipping

Weight LBx *

c. Burnham Commercial recommends maintaining

temperature differential (drop) across the system at 40°F or less, and return water temperature at minimum of 135°F for optimum operation and long-term reliability.

i. If minimum return water temperature can

be maintained at 135°F and temperature differential across the system is at 40°F or less, refer to Figure 31 or 32 for recommended minimum boiler piping details.

ii. If minimum return water temperature cannot

be maintained at 135°F or the temperature differential across the system varies, a blend pump is recommended as a minimum to help

protect the boiler from ue gas condensation

and/or thermal shock. See piping details in Figure 33. Primary secondary piping with a by-pass is an alternate to the blend pump method and is shown in Figure 34.

d. If conditions exist where the boiler is subjected

to prolonged periods of operating conditions below 135°F, other mixing methods such as three or four way valves or variable speed injection should be used. Burnham Commercial offers an RTC Return Temperature Control kit to protect the boiler. See separate RTC manual.

e. Multiple Boilers - Recommended minimum

multiple boiler piping is shown in Figure 35 as primary secondary with a by-pass. The boiler

circulator will maintain a constant ow through

the boiler during every heat demand while the by-pass diverts a portion of hot water back to

the return. Alternate minimum multiple boiler piping is shown in Figure 36. The blend pump

will maintain constant ow through the boiler

during every heat demand and provide a hot water blend back to the return.

f. Glycol Antifreeze Solutions - Many systems

today use ethylene or propylene glycol antifreeze solutions as a measure for freeze protection, as well as a pump lubricator and corrosion inhibitor. The properties of the glycol mixture have an impact on valve and pump sizing. All glycol

solutions have a lower specic heat than water.

This means that the glycol solution cannot transfer heat as well as pure water, resulting in

the need for higher ow rates. In addition, the

viscosity of the glycol solution is usually higher than water, requiring a higher pump head for the

same given ow. Consult factory for specic applications, pump selection and ow rate.

WARNING

A properly constructed Hartford Loop must be installed on all gravity return steam systems.

Hartford Loop is not required on pumped return

systems.

2. STEAM HEATING, consult I=B=R Installation and Piping Guide No. 200. For piping details, see Figure 37. Figure 38 shows a typical pumped return/boiler feed unit arrangement. Figure 39 illustrates the required elevations for McDonnell and

Miller 150 and 63 oat low water cut-offs.

Figure 31: V11 Series Minimum Piping Recommendation — Parallel — Water

Figure 32: V11 Series Minimum Piping Recommendation — Primary Secondary— Water

Figure 33: Minimum Piping Details, Bypass With Blend Pump

Figure 34: Minimum Piping Details, Primary/Secondary Piping With Bypass

Figure 35: Minimum Piping Details - Multiple Boiler Application, Primary/Secondary Piping With Bypass

Figure 36: Minimum Piping Details - Multiple Boiler Application, Parallel Piping With Blend Pump

'A'

V1104 AND V1105 V1106 AND V1109

'A'

'B'

V1110 AND V1113

'A'

'B'

'C'

'A'

'B'

'C'

'A'

'B'

'C'

'D'

18"

MIN.

24"

MIN.

HEADER

'E'

'D'

V1114 THRU V1117 V1118 THRU V1121 V1122 AND V1123

EQUALIZER

CLOSE NIPPLE

HARTFORD LOOP

(REQ'D ON GRAVITY

RETURN SYSTEM)

RETURN

BLOWOFF/DRAIN VALVE

(SEE NOTE 3)

REAR OF BOILER

2" TO 4"

WATER LINE

SUPPLY

(SEE NOTE 5)

RISER

NOTES:

1. All piping is schedule 40.

2. To prevent condensate from being trapped in header, do not reduce equalizer elbow

at header connection.

3. Ball valve preferable, gate valve acceptable alternative (supplied by others).

- Minimum valve size per ASME code is 1" NPT (V1104-1106).

1-1/4" NPT (V1107-1112), 1-1/2" NPT (V1113-1123).

- Increasing the valve size will improve the blowdown operation

- In all cases, piping connecting blowoff valve to boiler shall be full size to the point of

discharge.

4. Header piping may be run over the top of boiler if space does not allow for piping

arrangement shown. Increases service requirements will result, however.

5.Supplyfromboilerheadermustbeconnectedbetweentherstboilerriserandthe

header drip (or hartford loop). Do not connect supply between risers or opposite end

of boiler header.

Figure 37: Minimum Piping Requirements V11 Series Steam Boilers - Gravity Return

Figure 38: Typical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit

Figure 39: Mounting Elevations of M&M

150 and 63 Float Low Water Cut-offs.

Figure 40: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

Water Boilers

N. BOILER PIPING, DOMESTIC HOT WATER

(DHW) APPLICATION – The V11 boiler can be

used in many different piping applications to produce Domestic Hot Water (DHW). In some applications, depending on the control strategy (outdoor reset, setpoint operation, etc.) and size of the boiler, it is recommended to isolate the space heating load from the DHW load. For example, if the domestic load is more

than the space heating load, it is benecial to dedicate

one or more boilers solely to DHW production and one or more boilers solely to space heating, since during mild weather conditions, the boiler(s) will have more capacity than is required. Piped in the recommended manner, the space heating boiler(s) can be shut down during the summer months to conserve energy and to avoid short cycling. This section will address three methods of piping and controlling domestic hot water generation.

1. Hot Water Boiler/Tankless Coil(s) – Tankless coils, mounted into the side of the boiler(s), have been used successfully for many years and may be used in single and multiple boiler applications. When a boiler is arranged with tankless coils, it is not recommended that outdoor reset be used, unless there are controls in place to prevent overheating of the space heating zones. Figure 41 depicts

the addition of an automatic mixing valve to the tankless heater piping to obtain a dual temperature domestic system. The mixing valve provides

tempered water to the xtures, while the branch

prior to the valve provides high temperature water for dishwashing, washing machines and other appliances.

2. Hot Water Boiler/Tankless Coils/Storage Tank – This application involves the use of several tankless coils piped in parallel, emptying into a large storage tank, and is typically used in larger DHW production applications, such as hotel showers and laundries. See Figure 42a for recommended piping and wiring details for this type of application. The tempering valve and recirculation loop are advantageous in these applications, because they provide both high temperature and tempered domestic water to the system, eliminating the need to purge and waste water until it reaches the desired temperature. In the case where the boiler is used for domestic production only, and there is no space

heating involved, a destratication pump is utilized to provide ow within the boiler. This ow acts as

a means of preventing the hot water from stratifying

at the top of the boiler. Destratication pump ow

rates are given in the table in Figure 42a.

NOTICE

When possible, domestic hot water production should utilize a dedicated boiler(s). This will allow the other boiler(s) to be shut down and isolated during the summer months. If the boiler load is shared between

heating and domestic hot water, then one needs to determine if a hot water priority is required. If a priority

is not selected, erratic domestic hot water production may result during the beginning and end of every

heating season. Conversely, a priority for domestic hot water production may cause a signicant heating zone activation delay, in an improperly balanced system. Parallel piping conversions may require isolation from the heating system to prevent system ow inuence on DHW performance. Consult a qualied system

heating professional to design for the proper application.

Figure 41: Schematic Tankless Heater Piping

3. Hot Water Boiler/Indirect Water Heater - The use of indirect water heaters for domestic hot water generation is common and somewhat advantageous over tankless coils alone, since they also provide DHW storage. A tempering valve and recirculating pump are again recommended for a dual temperature system, to provide a constant temperature to the

xtures without waiting for cooler water to warm

up. Figure 42b shows a typical indirect heater piping application with no space heating. Indirect pump ow rates are calculated based on a 20°FDT.

Table V: Tankless Heater Ratings

NOTICE

DO NOT use the boiler circulator as an indirect domestic hot water system circulator.

O. C ONNECT TANKLES S HEATE R PIPIN G as

shown in Figure 41. See Table V for Tankless Heater Ratings.

THE FOLLOWING GUIDELINES SHOULD BE

FOLLOWED WHEN PIPING THE TANKLESS HEATER:

1. Flow Regulation

If ow through the heater is greater than its rating,

the supply of adequate hot water may not be able to keep up with the demand. For this reason a FLOW REGULATOR matching the heater rating should be installed in the cold waterline to the heater. Refer

to Figure 41 for piping recommendations. The ow

regulator should preferably be located below the inlet to the heater and a minimum of 3 feet away from the inlet so that the regulator is not subjected to excess temperatures that may occur during “off” periods when it is possible for heat to be conducted

back through the supply line. The ow regulator also limits the ow of supply water regardless of

inlet pressure variations in the range of 20 to 125 psi.

2. Tempering of Hot Water

WARNING

Install a mixing valve at the tankless heater outlet to avoid risk of burns or scalding due to

excessively hot water at xtures. Do not operate the boiler when equipped with a tankless heater

unless mixing valve is operating properly.

Installation of a tempering or mixing valve will

also lengthen the delivery of the available hot water by mixing some cold water with the hot. In addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking water temperatures to his liking. Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve. The mixing valve should be “trapped” by installing it below the cold water inlet to heater to prevent lime formation in the valve.

3. Flushing of Heater

All water contains some sediment which settles

on the inside of the coil. Consequently, the heater should be periodically backwashed. This is accomplished by installing hose bibs as illustrated in Figure 41 and allowing water at city pressure to

run into hose bib A, through the heater, and out hose bib B until the discharge is clear. The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop.

4. HARD WATER - A water analysis is necessary to determine the hardness of your potable water. This is applicable to some city water and particularly to well water. An appropriate water softener should be installed based on the analysis and dealer's

recommendation. This is not only benecial to the tankless heater but to piping and xtures plus the many other benets derived from soft water.

P. INSTAL L ELECT RIC WIR ING in accordance

with National Electric Code and local regulations. A separate ELECTRICAL CIRCUIT should be run from meter with a Fused Disconnect Switch in this Circuit.

Figure 42a: DHW Generation with Tankless Coils, Storage Tank and Destratication Pump

Figure 42b: DHW Generation with Indirect Water Heater

Figure 43: Steam Boiler - Safety Valve Hook-Up

Figure 44: Water Boiler - Pressure Relief Valve

Hook-Up

SECTION IV - OPERATING INSTRUCTIONS

WARNING

If you do not follow these instructions exactly,

a re or explosion may result causing property

damage or personal injury. If any unusual or improper operation or site

conditions are observed, turn the boiler off and contact an experienced and skilled service agency.

Follow component manufacturer's instructions. Component manufacturer's instructions were provided with the boiler. Contact component manufacturer for replacement if instructions are missing. Do not install, start up, operate, maintain or service this boiler without reading and understanding all of the component instructions. Do not allow the boiler to operate with altered, disconnected or jumpered components. Only use replacement components identical to those originally supplied with the boiler and burner.

A. ALWAYS INSPECT INSTALLATION BEFORE

STARTING BURNER.

B. FILL HEATING SYSTEM WITH WATER.

c. Attach a hose to hose bib located just below

isolation valve in boiler supply piping.

(Note - Terminate hose in ve gallon bucket at a

suitable oor drain or outdoor area).

d. Starting with one circuit, open zone valve.

e. Open hose bib.

f. Open ll valve (Make-up water line should be

located directly above isolation valve in boiler supply piping.

g. Allow water to overow from bucket until

discharge from hose is bubble free for 30 seconds.

h. Open zone valve to the second zone to be

purged, then close the rst. Repeat this step until

all zones have been purged, but always have one zone open. At completion, open all zone valves.

i. Close hose bib, continue lling the system until

the pressure gauge registers normal system

design operating pressure. Close ll valve.

(Note - If make-up water line is equipped with pressure reducing valve, system will

automatically ll to normal system design

operating pressure. Leave globe valve open).

j. Open isolation valve in boiler supply piping.

k. Remove hose from hose bib.

CAUTION

Failure to clean the system will result in erratic water lines and surging, and other improper system operations.

CLEAN HEATING SYSTEM IF boiler water or

condensate return water is dirty or if erratic water lines or surging exist after a few days of boiler operation. Refer to Paragraph (F) for proper cleaning instructions for steam and water boilers.

1. STEAM BOILERS - Fill boiler to normal water line. As shown in Figure 1, the normal water

line is 45¾" from the oor. At the start of each

heating season and once or twice during the season try SAFETY VALVE to be sure it is in working condition. To do this, fasten wire or cord to lever of valve and pull lever — standing safe distance away from valve.

2. HOT WATER BOILERS - Fill entire Heating System with water and vent air from system. Use the following procedure on a Series Loop or Multizoned System to remove air from system when

lling:

a. Close isolation valve in boiler supply piping.

b. Isolate all circuits by closing zone valves or

balancing valves.

DANGER

Do not operate boiler with pressure above maximum allowable working pressure listed on the Boiler Rating Label.

DO NOT draw water from boiler while in use. When adding water while boiler is in operation, do not open supply valve fully but add water slowly.

C. SET CONTRO LS with burner service switch turned

“OFF”.

1. PRESS RESET BUTTON on primary control and release.

2. On STEAM BOILERS set cutout pressure (MAIN

scale) on L404 Pressuretrol for ve (5) PSI and

differential pressure (DIFF scale) for two (2) PSI. These pressures may be varied to suit individual requirements of installation.

3. On STEAM BOILERS WITH TANKLESS DOMESTIC WATER HEATERS, set boiler water temperature dial on low limit operating control at 190°F (max.). Set differential at 10°.

4. ON WATER BOILERS WITHOUT TANKLESS HEATERS, set high limit dial on L4006A at 210°F. This temperature may be varied

to suit requirements of installation.

5. ON WATER BOILERS WITH TANKLESS HEATERS, set low limit operating control dial at 190°F and high limit dial 210°F. Operating control must be a minimum of 20 below high limit setting. Set differential at 25°.

D. ADJUST BURNER according to the Burner Manual.

1. FLAME FAILURE

The V11 boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to re and the reset button on the primary

control is tripped, the burner has experienced ignition failure. Before pressing the reset button, call your serviceman immediately.

4. CHECK OPERATING CONTROL on boiler equipped with tankless heaters. With burner off, draw hot water until burner starts, then turn off hot water and check burner shutdown.

F. BOILER AND SYSTEM CLEANING - STEAM

BOILER

NOTICE

A qualied water treatment chemical specialist

should be consulted fo r recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations.

WARNING

Do not attempt to start the burner when excess oil or gas has accumulated in the combustion chamber, when the unit is full of vapor, or when the combustion chamber is very hot.

E. TEST CONTROLS

WARNING

Before installation the b oiler is conside red complete, the operation of the boiler controls should be checked, particularly the low water cutoff and the high limit control.

1. CHECK OPERATING CONTROL OPERATION.

Raise and lower operating control setting as required

to start and stop burner.

2. CHECK OPERATION OF HIGH LIMIT CONTROL —

Jumper Operating Control Terminals. Allow burner

to operate until shutdown by limit. Installation is not considered complete until this check has been made.

REM OVE JUM PER.

3. CHECK LOW WATER CUTOFF control with water level at normal water line (see Figure 1). Raise operating control setting to allow burner to operate. Open boiler drain to allow water level to drop to bottom of sight glass until burner operation is shut down by low water cutoff.

Close boiler drain and rell to normal water line.

Burner should automatically restart during ll.

RESET OPERATING CONTROL.

CAUTION

Probe and float type low water cutoff devices

require annual inspection and maintenance.

Refer to Section V, Paragraph (C) for proper cleaning instructions.

WARNING

Chemicals used in treating boiler water are toxic and/or harmful. Always use protective clothing

and equipment when working with/near chemicals.

Contact local authorities to determine if treated boiler water can be discharged into local waste water system.

1. Oil, greases & sediments which accumulate in a new boiler and piping must be removed in order to prevent an unsteady water line and carry over of the water into the supply main above boiler. 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 returned to the boiler, boil out the boiler using the SURFACE BLOWOFF connection. See Figure 43.

a. Drain boiler until water is just visible in gauge

glass. Run temporarily 1½” pipe line from the surface blowoff connection to an open drain or some other location where hot water may be discharged safely. Do not install valve in this line.

b. Add an appropriate amount of recommended

boilout compounds.

c. Start burner and operate sufciently to boil

the water without producing steam pressure. Boil for about 5 hours. Open boiler feed pipe

sufciently to permit a steady trickle of water

from the surface blowoff pipe. Continue this

slow boiling and trickle of overow for several hours until the water coming from the overow

is clear.

d. Stop burner and drain boiler in a manner and to

a location that hot water can be discharged with safety.

e. Rell boiler to normal water line. If water in

gauge glass does not appear to be clear, repeat

steps (a. thru e.), and boil out the boiler for a longer time.

2. Low pressure steam boilers such as the V11 Series should be maintained with appropriate water treatment compounds. Add water treatment

compounds as recommended by your local qualied

water treatment company.

3. Remove temporary surface blowoff piping, plug tapping and reinstall safety valve. Boil or bring water temperature to 180°F promptly in order to drive off the dissolved gases in the fresh water.

4. If unsteady water line, foaming or priming persist, install gate valve in Hartford Loop and drain valves in return main and at boiler and proceed as follows:

a. Connect hoses from drain valves to oor drain.

Close gate valve in Hartford Loop and open drain valve in return main. Fill boiler to normal water level, turn on burner and operate boiler at this water level for at least 30 minutes after the condensate begins to run hot, then turn off burner.

Close all radiator valves. Remove all supply

main air valves and plug the openings in supply main.

b. Draw about 5 gallons of hot water from boiler

into a container and dissolve into it appropriate amount of a recommended boilout compound. Remove safety valve and pour this solution into boiler, then reinstall safety valve.

c. Turn on burner and keep operating while feeding

water to boiler slowly. This will raise water level in boiler slowly so that water will be boiling hot and will rise slowly into supply main and back

through return main, owing from drain hose

at about 180°F. Continue until water runs clear from drain hose for at least 30 minutes.

d. Stop feeding water to boiler but continue

operating burner until excess water in boiler

ows out through supply main and water lowers

(by steaming) until it reaches normal level in boiler. Turn off burner. Drain boiler. Open all radiator valves. Reinstall all supply main air valves. Open gate valve in Hartford Loop.

e. When boiler has cooled down sufciently (crown

sheet of sections are not too hot to touch), close the drain valves at boiler and in return main and feed water slowly up to normal level in boiler. Turn on burner and allow boiler to steam for 10 minutes then turn off burner. Draw off one

quart of water from bottom gauge glass tting

and discard. Draw off another quart sample and if this sample is not clear, repeat the cycle of

draining the boiler and return main and relling

the boiler until sample is clear.

f. If the boiler water becomes dirty again at a later

date due to additional sediment loosened up in the piping, close gate valve in Hartford Loop,

open drain valve in return main, turn on burner

and allow condensate to ow to drain until it has

run clear for at least 30 minutes while feeding water to boiler so as to maintain normal water level. Turn off burner, drain boiler, open gate valve in Hartford Loop, then repeat step (a) above.

5. Make pH or Alkalinity Test.

After boiler and system have been cleaned and

relled 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 hydrion paper which is used in the same

manner as litmus paper, except it gives specic

readings. A color chart on the side of the small hydrion dispenser gives the reading in pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7, but lower than 11. Add some appropriate water treatment chemicals, if necessary to bring the

pH within the specied range.

6. Boiler is now ready to be put into service.

G. BOILER AND SYSTEM CLEANING -

WATER BOILERS

1. Filling of Boiler and System --- General --- In a hot water heating system, the boiler and entire system (other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler pressure gauge registers normal system design operating pressure. To insure that the system is full, water should come out of all air vents when opened.

2. Boiling Out of Boiler and System. The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner.

a. Remove safety relief valve using extreme care to

avoid damaging it.

b. Add an appropriate amount of recommended

boilout compound.

c. Reinstall safety relief valve.

d. Fill the entire system with water.

e. Start ring the boiler.

f. Circulate the water through the entire system.

g. Vent the system, including the radiation.

h. Allow boiler water to reach operating

temperature, if possible.

i. Continue to circulate the water for a few hours.

j. Stop ring the boiler.

k. Drain the system in a manner and to a location

that hot water can be discharged with safety.

l. Remove plugs from all available returns and

wash the water side of the boiler as thoroughly as possible, using a high-pressure water stream.

m. Rell the system with fresh water.

3. Add appropriate boiler water treatment compounds

as recommended by your local qualied water

treatment company.

4. Make pH or Alkalinity Test.

After boiler and system have been cleaned and

relled 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, except it gives specic

readings. A color chart on the side of the small hydrion dispenser gives the reading in pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or thru your local druggist. The pH should be higher than 7 but lower than 11. Add some appropriate water treatment chemicals, if

necessary to bring the pH within the specied range.

With this lower level of protection, care must be exercised to eliminate all of the free oxygen in the system.

5. Boiler is now ready to be put into service.

H. FREQUENT WATER ADDITION

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD WATER MORE FREQUENTLY THAN ONCE A MONTH, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS.

A leaky system will increase the volume of make-up

water supplied to the boiler which can signicantly

shorten the life of the boiler. Entrained in make-up water are dissolved minerals and oxygen. When the fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas. Both can result in reduced boiler life. The accumulation of sediment can eventually isolate the water from contacting the cast iron. When this

happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the cast iron through from the inside. Since neither of these failure types are the result of a casting defect the warranty does not apply. Clearly it is in everyone’s best interest to prevent this type of failure. The maintenance of system integrity is the best method to achieve this.

I. OXYGEN CORROSION:

WARNING

Oxygen contamination of the boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham's standard warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime)

build-up caused by frequent addition of water.

There are many possible causes of oxygen

contamination such as: a. Addition of excessive make-up water as a

result of system leaks.

b. Absorption through open tanks and ttings.

c. Oxygen permeable materials in the

distribution system.

In order to ensure long product life, oxygen

sources should be eliminated. This can be accomplished by taking the following measures:

a. Repairing system leaks to eliminate the need

for addition of make-up water.

b. Eliminating open tanks from the system.

c. Eliminating and/or repairing ttings which

allow oxygen absorption.

d. Use of non-permeable materials in the

distribution system.

e. Isolating the boiler from the system water by

installing a heat exchanger.

SECTION V - SERVICE INSTRUCTIONS

DANGER

This boiler used ammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians. If any controls are replaced, they must be replaced with identical models. Read, understand and follow all the instructions and warnings contained in all the sections of this

manual. If any electrical wires are disconnected during service, clearly label the wires and assure that the wires

are reconnected properly. NEVER operate boiler without all sight glasses and brackets in place and securely fastened and sealed.

Very HOT combustion gas may cause burn injury. Read, understand and follow all the instructions and warnings contained in ALL of the component

instruction manuals. Assure that all safety and operating controls and components are operating properly before placing the

boiler back in service.

IMPORTANT - See Section IV, Paragraph (H), under

Operating Instructions if it becomes necessary to add water to the boiler more frequently than once a month.

A. GEN ERAL - Inspection should be conducted

annually. Service as frequently as specied in

paragraphs below. While service or maintenance is being done, electrical power to the boiler must be “off”.

B. CLEAN THE BO ILER HE ATING S URFACES

AND FLUE at least once each year, preferably at the

end of the heating season.

1. CLEAN THE VENT SYSTEM - Vent system should be checked annually for: a. Obstructions.

b. Accumulations of soot.

c. Deterioration of vent pipe or vent accessories

due to condensation or other reasons.

d. Proper support - no sags, particularly in

horizontal runs.

e. Tightness of joints.

Remove all accumulations of soot with wire brush

and vacuum. Remove all obstructions. Replace all deteriorated parts and support properly. Seal all joints.

2. CLEAN THE BOILER FLUEWAYS a. Remove the smokepipe.

b. Remove the jacket top and left side panels.

c. Remove the canopy being careful not to damage

the cerafelt gasket.

d. Loosen nuts securing the ue cleanout plates

and remove the plates. The insulation should be removed with the plates taking care not to damage the insulation.

e. Using a 1¼” diameter wire or bre bristle brush

(36” handle) to clean the ueways. Start at the top of each ueway opening and work down the

pin rows using two or three horizontal strokes per row for best results.

3. CLEAN TOP OF BOILER SECTIONS.

Brush and vacuum the tops of the boiler sections.

4. CLEAN THE FIREBOX a. Disconnect fuel line(s) and remove burner and

burner mounting plate.

b. Using wire or bre bristle brush clean crown of

boiler and inside of water legs.

c. Inspect rewall plates for damage or

deterioration. Replace as needed per instructions outlined in Section III, Paragraph (E).

5. REASSEMBLE BOILER

CAUTION

Do not start the burner unless canopy, smokepipe, burner mounting plate and all flue plates are secured in place.

a. Install the canopy taking care to align the cerafelt

strips. If strips are damaged replace as needed.

b. Reinstall burner mounting plate to front section

making sure 3/16" diameter rope gasket is in place and forms gas tight seal. If gasket is damaged, replace.

c. Bolt burner to burner mounting plate. Inspect

gasket to assure adequate seal. Replace if damaged. Connect oil line(s) and/or gas line(s).

d. Reinstall ue plates making sure gasket on each

plate is in place and forms gas tight seal. If damaged, all edges of the cleanout plates should be sealed with Silastic sealant when reinstalled until insulation can be replaced.

e. Reinstall jacket top and left side panels.

f. Reinstall smokepipe.

C. MAI NTENANC E OF LOW WATER CUTOFF

DEVICES

NOTICE

Probe and float type low water cutoff devices

require annual inspection and maintenance.

1. PROBE TYPE LOW WATER CUTOFF Although these devices are solid state in their

operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.

It is important to physically remove the probe from

the boiler tapping annually and inspect that probe for accumulation of scale or sediment.

Follow these steps to inspect, clean and /or replace

the probe: a. Turn off electric service to the boiler.

b. Drain boiler water to a level below the tapping

for the probe.

c. Disconnect wiring connections between the low

water cutoff control and the probe.

DANGER

Assure that the boiler is at zero pressure before removing the LWCO probe. Do not rely on the pressure gauge to indicate that the boiler is at zero pressure. Open the safety valve to relieve all internal pressure prior to proceeding. Safety valve discharge piping must be piped such that the potential for burns is eliminated.

d. Dismount the low water cutoff control from the

probe. e. Unscrew the probe from the boiler tapping. f. Inspect that portion of the probe that is exposed

to the boiler water for a scale or sediment

buildup. g. Light deposits may be removed by wiping the

probe with a damp cloth. Wiping the probe

with a cloth soaked in vinegar will remove more

tenacious lime deposits. The most stubborn

deposits may be removed from the probe by

using a diluted amount (3 part of water to 1 part)

of phosphoric acid (H2PO4).

WARNING

Exercise caution when handling phosphoric acid and follow the instructions on container label.

Always use protective clothing and equipment

when working with/near chemicals.

h. Wire brushing of the probe is not recommended

as the soft platinum guard ring sandwiched

between the ceramic insulators may be damaged.

Care must be taken not to damage this ring in

any way or the useful life of the probe may be

shortened.

i. Clean the pipe threads of the probe to remove

old, hardened pipe dope and other foreign matter.

j. Apply a moderate amount of good quality pipe

dope to the pipe threads on the probe, leaving the

two end threads bare. Do not use PTFE (Teon)

tape.

k. Screw the probe into the boiler tapping.

l. Mount the low water cutoff control on the probe.

m. Reconnect the control to probe wiring.

n. Fill the boiler to its normal waterline.

o. Add boiler water treatment compound as needed.

p. Restore electric service to the boiler.

q. Fire burner to bring the water in the boiler to a

boil to drive off free oxygen.

r. BEFORE RETURN ING BOI LER TO

SERVICE: Follow the low water cutoff check

out procedure on page 51.

2. FLOAT TYPE LOW WATER CUTOFF

During the heating season, if an external low water

cutoff is on the boiler, the blow off valve should be opened once a month (use greater frequency

where conditions warrant), to ush out the sediment

chamber so the device will be free to function properly.

Low water cutoffs and water feeders should be

dismantled annually by qualied personnel, to the

extent necessary to insure freedom from obstructions and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc., and clean as required. Examine

all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly. Give special attention to solder

joints on bellows and oat when this type of control is used. Check oat for evidence of collapse and

check mercury bulb (where applicable) for mercury separation or discoloration. DO NOT ATTEMPT TO REPAIR MECHANISMS IN THE FIELD. Complete replacement mechanisms, including necessary gaskets and installation instructions, are available from the manufacturer.

D. CHECK BURNER AND CONTROLS at least once

a year. See Section IV, Paragraph (E) under Operating Instructions for control checks. See Burner Manual for burner tests and adjustments.

E. LUBRICATE BOILER COMPONENTS

according to manufacturer’s instructions. Generally, this involves the oil burner and circulator. This includes the type of lubricant to use, frequency of lubrication, and points to lubricate.

F. GENERAL MAINTEN ANCE

CONSIDERATIONS

1. Keep radiators and convectors clean.

2. If a hot water radiator is hot at the bottom but not at the top, it indicates that air has accumulated inside and should be vented. To vent radiator, hold small cup under air vent (located near top of radiator), open vent until water escapes and then close.

3. If much water is added to system, it is advisable to heat system to a high temperature and vent again. This will make less venting necessary during the winter.

4. Where an expansion tank is used, make sure that neither the tank nor its drain pipe is exposed to freezing temperatures. Never place valves in piping leading to or from expansion tank.

5. Boiler and system cleaning will help assure trouble free operation. See Section IV, Paragraphs (F and G) under Operating Instructions for procedure.

G. ATTENTION TO BOILER WHILE NOT IN

OPERATION

WARNING

If boiler is not used during winter time, it must be fully drained to prevent freeze damage.

1. Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners.

2. With steam boilers, at end of season add sufcient water to ll boiler to top of water column and leave

it that way until fall when water should be drained again to proper level. If at this time boiler water is

dirty, drain water, ush out boiler, and rell with

clean water to prescribed water level.

3. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time.

4. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section IV - Operating Instructions, Paragraphs (B) through (E).

SECTION VI - BURNER SPECIFICATIONS

NOTICE

V11 boiler ratings and capacities are based upon the following burners, pump pressures, nozzle sizes and manifold pressures. Refer to instructions furnished with burner for additional information regarding proper installation, fuel piping, wiring details, burner adjustments, service instructions and burner start-up.

Table VIa: Beckett Oil Burner Specications

Boiler

Model

V1104 5.8 Beckett CF1400 CG66KD 0 2.5 5.0 150 300 Hago 3.50 x 45° - P

V1105 7.4 Beckett CF1400 CF66KE 0 3.0 5.0 150 300 Hago 4.50 x 45° - P

V1106 9.2 Beckett CF1400 CF66KE 2 3.0 6.0 150 300 Hago 4.50 x 45° - P

V1107 11.0 Beckett CF2300A CF66KG 2 3.0 6.0 150 300 Hago 6.50 x 45° - P

V1108 13.0 Beckett CF2300A CF66KG 4 3.5 6.0 150 300 Hago 7.50 x 45° - P

V1109 14.8 Beckett CF2300A CF66KG 4 3.5 7.5 150 300 Hago 8.50 x 45° - P

V1110 16.6 Beckett CF2300A CF44KS 4 3.0 5.5 150 300 Hago 9.50 x 45° - P

V1111 18.4 Beckett CF2300A CF66KS 6 4.0 6.0 150 300 Hago 10.50 x 45° - P

V1112 20.0 Beckett CF2500 CF66KP 4 1.5 4.5 300 300 Hago

V1113 21.5 Beckett CF2500 CF66KP 5 1.0 5.5 300 300 Hago

V1114 23.5 Beckett CF3500A CF80KH 2 2.0 8.0 300 300 Hago

V1115 25.5 Beckett CF3500A CF80KM 3 1.5 9.0 300 300 Hago

V1116 27.0 Beckett CF3500A CF114KR 6 2.5 8.5 300 300 Hago

Burner Input

(GPH)

Burner

Mfr.

Burner

Model

Air Tube

Comb.

Head

Burner Settings

Low Fire Air

or Shutter

High Fire Air

or Band

Pump Pressure

(PSI)

Low

Fire

High

Fire

Nozzle

Make

Nozzle Data

GPH x Angle - Type

(L) 5.50 x 45° - P

(H) 5.50 x 45° - P

(L) 6.00 x 45° - P

(H) 6.00 x 45° - P

(L) 6.50 x 45° - P

(H) 6.50 x 45° - P

(L) 7.00 x 45° - P

(H) 7.00 x 45° - P

(L) 7.50 x 45° - P

(H) 7.50 x 45° - P

Table VIb: Beckett Gas Burner Specications

Boiler

Model

V1104 837 Beckett CG10.6S --- --- 8 1 (1) 3.3 4.53

V1105 1068 Beckett CG10.6S --- --- 10 5 (1) 4.75 6.51

V1106 1328 Beckett CG15.4S 25 67 --- --- 1.15 3.55 6.16

V1107 1588 Beckett CG25.2S 12 38 --- --- 0.8 3.1 5.16

V1108 1876 Beckett CG25.3S 15 44 --- --- 0.8 3.36 4.94

V1109 2136 Beckett CG25.4S 20 53 --- --- 0.8 3.32 5.11

V1110 2396 Beckett CG25.5S 22 95 --- --- 0.8 2.94 5.19

V1111 2656 Beckett CG50.2S 9 29 --- --- 0.8 2.95 5.7

V1112 2887 Beckett CG50.3S 12 30 --- --- 0.8 2.5 4.27

V1113 3103 Beckett CG50.3S 12 32 --- --- 0.8 3.4 5.62

V1114 3392 Beckett CG50.4S 14 35 --- --- 0.8 2.97 5.62

V1115 3680 Beckett CG50.4S 14 39 --- --- 0.8 2.95 6.07

V1116 3897 Beckett CG50.5S 16 50 --- --- 0.8 3.0 5.27

V1117 4186 Beckett CG50.5S 16 65 --- --- 0.8 3.44 6.06

V1118 4474 Beckett CG50.5S 16 80 --- --- 0.8 3.85 6.85

V1119 4691 Beckett CG50.5S 16 95 --- --- 0.8 3.95 7.24

Burner Input

(MBH)

Burner

Mfr.

Burner

Model

Low Fire High Fire Shutter Band

Damper Settings

Manifold Pressure

- "WC

Low Fire

(Start)

High Fire

Minimum Inlet

Pressure - "WC

Nozzle Data

GPH x Angle - Type

Make

Nozzle

Fire

High

Pump

Fire

Low

Pressure (PSI)

Top/Bottom Damper

Approx. Damper Settings

Low Fire High Fire

Blade

Setting

Diffuser

Model

Burner

Burner Mfr.

Input

(GPH)

Burner

V1111 18.4 Power Flame CR3 - O 3/8" 1/2" / 1/2" 1-3/4" / 1-1/2" 100 300 Delavan 10.0 x 80° - 33769

V1110 16.6 Power Flame CR2 - OAS 3/8" 1/2" / 1/2" 1-1/4" / 1-1/4" 100 300 Delavan 9.5 x 70° - B

V1112 20.0 Power Flame CR3 - O 1/4" 3/16" / 3/16" 1-1/4" / 1-1/4" 100 280 Delavan 12.0 x 80° - 33769

V1104 5.8 Power Flame CR1 - OS 1/4" 1/4" / 1/4" 1" / 1" 100 300 Delavan 3.5 x 90° - B

V1105 7.4 Power Flame CR1 - OS 3/8" 1/4" / 1/4" 1" / 1" 100 300 Delavan 4.5 x 90° - B

V1106 9.2 Power Flame CR2 - OAS 3/16" Closed / 1/4" 3/4" / 1/4" 100 280 Delavan 5.5 x 80° - B

V1107 11.0 Power Flame CR2 - OAS 3/16" Closed / 1/4" 3/4" / 1/4" 100 290 Delavan 6.5 x 80° - B

V1108 13.0 Power Flame CR2 - OAS 1/4" Closed / 1/4" 3/4" / 1/2" 100 300 Delavan 7.5 x 80° - B

Boiler

Table VIIa: Power Flame Oil Burner Specications

Model

V1109 14.8 Power Flame CR2 - OAS 3/8" 1/4" / 1/4" 1" / 1" 100 300 Delavan 8.5 x 80° - B

V1113 21.5 Power Flame CR3 - O 1/4" 3/16" / 3/16" 1-1/2" / 1-1/2" 100 300 Delavan 12.0 x 80° - 33769

V1114 23.5 Power Flame CR3 - O 1/4" 1/4" / 1/4" 1-3/4" / 1-3/4" 100 300 Delavan 16.0 x 80° - 33769

V1115 25.5 Power Flame CR3 - O 3/8" 1/4" / 1/4" 1-7/8" / 1-7/8" 100 285 Delavan 16.0 x 80° - 33769

V1116 27.0 Power Flame CR3 - O 3/16" 1/8" / 1/8" 1-1/4" / 1-1/4" 100 300 Delavan 16.0 x 80° - 33769

V1117 29.0 Power Flame CR3 - O 1/4" 1/8" / 1/8" 1-1/4" / 1-1/4" 100 285 Delavan 18.0 x 80° - 33769

V1118 31.0 Power Flame CR3 - OB 1/4" 1/8" / 1/8" 1-3/8" x / 1-3/8" 100 300 Delavan 18.0 x 80° - 33769

V1119 32.5 Power Flame CR3 - OB 1/4" 1/4" / 1/4" 1-1/2" / 1-1/2" 100 300 Delavan 20.0 x 80° - 33769

V1120 34.5 Power Flame CR3 - OB 3/8" 1/4" / 1/4" 1-7/8" / 1-7/8" 100 300 Delavan 20.0 x 80° - 33769

V1121 36.5 Power Flame CR3 - OB 1/2" 1/4" / 1/4" 1-7/8" / 1-7/8" 100 300 Delavan 22.0 x 80° - 33769

V1122 38.0 Power Flame CR4 - OA 1/4" Closed / 1/2" 1-1/4" / 1/2" 100 300 Delavan 40.0 x 80° - 30630

V1123 40.0 Power Flame CR4 - OA 3/8" Closed / 1/2" 1-1/2" / 1/2" 100 300 Delavan 40.0 x 80° - 30630

(Inch)

for Natural Gas

SideOriceSize

"WC

** Minimum

Inlet Pressure

Approx. Nat.

Gas Manifold

(atoricetee)

Pressure "WC

Top/Bottom Damper

Low Fire High Fire

Approx. Damper Settings

1/4" / 1/4" 1" / 1" 2.2 4.8 N/A

Closed / 1/4" 3/4" / 1/4" 2.1 6.4 1-1/16"

3/8"

Diffuser

Blade

Setting

3/16"

Burner Mfr. Burner Model

1068 Power Flame CR1 - G - 12

V1105

1588 Power Flame CR2 - G - 15

V1106 1328 Power Flame CR2 - G - 15 3/16" Closed / 1/4" 3/4" / 1/4" 1.4 5.4 N/A

V1107

V1108 1876 Power Flame CR2 - G - 15 1/4" Closed / 1/4" 3/4" / 1/2" 1.9 7.5 N/A

V1109 2136 Power Flame CR2 - G - 15 3/8" 1/4" / 1/4" 1" / 1" 1.3 5.6 N/A

V1110 2396 Power Flame CR2 - G - 20A 3/8" 1/2" / 1/2" 1-1/4" / 1-1/4" 1.5 5.8 N/A

V1111 2656 Power Flame CR3 - G - 20 3/8" 1/2" / 1/2" 1-3/4" / 1-1/2" 3.2 5.8 1-1/8"

V1112 2887 Power Flame CR3 - G - 20 1/4" 3/16" / 3/16" 1-1/4" / 1-1/4" 2.9 6.0 1-1/4"

V1113 3103 Power Flame CR3 - G - 20 1/4" 3/16" / 3/16" 1-1/2" / 1-1/2" 3.2 6.8 1-1/4"

Input

(MBH)

Burner

Boiler

Model

V1104 837 Power Flame CR1 - G - 12 1/4" 1/4" / 1/4" 1" / 1" 3.1 4.7 5/8"

Table VIIb: Power Flame Gas Burner Specications

V1114 3392 Power Flame CR3 - G - 20 1/4" 1/4" / 1/4" 1-3/4" / 1-3/4" 3.1 7.4 1-3/8"

V1115 3680 Power Flame CR3 - G - 20 3/8" 1/4" / 1/4" 1-7/8" / 1-7/8" 2.2 7.3 N/A

V1116 3897 Power Flame CR3 - G - 25 3/16" 1/8" / 1/8" 1-1/4" / 1-1/4" 3.0 6.6 1-1/2"

V1117 4186 Power Flame CR3 - G - 25 1/4" 1/8" / 1/8" 1-1/4" / 1-1/4" 3.0 7.1 1-5/8"

V1118 4474 Power Flame CR3 - G - 25B 1/4" 1/8" / 1/8" 1-3/8" / 1-3/8" 3.0 7.7 1-3/4"

V1119 4691 Power Flame CR3 - G - 25B 1/4" 1/4" / 1/4" 1-1/2" / 1-1/2" 3.0 6.5 1-7/8"

V1120 4979 Power Flame CR3 - G - 25B 3/8" 1/4" / 1/4" 1-7/8" / 1-7/8" 3.1 7.0 2"

V1121 5268 Power Flame CR3 - G - 25B 1/2" 1/4" / 1/4" 1-7/8" / 1-7/8" 2.7 7.0 N/A

V1122 5485 Power Flame CR4 - G - 25 1/4" Closed / 1/2" 1-1/4" / 1/2" 2.6 6.3 N/A

V1123 5773 Power Flame CR4 - G - 25 3/8" Closed / 1/2" 1-1/2" / 1/2" 2.8 6.9 N/A

** Minimum inlet pressure for UL gas trains only. Consult factory for additional information.

(Inch)

for Natural Gas

SideOriceSize

"WC

** Minimum

Inlet Pressure

Approx. Nat.

Gas Manifold

(atoricetee)

Pressure "WC

Top/Bottom Damper

Blade

Setting

Low Fire High Fire

Approx. Damper Settings

Diffuser

Burner Mfr. Burner Model

Gas

(MBH)

Burner Input

Oil

(GPH)

V1111 18.4 2656 Power Flame CR3 - GO - 20 3/8" 1/2" / 1/2" 1-3/4" / 1-1/2" 3.2 5.8 1-1/8"

V1110 16.6 2396 Power Flame CR2 - GO - 20A 3/8" 1/2" / 1/2" 1-1/4" / 1-1/4" 1.5 5.8 N/A

V1112 20.0 2887 Power Flame CR3 - GO - 20 1/4" 3/16" / 3/16" 1-1/4" / 1-1/4" 2.9 6.0 1-1/4"

V1113 21.5 3103 Power Flame CR3 - GO - 20 1/4" 3/16" / 3/16" 1-1/2" / 1-1/2" 3.2 6.8 1-1/4"

V1114 23.5 3392 Power Flame CR3 - GO - 20 1/4" 1/4" / 1/4" 1-3/4" / 1-3/4" 3.1 7.4 1-3/8"

V1115 25.5 3680 Power Flame CR3 - GO - 20 3/8" 1/4" / 1/4" 1-7/8" / 1-7/8" 2.2 7.3 N/A

V1116 27.0 3897 Power Flame CR3 - GO - 25 3/16" 1/8" / 1/8" 1-1/4" / 1-1/4" 3.0 6.6 1-1/2"

V1117 29.0 4186 Power Flame CR3 - GO - 25 1/4" 1/8" / 1/8" 1-1/4" / 1-1/4" 3.0 7.1 1-5/8"

V1104 5.8 837 Power Flame CR1 - GO - 12 1/4" 1/4" / 1/4" 1" / 1" 3.1 4.7 5/8"

V1105 7.4 1068 Power Flame CR1 - GO - 12 3/8" 1/4" / 1/4" 1" / 1" 2.2 4.8 N/A

V1106 9.2 1328 Power Flame CR2 - GO - 15 3/16" Closed / 1/4" 3/4" / 1/4" 1.4 5.4 N/A

V1107 11.0 1588 Power Flame CR2 - GO - 15 3/16" Closed / 1/4" 3/4" / 1/4" 2.1 6.4 1-1/16"

V1108 13.0 1876 Power Flame CR2 - GO - 15 1/4" Closed / 1/4" 3/4" / 1/2" 1.9 7.5 N/A

Boiler

Table VIIc: Power Flame Combination Gas/Oil Burner Specications *

Model

V1109 14.8 2136 Power Flame CR2 - GO - 15 3/8" 1/4" / 1/4" 1" / 1" 1.3 5.6 N/A

V1118 31.0 4474 Power Flame CR3 - GO - 25B 1/4" 1/8" / 1/8" 1-3/8" / 1-3/8" 3.0 7.7 1-3/4"

V1119 32.5 4691 Power Flame CR3 - GO - 25B 1/4" 1/4" / 1/4" 1-1/2" / 1-1/2" 3.0 6.5 1-7/8"

V1120 34.5 4979 Power Flame CR3 - GO - 25B 3/8" 1/4" / 1/4" 1-7/8" / 1-7/8" 3.1 7.0 2"

V1121 36.5 5268 Power Flame CR3 - GO - 25B 1/2" 1/4" / 1/4" 1-7/8" / 1-7/8" 2.7 7.0 N/A

V1122 38.0 5485 Power Flame CR4 - GO - 25 1/4" Closed / 1/2" 1-1/4" / 1/2" 2.6 6.3 N/A

V1123 40.0 5773 Power Flame CR4 - GO - 25 3/8" Closed / 1/2" 1-1/2" / 1/2" 2.8 6.9 N/A

* See oil burner data for nozzle sizes and pump pressure settings.

** Minimum inlet pressure for UL gas trains only. Consult factory for additional information.

Pump

Pressure

Air Inlet

Settings

Nozzle Data

GPH x Angle - Type

Make

Nozzle

Fire

High

(PSI)

Fire

Low

Fire

High

Fire

Low

Cylinder

Inner Fire

(2) 4.50 x 80° - B

Blade

Diffuser

Settings

Burner Settings

Diffuser

Nozzle to

Model

Burner

Mfr.

Burner

Input

(GPH)

Burner

V1104 5.8 Webster JB1O - 03 1/16" 1/8" 1/4" N/A 1/2" N/A 280 Delavan (2) 1.75 x 80° - B

V1105 7.4 Webster JB1O - 03 3/8" 1/8" 1/4" N/A 7/8" N/A 300 Delavan (2) 2.25 x 80° - B

V1106 9.2 Webster JB1O - 03 1/4" 1/8" 1/4" 5/8" 7/8" 100 300 Delavan (2) 2.70 x 80° - B

Boiler

Table VIIIa: Webster Oil Burner Specications

Model

V1107 11.0 Webster JB1O - 05 1/4" 1/8" 1/2" 3/8" 7/8" 100 300 Delavan (2) 3.20 x 80° - B

1/8" 1/4" 1-1/16" 1" 100 271 Delavan

1/4"

Webster JB1O - 07

V1111 18.4 Webster JB2O - 10 3/8" 0.015" 5/16" 7/8" 1-1/8" 100 286 Delavan (2) 5.50 x 80° - B

V1110 16.6 Webster JB1O - 07 1/4" 1/8" 1/4" 3/4" 1-1/16" 100 276 Delavan (2) 5.00 x 80° - B

V1112 20.0 Webster JB2O - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 100 292 Delavan (2) 6.00 x 80° - B

V1113 21.5 Webster JB2O - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 100 287 Delavan (2) 6.50 x 80° - B

V1108 13.0 Webster JB1O - 05 1/4" 1/8" 3/4" 5/8" 1" 100 300 Delavan (1) 3.50; (1) 4.00 x 80° - B

V1109 14.8

V1114 23.5 Webster JB2O - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 100 294 Delavan (2) 7.00 x 80° - B

V1115 25.5 Webster JB2O - 10 3/8" 0.015" 5/16" 1-1/8" 1-3/4" 100 300 Delavan (2) 7.50 x 80° - B

V1116 27.0 Webster JB2O - 15 5/16" 0.015" 1/2" 7/8" 1-1/2" 100 300 Delavan (2) 5.50; (1) 5.00 x 80° - B

V1117 29.0 Webster JB2O - 30 5/16" 0.015" 1/2" 5/16" 3/4" 100 300 Delavan (2) 5.50; (1) 6.00 x 80° - B

V1118 31.0 Webster JB2O - 30 5/16" 0.015" 3/8" 15/16" 1-5/32" 100 300 Delavan (3) 6.00 x 80° - B

V1119 32.5 Webster JB2O - 30 5/16" 0.015" 3/8" 1" 1-3/8" 100 300 Delavan (2) 6.50; (1) 6.00 x 80° - B

V1120 34.5 Webster JB2O - 30 3/8" 0.015" 1/2" 1" 1-1/2" 100 300 Delavan (2) 6.50; (1) 7.00 x 80° - B

V1121 36.5 Webster JB2O - 50 3/8" 0.015" 1/2" 1" 1-1/4" 100 300 Delavan (3) 7.00 x 80° - B

V1122 38.0 Webster JB2O - 50 5/16" 0.015" 1-1/8" 1" 1-3/8" 100 300 Delavan (3) 7.50 x 80° - B

V1123 40.0 Webster JB2O - 50 5/16" 0.015" 1-1/8" 1" 1-1/2" 100 285 Delavan (3) 8.00 x 90° - B

Manifold

Pressure

High Fire

Inch W.C.

Fire

High

Fire

Low

Cylinder

Inner Fire

Drawer

Assembly

1/8" 1/4" N/A 7/8" 2.4

Burner Settings Air Inlet Settings

Diffuser

Nozzle to

3/8"

Burner Model

Mfr.

Burner

Input

(MBH)

Burner

Boiler

Model

1068 Webster JB1G - 03

V1104 837 Webster JB1G - 03 1/16" 1/8" 1/4" N/A 5/8" 1.8

V1105

V1106 1328 Webster JB1G - 03 1/4" 1/8" 1/4" 5/8" 7/8" 3.0

V1107 1588 Webster JB1G - 05 1/4" 1/8" 1/2" 3/8" 7/8" 3.6

Table VIIIb: Webster Gas Burner Specications

V1108 1876 Webster JB1G - 05 1/4" 1/8" 3/4" 5/8" 1-1/4" 4.5

V1109 2136 Webster JB1G - 07 1/4" 1/8" 1/4" 3/4" 1" 2.6

V1110 2396 Webster JB1G - 07 1/4" 1/8" 1/4" 3/4" 1-1/16" 3.1

V1111 2656 Webster JB2G - 10 3/8" 0.015" 5/16" 7/8" 1-1/8" 2.4

V1112 2887 Webster JB2G - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 2.6

V1113 3103 Webster JB2G - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 2.9

V1114 3392 Webster JB2G - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 3.2

0.015" 1/2" 7/8" 1-1/2" 4.0

5/16"

3897 Webster JB2G - 15

V1115 3680 Webster JB2G - 10 3/8" 0.015" 5/16" 1-1/8" 1-3/4" 3.7

V1116

0.015" 3/8" 15/16" 1-5/32" 4.7

5/16"

4474 Webster JB2G - 30

V1117 4186 Webster JB2G - 30 5/16" 0.015" 1/2" 3/4" 15/16" 4.3

V1118

V1119 4691 Webster JB2G - 30 5/16" 0.015" 3/8" 1" 1-3/8" 5.4

V1120 4979 Webster JB2G - 30 3/8" 0.015" 1/2" 1" 1-1/8" 5.8

V1121 5268 Webster JB2G - 50 3/8" 0.015" 1/2" 1" 1-1/4" 6.2

V1122 5485 Webster JB2G - 50 5/16" 0.015" 1-1/8" 1" 1-3/8" 7.2

V1123 5773 Webster JB2G - 50 5/16" 0.015" 1-1/8" 1" 1-1/2" 7.5

Nozzle Data

Nozzle

(PSI)

Pump

Pressure

Manifold

Pressure

Air Inlet

Settings

GPH x Angle - Type

Make

High

Low

High Fire

High

Low

Fire

Inch W.C.

Fire

Cylinder

Inner Fire

Drawer

Assembly

Burner Settings

Diffuser

Nozzle to

Model

Burner

Mfr.

Burner

Gas

(MBH)

Burner Input

Oil

(GPH)

0.015" 1-1/8" 1" 1-3/8" 7.2 100 300 Delavan (3) 7.50 x 80° - B

5/16"

5485 Webster JB2C - 50

9.2 1328 Webster JB1C - 03 1/4" 3/32" 1/4" 5/8" 7/8" 3.0 100 300 Delavan (2) 2.70 x 80° - B

V1111 18.4 2656 Webster JB2C - 10 3/8" 0.015" 5/16" 7/8" 1-1/8" 2.4 100 286 Delavan (2) 5.50 x 80° - B

V1110 16.6 2396 Webster JB1C - 07 1/4" 3/32" 1/4" 3/4" 1-1/16" 3.1 100 276 Delavan (2) 5.00 x 80° - B

V1112 20.0 2887 Webster JB2C - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 2.6 100 292 Delavan (2) 6.00 x 80° - B

V1104 5.8 837 Webster JB1C - 03 1/16" 3/32" 1/4" N/A 1/2" 1.8 N/A 280 Delavan (2) 1.75 x 80° - B

V1105 7.4 1068 Webster JB1C - 03 3/8" 3/32" 1/4" N/A 5/8" 2.4 N/A 300 Delavan (2) 2.25 x 80° - B

V1106

V1107 11.0 1588 Webster JB1C - 05 1/4" 3/32" 1/2" 3/8" 7/8" 3.6 100 300 Delavan (2) 3.20 x 80° - B

V1108 13.0 1876 Webster JB1C - 05 1/4" 3/32" 3/4" 5/8" 1" 4.5 100 300 Delavan (1) 3.50; (1) 4.00 x 80° - B

Boiler

Table VIIIc: Webster Combination Gas/Oil Burner Specications

Model

V1109 14.8 2136 Webster JB1C - 07 1/4" 3/32" 1/4" 11/16" 1" 2.6 100 271 Delavan (2) 4.50 x 80° - B

V1113 21.5 3103 Webster JB2C - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 2.9 100 287 Delavan (2) 6.50 x 80° - B

V1114 23.5 3392 Webster JB2C - 10 3/8" 0.015" 5/16" 3/4" 1-1/4" 3.2 100 294 Delavan (2) 7.00 x 80° - B

V1115 25.5 3680 Webster JB2C - 10 3/8" 0.015" 5/16" 1-1/8" 1-3/4" 3.7 100 300 Delavan (2) 7.50 x 80° - B

V1116 27.0 3897 Webster JB2C - 15 5/16" 0.015" 1/2" 7/8" 1-1/2" 4.0 100 300 Delavan (2) 5.50; (1) 5.00 x 80° - B

V1117 29.0 4186 Webster JB2C - 30 5/16" 0.015" 1/2" 5/16" 3/4" 4.3 100 300 Delavan (2) 5.50; (1) 6.00 x 80° - B

V1118 31.0 4474 Webster JB2C - 30 5/16" 0.015" 3/8" 15/16" 1-5/32" 4.7 100 300 Delavan (3) 6.00 x 80° - B

V1119 32.5 4691 Webster JB2C - 30 5/16" 0.015" 3/8" 1" 1-3/8" 5.4 100 300 Delavan (2) 6.50; (1) 6.00 x 80° - B

V1120 34.5 4979 Webster JB2C - 30 3/8" 0.015" 1/2" 1" 1-1/2" 5.8 100 300 Delavan (2) 6.50; (1) 7.00 x 80° - B

V1121 36.5 5268 Webster JB2C - 50 3/8" 0.015" 1/2" 1" 1-1/4" 6.2 100 300 Delavan (3) 7.00 x 80° - B

V1122 38.0

V1123 40.0 5773 Webster JB2C - 50 5/16" 0.015" 1-1/8" 1" 1-1/2" 7.5 100 285 Delavan (3) 8.00 x 90° - B

Table IX: Carlin Burner Specications

Pump

Pressure

(PSI)

Low

Fire

High

Fire

Nozzle

Make

Nozzle Data

GPH x Angle - Type

5.50 x 60° - B

(1) 5.50; (1) 4.50 x 45° - H

(2) 5.50 x 45° - H

(2) 6.00 x 45° - H

Boiler

Model

V1105 7.4 Carlin 702CRD 97979 9/16" 1/2" 100 300 Delavan 4.50 x 60° - B

V1106 9.2

V1107 11.0

V1108 13.0

V1109 14.8

V1110 16.6 Carlin 1050FFD 97981 1/4" 1/8" 100 100 Hago (1) 9.00; (2) 3.75 x 45° - SS

V1111 18.4 Carlin 1050FFD 97981 7/16" 11/16" 100 100 Hago (1) 9.00; (2) 4.50 x 45° - SS

V1112 20.0

V1113 21.5 Carlin 1050FFD 97981 9/16" 1/2" 100 100 Hago (1) 9.00; (1) 6.50; (1) 6.00 x 45° - SS

V1114 23.5 Carlin 1150FFD 97986 0 1/4" 100 100 Hago (1) 12.00; (1) 6.00; (1) 5.50 x 45° - SS

V1115 25.5

V1116 27.0

V1117 29.0 Carlin 1150FFD 97986 5/8" 1/2" 100 100 Hago (1) 12.00; (2) 8.50 x 45° - SS

Burner

Input

(GPH)

Burner

Mfr.

Carlin 702CRD 97979

Carlin 801CRD 97980

Carlin 1050FFD 97981

Carlin 1150FFD 97986

Burner

Model

Air

Tube

Comb.

Settings

Head

9/16"

1/8"

1/2"

3/4"

3/8"

1/8"

3/8"

Burner

Air

Shutter

1/2" 100 300 Delavan

1/2" 150 150 Hago

9/16" 100 100 Hago (1) 9.00; (2) 5.50 x 45° - SS

1/2" 100 100 Hago (1) 12.00; (1) 7.00; (1) 6.50 x 45° - SS

1/2" 100 100 Hago (1) 12.00; (2) 7.50 x 45° - SS

SECTION VII - REPAIR PARTS

All V11 Series repair parts may be obtained through your local Burnham Wholesale Distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.

Figure 45: V11 Series Jacket Assembly (Boiler Models V1104 Thru V1112)

JACKET REPAIR PARTS (Models V1104 Thru 1112)

ITEM

NO.

1 Jacket Front Panel Assembly 1 1 1 1 1 1 1 1 1 60426001

2 Jacket Rear Panel Assembly 1 1 1 1 1 1 1 1 1 60426002

3 Jacket 'U' Channels:

3A 'U' Channel No. U26 4 6042665

3B 'U' Channel No. U32 4 6042666

3C 'U' Channel No. U38 4 6042668

3D 'U' Channel No. U44 4 6042670

3E 'U' Channel No. U50 4 6042672

3F 'U' Channel No. U56 4 6042674

3G 'U' Channel No. U63 4 6042676

3H 'U' Channel No. U69 4 6042678

3 I 'U' Channel No. U75 4 6042680

4 Jacket 'J' Channels:

4A 'J' Channel No. J26 2 6042648

4B 'J' Channel No. J32 2 6042649

4C 'J' Channel No. J38 2 6042651

4D 'J' Channel No. J44 2 6042653

4E 'J' Channel No. J50 2 6042655

4F 'J' Channel No. J56 2 6042657

4G 'J' Channel No. J63 2 6042659

4H 'J' Channel No. J69 2 6042661

4 I 'J' Channel No. J75 2 6042663

5 Jacket Channel Support Bracket 1 1 1 1 1 60426004

(Required on Bottom 'U' Channels 46" Lg. and Larger)

6 Jacket Top Panel Assemblies:

6A Jacket Top Panel Assembly, V1104 1 60426040

6B Jacket Top Panel Assembly, V1105 1 60426050

6C Jacket Top Panel Assembly, V1106 1 60426060

6D Jacket Top Panel Assembly, V1107 1 60426070

6E Jacket Top Panel Assembly, V1108 1 60426080

6F Jacket Top Panel Assembly, V1109 1 60426090

6G Jacket Top Panel Assembly, V1110 1 60426100

6H Jacket Top Panel Assembly, V1111 1 60426110

6 I Jacket Top Panel Assembly, V1112 1 60426120

7 Jacket Single Left Side Panel Assemblies:

7A Single L.S. Pnl. Assy., No. SLS24 1 60426043

7B Single L.S. Pnl. Assy., No. SLS30 1 60426053

7C Single L.S. Pnl. Assy., No. SLS36 1 60426063

8 Jacket Forward Left Side Panel Assemblies:

8A Forward L.S. Pnl. Assy., No. FLS27 1 1 1 1 6042636

8A Forward L.S. Pnl. Assy., No. FLS39 1 1 6042637

9 Jacket Rearward Left Side Panel Assemblies:

9A Rearward L.S. Pnl. Assy., No. RLS15 1 6042641

9B Rearward L.S. Pnl. Assy., No. RLS21 1 6042642

9C Rearward L.S. Pnl. Assy., No. RLS27 1 1 6042643

9D Rearward L.S. Pnl. Assy., No. RLS33 1 1 6042644

10 Jacket Single Right Side Heater Panel Assemblies:

10A Single R.S. Htr. Pnl. Assy., No. SRH24 1 60426042

10B Single R.S. Htr. Pnl. Assy., No. SRH30 1 60426052

10C Single R.S. Htr. Pnl. Assy., No. SRH36 1 60426062

11 Jacket Froward Right Side Heater Panel Assemblies:

11A Forward R.S. Htr. Pnl. Assy., No. FRH27 1 1 1 1 6042624

11B Forward R.S. Htr. Pnl. Assy. No. FRH39 1 1 6042625

12 Jacket Rearward Right Side Heater Panel Assemblies:

12A Rearward R.S. Htr., Pnl. Assy., No. RRH15 1 6042629

12B Rearward R.S. Htr., Pnl. Assy., No. RRH21 1 6042630

12C Rearward R.S. Htr., Pnl. Assy., No. RRH27 1 1 6042631

12D Rearward R.S. Htr., Pnl. Assy., No. RRH33 1 1 6042632

13 Thumb Hole Bushing, Heyco SB-1093-15, #2166 Black 4 4 4 6 8 8 8 8 8 8136257

DESCRIPTION

V1104 V1105 V1106 V1107 V1108 V1109 V1110 V1111 V1112

B1OILER SECTIONS / QUANTITY

PART NO.

Figure 46: V11 Series Jacket Assembly (Boiler Models V1113 Thru V1123)

JACKET REPAIR PARTS (Models V1113 Thru 1123)

ITEM

NO.

1 Jacket Front Panel Assembly 1 1 1 1 1 1 1 1 1 1 1 60426001

2 Jacket Rear Panel Assembly 1 1 1 1 1 1 1 1 1 1 1 60426002 3 Jacket Intermediate Panel Assembly 2 2 2 2 2 2 2 2 2 2 2 60426003 4 Jacket Intermediate Panel Mounting Brackets:

4A Bracket No. 1 1 1 1 1 1 1 1 1 1 1 1 6042601 4B Bracket No. 2 1 1 1 1 1 1 1 1 1 1 1 6042602

4C Bracket No. 3 2 2 2 2 2 2 2 2 2 2 2 6042603

5 Jacket 'U' Channels:

5A 'U' Channel No. U34 4 6042667 5B 'U' Channel No. U40 4 6042669 5C 'U' Channel No. U46 4 4 8 4 6042671 5D 'U' Channel No. U52 4 8 4 4 6042673 5E 'U' Channel No. U58 4 4 6042675 5F 'U' Channel No. U65 4 4 8 4 4 6042677 5G 'U' Channel No. U71 4 6042679 5H 'U' Channel No. U77 4 6042681

6 Jacket 'J' Channels"

6A 'J' Channel No. J34 2 6042650 6B 'J' Channel No. J40 2 6042652 6C 'J' Channel No. J46 2 2 4 2 6042654 6D 'J' Channel No. J52 2 4 2 2 6042656 6E 'J' Channel No. J58 2 2 6042658 6F 'J' Channel No. J65 2 2 4 2 2 6042660 6G 'J' channel No. J71 2 6042662 6H 'J' Channel No. J77 2 6042664

7 Jacket Channel Support Bracket 2 2 4 4 4 4 4 4 4 4 4 60426004

(Required on Bottom 'U' Channels 46" Lg. and Larger)

8 Jacket Front Top Panel Assemblies:

8A Jacket Front Top Panel Assy., V1113 1 60426130 8B Jacket Front Top Panel Assy., V1114/15 1 1 60426140 8C Jacket Front Top Panel Assy., V1116/17 1 1 60426160 8D Jacket Front Top Panel Assy., V1118 1 60426180 8E Jacket Front Top Panel Assy., V1119/21 1 1 1 60426190 8F Jacket Front Top Panel Assy., V1122/23 1 1 60426200

9 Jacket Rear Top Panel Assemblies:

9A Jacket Rear Top Panel Assy., V1113 1 60426134 9B Jacket Rear Top Panel Assy., V1114 1 60426144 9C Jacket Rear Top Panel Assy., V1115 1 60426154

9D Jacket Rear Top Panel Assy., V1116 1 60426164

9E Jacket Rear Top Panel Assy., V1117 1 60426174 9F Jacket Rear Top Panel Assy., V1118 1 60426184 9G Jacket Rear Top Panel Assy., V1119 1 60426194 9H Jacket Rear Top Panel Assy., V1120 1 60426204 9 I Jacket Rear Top Panel Assy., V1121 1 60426214 9J Jacket Rear Top Panel Assy., V1122 1 60426224 9K Jacket Rear Top Panel Assy., V1123 1 60426234

10 Jacket Forward Left Side Panel Assemblies:

10A Forward L.S. Panel Assy., No.FLS17 1 1 1 6042639

10B Forward L.S. Panel Assy., No.FLS27 1 1 1 6042636

10C Forward L.S. Panel Assy., No.FLS29 1 1 1 1 1 1 1 1 6042640

10D Forward L.S. Panel Assy., No.FLS33 1 1 1 1 1 1 1 1 6042638 11 Jacket Auxiliary L.S. Panel Assy., No. ALS24 12 Jacket Rearward Left Side Panel Assemblies:

12A Rearward L.S. Panel Assy., No. RLS15 1 1 1 6042641

12B Rearward L.S. Panel Assy., No. RLS17 1 1 1 1 1 1 6042645

12C Rearward L.S. Panel Assy., No. RLS21 1 1 1 1 6042642

12D Rearward L.S. Panel Assy., No. RLS27 1 1 1 6042643

12E Rearward L.S. Panel Assy., No. RLS29 1 1 1 1 1 6042646

12F Rearward L.S. Panel Assy., No. RLS33 1 6042644 13 Jacket Forward Right Side Heater Panel Assemblies:

13A Forward R.S. Htr. Pnl. Assy., No. FRH17 1 1 1 6042627

13B Forward R.S. Htr. Pnl. Assy., No. FRH27 1 1 1 6042624

13C Forward R.S. Htr. Pnl. Assy., No. FRH29 1 1 1 1 1 1 1 1 6042628

13D Forward R.S. Htr. Pnl. Assy., No. FRH33 1 1 1 1 1 1 1 1 6042626 14 Jacket Auxiliary Right Side Heater Panel Assy., No. ARH24 15 Jacket Rearward Right Side Heater Panel Assemblies:

15A Rearward R.S. Htr. Pnl. Assy., No. RRH15 1 1 1 6042629

15B Rearward R.S. Htr. Pnl. Assy., No. RRH17 1 1 1 1 1 1 6042633

15C Rearward R.S. Htr. Pnl. Assy., No. RRH21 1 1 1 1 6042630

15D Rearward R.S. Htr. Pnl. Assy., No. RRH27 1 1 1 6042631

15E Rearward R.S. Htr. Pnl. Assy., No. RRH29 1 1 1 1 1 6042634

15F Rearward R.S. Htr. Pnl. Assy., No. RRH33 1 6042632 16 Thumb Hole Bushing, Heyco #2166, Black 10 12 12 12 14 14 16 16 16 16 20 8136257

DESCRIPTION

V1113 V1114 V1115 V1116 V1117 V1118 V1119 V1120 V1121 V1122 V1123

B1OILER SECTIONS / QUANTITY

PART NO.

NOTE: Flue top insulation

not shown.

Figure 47: Bare Boiler Assembly

REPAIR PARTS FOR BARE BOILER ASSEMBLY

ITEM

NO.

1 Front Section 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7172614

2 "C" Center Section - Steam Boiler 2 3 4 5 6 7 7 8 9 10 10 11 12 13 13 14 15 16 16 17 7172617

Optional - "CT" Center Section w/Tankless Heater Opening -

3 Max. No. Heater - 1 2 2 3 3 4 4 4 5 5 5 6 6 6 7 7 8 8 9 9 7172619

("CT") Replaces "C" Center Section

4 "CX" Center Section with 4" Supply Tapping - Steam Boiler 1 1 1 1 2 2 2 2 3 3 3 3 4 4 7172618

5 Back Section 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7172616

6 Target Wall (V1104 thru V1106 only) 1 1 1 6202601

Silastic, 500°F, 10 oz. Tube 2 2 3 4 5 5 6 7 8 8 9 10 11 11 12 13 14 14 15 16 9056060

7 7" Cast Iron Slip Nipple 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7066004

8 3" Cast Iron Slip Nipple 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 7066002

Nipple Gauge, 3" & 7" 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 806600023

Nipple Lubricant, Loctitie® #592, 50 ml 2 2 3 3 1 1 2 2 3 3 8056254

9 3/4" - 10 x 11" Lg. Tie Rod 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 80861092

10 "Front" Firewall Plate 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8202603

11 "Common" Firewall Plate 1 1 2 2 3 3 4 4 5 5 5 5 5 5 5 5 5 5 8202604

12 Formed Steel Flue Cover Plate 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 6112601

13 Flue Cover "J" Bolt, 5/16" -18 x 2-3/4" Lg. 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 80861680

14 Tankless Heater/Cover Plate Gasket (One Required for each "CT" Section) 8032601

15A V11-2 Tankless Heater Assembly (One Required for each "CT" Section) 6032601

15B Blank Heater Cover Plate Only (One Required for each "CT" Section) 6032602

Rear Observation Port Cover

(Incls. gasket & mounting hdwe)

17 Canopy Assemblies

17A Canopy Assembly, V1104 1 6112604

17B Canopy Assembly, V1105 1 6112605

17C Canopy Assembly, V1106 1 6112606

17D Canopy Assembly, V1107 1 6112607

17E Canopy Assembly, V1108 1 6112608

17F Canopy Assembly, V1109 1 6112609

17G Canopy Assembly, V1110 1 6112610

17H Canopy Assembly, V1111 1 6112611

17I Canopy Assembly, V1112 1 6112612

17J Canopy Front Portion Assembly, V1113 1 6112624

17K Canopy Front Portion Assembly, V1114 / V1117 1 1 1 1 6112625

17L Canopy Front Portion Assembly, V1118 / V1121 1 1 1 1 6112626

17M Canopy Front Portion Assembly, V1122 / V1123 1 1 61126260

17N Canopy Front Portion Assembly, V1113 1 6112613

17O Canopy Front Portion Assembly, V1114 1 6112614

17P Canopy Front Portion Assembly, V1115 1 6112615

17Q Canopy Front Portion Assembly, V1116 1 6112616

17R Canopy Front Portion Assembly, V1117 1 6112617

17S Canopy Front Portion Assembly, V1118 1 6112618

17T Canopy Front Portion Assembly, V1119 1 6112619

17U Canopy Front Portion Assembly, V1120 1 6112620

17V Canopy Front Portion Assembly, V1121 1 6112621

17W Canopy Front Portion Assembly, V1122 1 6112622

17X Canopy Front Portion Assembly, V1123 1 6112623

18 Cerafelt Gasket (1/2" x 2" Wide x L.F.) 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 9206003

19 Canopy Mounting Bracket 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 71126002

DESCRIPTION

Water Boiler 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 19 20 7172617

Water Boiler 1 1 1 1 1 1 1 1 7172618

250 ml 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 8056255

- OR -

One Piece Canopy

Two Piece Canopy

04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 609600011

BOILER SECTIONS / QUANTITY

PART

NO.

Figure 47: Bare Boiler Assembly

REPAIR PARTS FOR BARE BOILER ASSEMBLY (continued)

ITEM

NO.

20 Canopy 'J' Bolt, 5/16 - 18 x 7-3/4 Lg. 2 2 2 2 4 4 6 6 8 8 10 10 12 12 14 14 16 16 18 18 80861679

21 Adhesive Fiber Gasket, 1/8" x 1" Wide x L.F. 12 12 12 13 13 13 13 13 13 17 17 17 17 17 18 18 18 18 19 19 9206032

22 Top Flue Outlet Assembly, 8" 1 1 1 6112627

10" 1 1 1 6112628

12" 1 1 1 1 6112629

14" 1 1 1 1 6112630

16" 1 1 1 1 6112631

18" 1 1 6112637

22A Top Outlet Canopy Cover, 8" Opening 1 1 1 7112638

23 Rear Flue Outlet Assembly, 8" Collar 1 1 1 6112632

23A Rear Flue Outlet Cover 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7112632

24 3/16" Dia. Rope Gasket x L.F. 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 72026021

25 5/16" - 18 x 2" Lg. Tap-end Stud 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 80861606

26 Standard Burner Mounting Plate Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6022601

(Above Assembly Includes Items 27A, 28 and 29)

27 Standard C.I. Burner Mounting Plate (Machined) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7172601

28 Shutter Door Assembly Parts:

28A Handle Knob 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8026036

28B Shutter Handle 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8026033

28C Shutter Spring 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8026034

28D Observation Port Shutter (Machined & painted) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 70260051

28E Spring Pin 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8026035

29 Observation Port Asssembly Parts:

29A Observation Port Cover (Machined & Painted) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 70260041

29B Observation Port Outer Gasket 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8206001

29C Observation Port Glass 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8026032

29D Observation Port Inner Gasket 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8206002

30 Standard Burner Mounting Plate Insulation 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8202601

31 Burner Adapter Plate Assembly w/Gasket and Hardware:

31A Beckett ("CF") BAP No. "00", 6-3/4" Dia. Hole 1 1 1 1 1 1 1 1 602263001

31B Beckett ("CF") BAP No. "01", 8-1/4" Dia. Hole 1 1 1 1 600263011

31C Beckett ("CF") BAP No. "02", 10-1/4" Dia. Hole 1 602263021

31D Power Flame ("C") BAP No. "40", 7-1/2" Dia. Hole 1 1 602263401

31E Power Flame ("C") BAP No. "41", 9" Dia. Hole 1 1 1 1 1 602263411

31F Power Flame ("C") BAP No. "42", 10-3/8" Dia. Hole 1 1 1 1 1 1 1 1 1 1 1 602263421

31G Power Flame ("JR") BAP No. "45", 6-3/8" Dia. Hole 1 1 602263451

31H Power Flame ("JR") BAP No. "46", 8-3/8" Dia. Hole 1 1 1 602263461

32 Burner Adapter Plate Gasket Only 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8022601

33 3/8" Dia. Rope Gasket 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 7202648

DESCRIPTION

10" 1 1 1 7112639

12" 1 1 1 1 7112640

14" 1 1 1 1 7112641

16" 1 1 1 1 7112642

18" 1 1 71126420

- OR -

10" 1 1 1 6112633

12" 1 1 1 1 6112634

14" 1 1 1 1 6112635

16" 1 1 1 1 6112636

18" 1 1 6112638

- OR -

04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23

BOILER SECTIONS / QUANTITY

PART

NO.

STEAM TRIM / WATER TRIM

STEAM TRIM V1104-6 V1107-9 V1110-12 V1113-17 V1118-20 V1121-23 PART NO.

Pressuretrol, Honeywell L404A1354 1 1 1 1 1 1 80160301

Steam Gauge, 4" Dia., 30" -0-30 PSI, 1/4" NPT 1 1 1 1 1 1 8056022

Gauge Glass Set, Conbraco #20-104-10 (8-5/8") 1 1 1 1 1 1 8056150

Safety Valve Piping:

Nipple, 3" NPT x Close, Black 1 1 1 1 1 806600223

Nipple, 3" NPT x 4", Black 1 806600110

Tee, 3" NPT, Black 1 1 1 1 1 1 806601064

Hex Bushing, 3" NPT x 1¼" FPT, Black 1 806600560

Hex Bushing, 3" NPT x 1½" FPT, Black 1 806600542

Hex Bushing, 3" NPT x 2" FPT, Black 1 806600557

Hex Bushing, 3" NPT x 2½" FPT, Black 1 806600543

Safety Valve, Conbraco #13-213-08, 1¼" MPT x 1½" FPT 1 81660505

Safety Valve, Conbraco #13-214-08, 1½" MPT x 2" FPT 1 81660503

Safety Valve, Conbraco #12-205-08, 2" MPT x 2" FPT 1 81660507

Safety Valve, Conbraco #12-206-08, 2½" MPT x 2½" FPT 1 81660508

Safety Valve, Conbraco #12-208-08, 3" MPT x 3" FPT 1 81660509

Safety Valve, Conbraco #14-207-08, 3" MPT x 3" FPT 1 81660521

Hex Bushing, ¾" MPT x ¼" FPT, Black (Mount Syphon) 1 1 1 1 1 1 806600508

Hex Bushing, 3" MPT x ¾" FPT, Black (Mount Drain Valve) 1 1 1 1 1 1 806600509

Hex Bushing, ½" MPT x ¼" FPT, Black (Mount Steam Gauge) 1 1 1 1 1 1 806600524

Drain Valve, ¾" x 1½" Lg. Conbraco #31-606-02 1 1 1 1 1 1 806603011

Syphon, ¼" x 90°, 1-7/8" x 4" Extended Leg 1 1 1 1 1 1 806603010

Plug Extra Tappings:

Pipe Plug, ¾" NPT, Countersunk, Black 1 1 1 1 1 1 806603504

Pipe Plug, 1" NPT, Countersunk, Black 1 1 1 1 1 1 806603517

Pipe Plug, ¾" NPT, Square Head, Black 2 2 2 2 2 2 806603512

Pipe Plug, 1" NPT, Square Head, Black 3 3 3 3 3 3 806603501

Pipe Plug, 3" NPT, Square Head, Black 1 1 1 1 1 1 806603514

Lowest Permissible Water Level Plate, Form No. 1204A 1 1 1 1 1 1 81460009

WATER TRIM V1104-7 V1108-11 V1112-20 V1121-23 PART NO.

Aquastat Controller, Honeywell L4006A2015 1 1 1 1 80160400U

Immersion Well, Honeywell #123871A, ¾" NPT 1 1 1 1 80160452

Temperature Pressure Gauge, 100 PSI, 80-320°F, ½" NPT 1 1 1 1 8056028

Relief Valve Piping:

Hex Bushing, 3" NPT x ¾" FPT, Black 1 806600509

Hex Bushing, 3" NPT x 1" FPT, Black 1 806600559

Hex Bushing, 3" NPT x 1¼" FPT, Black 1 806600560

Hex Bushing, 3" NPT x 1½" FPT, Black 1 806600542

Nipple, ¾" NPT x 3" Lg., Black 1 806600002

Nipple,1" NPT x 3" Lg., Black 1 806600027

Nipple, 1¼" NPT x 3" Lg., Black 1 806600005

Nipple, 1½" NPT x 3" Lg., Black 1 806600006

Street Elbow, ¾" NPT x 90°, Malleable 1 806601501

Street Elbow, 1" NPT x 90°, Malleable 1 806601514

Street Elbow, 1¼" NPT x 90°, Malleable 1 806601516

Street Elbow,1½" NPT x 90°, Malleable 1 806601517

Relief Valve, Conbraco #10-614-10, ¾" x 1" FPT, 50# Working Pressure 1 81660359

Relief Valve, Conbraco #10-615-10, 1" x 1¼" FPT, 50# Working Pressure 1 81660362

Relief Valve, Conbraco #10-616-10, 1¼" x 1" FPT, 50# Working Pressure 1 81660357

Relief Valve, Conbraco #10-617-10, 1½" x 2" FPT, 50# Working Pressure 1 81660364

Hex Bushing, 3" NPT x ¾" FPT, Black (Mount Drain Valve) 1 1 1 1 806600509

Drain Valve, ¾" NPT x 1½" Lg., Conbraco #31-606-02 1 1 1 1 806603011

Plug Extra Tappings:

Pipe Plug, ½" NPT, Countersunk, Black 2 2 2 2 806603510

Pipe Plug, ¾" NPT, Countersunk, Black 1 1 1 1 806603504

Pipe Plug, 1" NPT, Countersunk, Black 1 1 1 1 806603517

Pipe Plug, ¾" NPT, Square Head, Black 2 2 2 2 806603512

Pipe Plug, 1" NPT, Square Head, Black 3 3 3 3 806603501

Pipe Plug, 3" NPT, Square Head, Black 2 2 1 806603514

Pipe Plug, 4" NPT, Square Head, Black 1 1 1 1 806603590

SERVICE RECORD

DATE SERVICE PERFORMED

Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and/or accessories manufactured and shipped on or after October 1, 2009:

ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY BURNHAM COMMERCIAL.

Burnham Commercial warrants to the original owner that its commercial grade water and steam boilers and parts/accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a commercial grade boiler or any part or accessory provided by Burnham Commercial is found to be defective in material or workmanship during this one year period, Burnham Commercial will, at its option, repair or replace the defective part (not including labor).

HEAT EXCHANGER WARRANTIES

Burnham Commercial warrants to the original owner that the heat exchanger of its commercial grade boilers will remain free from defects in material and workmanship under normal usage for the time period specified in the chart below to the original owner at the original place of installation. If a claim is made under this warranty during the “No

Charge” period from the date of original installation, Burnham Commercial will, at its

option, repair or replace the heat exchanger (not including labor). If a claim is made under this warranty after the expiration of the “No Charge” period from the date of original installation, Burnham Commercial will, at its option and upon payment of the pro-rated service charge set forth below, repair or replace the heat exchanger. The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows:

NOTE: If the heat exchanger involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as set forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger, whichever is greater.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These warranties are applicable only to boilers, parts, or accessories designated as commercial grade by Burnham Commercial and installed and used exclusively for purposes of commercial space heating or domestic hot water generation through a heat exchanger (or a combination for such purposes) and do not apply to residential grade products or industrial uses.

2. Components Manufactured by Others: Upon expiration of the one year limited warranty on commercial grade boilers, all boiler components other than heat exchangers manufactured by others but furnished by Burnham Commercial (such as oil burner, circulator and controls) will be subject only to the

manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by Burnham Commercial are conditioned upon the installation of the commercial grade boiler, parts, and accessories in strict compliance with Burnham Commercial installation instructions. Burnham Commercial specifically disclaims liability of any kind caused by or relating to improper installation.

4. Proper Use and Maintenance: The warranties extended by Burnham Commercial conditioned upon the use of the commercial grade boiler, parts, and accessories for its intended purposes and its maintenance accordance with Burnham Commercial recommendations and hydronics industry standards. For proper installation, use, and maintenance, see all applicable sections of the Installation and Operating, and Service Instructions Manual furnished with the unit.

5. This warranty does not cover the following: a. Expenses for removal or reinstallation. The owner will be responsible for

the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith, and transportation to and from Burnham Commercial.

b. Components that are part of the heating system but were not furnished by

Burnham Commercial as part of the commercial boiler. c. Improper burner adjustment, control settings, care or maintenance. d. This warranty cannot be considered as a guarantee of workmanship of an

installer connected with the installation of the Burnham Commercial boiler, or

as imposing on Burnham Commercial liability of any nature for unsatisfactory

performance as a result of faulty workmanship in the installation, which

liability is expressly disclaimed.

e. Boilers, parts, or accessories installed outside the 48 contiguous United

States, the State of Alaska and Canada.

f. Damage to the boiler and/or property due to installation or operation of the

boiler that is not in accordance with the boiler installation and operating instruction manual.

g. Any damage or failure of the boiler resulting from hard water, scale buildup

or corrosion the heat exchanger.

h. Any damage caused by improper fuels, fuel additives or contaminated

combustion air that may cause fireside corrosion and/or clogging of the burner or heat exchanger.

i. Any damage resulting from combustion air contaminated with particulate

which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles, dirt, and dust particulate.

j. Any damage, defects or malfunctions resulting from improper operation,

maintenance, misuse, abuse, accident, negligence including but not limited to operation with insufficient water flow, improper water level, improper water chemistry, or damage from freezing.

k. Any damage caused by water side clogging due to dirty systems or

corrosion products from the system. l. Any damage resulting from natural disaster. m. Damage or malfunction due to the lack of required maintenance outlined in

the Installation and Operating Manuals furnished with the unit.

6. Exclusive Remedy: Burnham Commercial obligation for any breach of these warranties is limited to the repair or replacement of its parts (not including labor) in accordance with the terms and conditions of these warranties.

7. Limitation of Damages: Under no circumstances shall Burnham Commercial be liable for incidental, indirect, special or consequential damages of any kind whatsoever under these warranties, including, but not limited to, injury or damage to persons or property and damages for loss of use, inconvenience or loss of time. Burnham Commercial liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the commercial grade boiler involved. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entire obligation of Burnham Commercial with respect to any defect in a commercial grade boiler, parts, or accessories and Burnham Commercial shall have no express obligations, responsibilities or liabilities of any kind whatsoever other than those set forth herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A COMMERCIAL GRADE BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to complete and mail the Warranty Card provided with the product or register product online at www.burnhamcommercialcastiron.com within ten days after the installation of

the boiler, although failure to comply with this request will not void the owner’s

rights under these warranties. Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the owner should write to Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604, giving full particulars in support of the claim. The owner is required to make available for inspection by Burnham Commercial or its representative the parts claimed to be defective and, if requested by Burnham Commercial to ship these parts prepaid to Burnham Commercial at the above address for inspection or repair. In addition, the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

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Using Cast Iron, Carbon Steel,

or Stainless Steel Heat Exchangers

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Years in Service 1 2 3 4 5 6 7 8 9 10+

Cast Iron 100

Carbon Steel No Charge

Stainless Steel 20 40 60 80 100

100

No Charge

Service Charge as a % of Retail Price

Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604

Pub. No. BCL1109041

Revised November 1, 2009

Commercial Boilers

Burnham V11 Installation and Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual