Burnham V7 User Manual
Price - $3.00
INSTALLATION,
OPERA TING AND SERVICE
INSTRUCTIONS FOR
V7 SERIES OIL FIRED BOILER
KNOCKDOWN & P ACKAGED
HEA TING UNITS
These instructions have been
reviewed by ULC and found
suitable for use in the
installation of ULC labeled
As an
ENERGY
STAR® Partner,
Burnham Corporation
has determined that the
V73WR (0.60 GPH),
V74WR (0.80 GPH),
V75WR (0.90 GPH),
and V76WR (1.15 GPH)
meet the ENERGY STAR
guidelines for Energy
efficiency established by the
United States Environmental
Protection Agency (EPA).
For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number Boiler Serial Number Installation Date
_V7 ____-____
®
6_ _ _ _ _ _ _
V-7 Series Boilers.
The ULC label or listed
marking on a product is the
only evidence provided by
Underwriters' Laboratories of
Canada to identify products
which have been produced
under the listing and follow-up
service.
Heating Contractor Phone Number
Address
8142711R24-7/99
1
IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY
1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS
MANUAL.
2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CANNOT BE INSTALLED ON CARPETING.
3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL PLUMBING,
HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY
DIFFER FROM THIS 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 clearances between boiler, vent connector and
combustible material.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Chimney require-
ments, type of venting material and clearances between vent connector pipe and combustible materials.
C. 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.
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment”, for recommended Installation Practices.
4. 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.
5. THE BOILER MUST BE CONNECTED TO AN APPROVED CHIMNEY IN GOOD CONDITION. SERIOUS PROPERTY
DAMAGE COULD RESULT IF THE BOILER IS CONNECTED TO A DIRTY OR INADEQUATE CHIMNEY. THE
INTERIOR OF THE CHIMNEY FLUE MUST BE INSPECTED AND CLEANED BEFORE THE START OF THE HEATING SEASON AND SHOULD BE INSPECTED PERIODICALLY THROUGHOUT THE HEATING SEASON FOR ANY
OBSTRUCTIONS. A CLEAN AND UNOBSTRUCTED CHIMNEY FLUE IS NECESSARY TO ALLOW NOXIOUS
FUMES THAT COULD CAUSE INJURY OR LOSS OF LIFE TO VENT SAFELY AND WILL CONTRIBUTE TOWARD
MAINTAINING THE BOILER’S EFFICIENCY.
6. READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESSORY DEVICES.
THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS
OF THE MANUFACTURER.
7. 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.
8. FOR OPTIMUM PERFORMANCE AND SERVICEABILITY FROM THIS BOILER ADHERE TO THE FOLLOWING
RECOMMENDATIONS:
A. DO NOT TAMPER WITH THE BOILER OR CONTROLS. Retain your contractor or a competent serviceman to assure that the boiler is properly adjusted and
maintained.
B. Clean flueways at least once a year - preferably at the end of the heating season to remove soot and scale. Inside of firebox should also be cleaned at the same
time.
C. Have oil burner and controls checked at least once a year or as may be necessitated.
CANADA BOILERS
WARNING
This boiler is designed to burn No. 2 fuel oil 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) or gaseous fuel (i.e. natural gas, LP/propane). All flammable debris, rags, paper, wood scraps,
etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of fire hazards.
WARNING
All boilers equipped with burner swing door have a potential hazard which can cause severe property
damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to
boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door
fastener completely when service is completed.
WARNING
High water temperatures increase the risk of burns or scalding injury. Install an automatic tempering
(mixing) valve at the tankless heater outlet to avoid excessively hot water at the fixtures.
2
IMPOR TANT
p
g
Before star ting to in st a ll t his o i l b o ile r, r e ad t he se inst r uc t io n s ca r efu lly. K e ep ins t r uc t ions i n legible condition and
osted near oil boiler for reference by o w ne r an d s er v i c e tec hn i cian.
TABLE OF CONTENTS
I. General Information ............................. 3
II. Knockdown Boiler Assembly ............... 7
III. Installation Instructions...................... 12
IV. Operating Instructions ........................ 21
V. Boiler Cleaning .................................. 29
VI. Repair Parts ........................................ 31
Burner Specifications ......................... 46
SECTION I: GENERAL INFORMATION
Figure 1A: V72 thru V79 Water Boiler Without Tankless Heater (WB)
TABLE 1: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1E)
Boiler
Model
No.
V72 11-3/8" 6-3/ 8" 5" 8" x 8 " x 15' --- - 10.6 --- - 381
V71 3 16" 8-3/ 4" 6" 8" x 8" x 15' --- - 1 3.5 ---- 524
V73 15-3/8" 8-3/8" 6" 8" x 8" x 15' 10. 8 13.2 13. 8 47 8
V71 4 20" 10-3/ 4" 6" 8" x 8 " x 15' --- - 15.9 --- - 580
V74 19-3/8" 10-3/ 8" 6" 8" x 8 " x 15' 1 3. 5 15.9 1 9.7 575
V75 23-3/8" 12-3/ 8" 7" 8" x 8 " x 15' 1 6. 1 18.5 2 5.6 674
V76 27-3/8" 14-3/ 8" 7" 8" x 8 " x 15' 1 8. 6 21 31. 4 77 3
V77 31 -3/8" 16 -3/8" 8" 8 " x 12" x 15' 21.2 2 3. 6 37. 3 872
V78 35 -3/8" 18 -3/8" 8" 8 " x 12" x 15' 23.8 2 6. 2 43. 1 971
V79 39 -3/8" 20 -3/8" 8" 8 " x 12" x 15' 26.4 2 8. 8 49. 0 1070
Dimensions
Minimum
Chimney S ize
"A" "B" "C"
NO TE: 1. M aximum Working Pressure 15 PS I (S team) and 30 PSI (Water )
2. The V72 , V713 an d V71 4 Boilers are avail abl e as pack aged wa ter boi lers only
3. The V713 and V714 are no t ULC li sted Models
Water Content -
Ga llons
Steam
Boiler
Water
Boiler
3
Heat Transfer
Surface Area -
Sq. Ft .
Steam Boiler
Approximate
Shippin
(LB.)
Weight
Figure 1B: V73 thru V79 Water Boiler with Tankless Heater (WBT)
Figure 1C: V73 thru V79 Steam Boiler with or without Tankless Heater ("SBT" or "SB")
4
Βυρνηαµ
Figure 1D: V713 and V714 Packaged Water Boiler Less Tankless Heater (WB)
Burnham
Figure 1E: V713 and V714 Packaged Water Boiler with Tankless Heater (WBT)
5
A. INSPECT SHIPMENT carefully for any signs of
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated boiler to the carrier in good
condition.
2. ANY CLAIMS for damage or shortage in shipment
must be filed immediately against the carrier by the
consignee. No claims for variances from, or
shortage in orders, will be allowed by the
manufacturer unless presented within sixty (60)
days after receipt of goods.
B. LOCATE BOILER in front of final position before
removing crate. See Figures 1A thru 1E.
1. LOCATE so that smoke pipe connection to
chimney will be short and direct. BOILER IS
SUITABLE FOR INSTALLATION ON
COMBUSTIBLE FLOOR. Boiler cannot be
installed on carpeting.
2. FOR BASEMENT INSTALLATION, provide a
solid base, such as concrete, if floor is not level, or
if water may be encountered on floor around boiler.
3. PROVIDE SERVICE CLEARANCE of at least 24”
on right side of boiler for removal of rear tankless
heater. Provide at least 24” clearance from front
jacket panel for servicing and removal of front
tankless heater (increase to 30" for #A54 heater).
Provide at least 24" clearance from right side of
boiler or top of boiler for cleaning flueways. Boiler
flueways may be cleaned either from the top or
from the side.
4. For minimum clearances to combustible materials.
See Table 2.
C. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate proper combustion. If natural ventilation
is inadequate, provide a screened opening or duct from
the boiler room to the outside. The opening or duct
must be sized so the boiler input will not exceed 4,000
BTUH/Sq. In. of free area. If other air consuming
appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.
TABLE 2: Minimum Installation Clearances To
Combustible Materials (Inches)
C
Chimney
BoilerAAboveBFront
V7 6 24 18 6 6
ConnectorDRearESides
NO TE 1: Listed c l ear anc es c om ply with A m er ica n
National Standard ANSI/NFPA 31, Installation of Oil
Burning Equipment.
NOT E 2: V7 Serie s boilers can be ins ta lled in room s
with clea rance s from combus tible ma te rial as listed
a bove. List ed c lea ranc es can not b e red uced for
alcove or clos et installations.
N OTE 3: F or redu ced cle ara nc es to co mbus tib le
mater ial, prot ection mu st be pro vided as desc ribed in
the abo ve ANSI/NF PA 31 standa rd.
6
SECTION II: KNOCKDOWN BOILER ASSEMBLY
Note: If Boiler is Packaged Go To Section III
A. REMOVAL OF BARE BOILER FROM SKID
1. Boiler is secured to base with 4 bolts, 2 on front and
2 on rear, see Figure 2. Remove all bolts.
2. Tilt boiler to right and to rear. Using right rear leg
as pivot, rotate boiler 90° in a clockwise direction,
and lower left side of boiler to floor. Tilt boiler and
remove crate skid.
Figure 2
B. MOVE BOILER TO PERMANENT POSITION by
sliding or walking.
C. TEST BOILER FOR LEAKS before installing
controls, trim, and jacket, and before connecting to
heating system.
1. Loosen nuts on tie rods until only finger tight.
2. Install pressure gauge (at least 30 P.S.I. capacity), a
hose to the city water and a valve in the supply
tapping. Plug remainder of tappings.
3. Fill boiler with water and apply a pressure of at
least 10 pounds but no more than 30 pounds gauge
pressure.
4. Examine Boiler carefully inside and outside for
leaks or damage due to shipment or handling.
D. DRAIN WATER FROM BOILER. Remove gauge,
valve and plugs from those tappings to be used. Leave
other tappings plugged or bushed according to Figure
4.
E. INSPECT JOINTS BETWEEN SECTIONS. All joints
are factory sealed. If there are any spaces due to
shipment or handling, seal them with boiler putty.
F. INSPECT FLUE COVER PLATES for tightness. If
loose, retighten mounting hardware. If flue plate or
sealing insulation is damaged repair or replace as
needed.
G. INSTALL AND SECURE CANOPY with cerafelt
gasket and hardware provided to ensure gas tight seal
— see Figure 3.
1. Cut two (2) strips 13 ¾” lg. from the roll of cerafelt
gasket insulation. Place one (1) strip across the top
of the front section and the other across the rear
section as shown in Fig. 3. Place gaskets so as not
to allow any flueway blockage.
2. Cut the remainder of the roll into two (2) equal
pieces. Place each piece along the sides, allowing
the ends to overlap the front and rear pieces.
Do not allow any flueway blockage.
3. Position canopy body within the retaining bar
which borders the flueway openings on top of the
bare boiler block assembly.
Figure 3
IMPORTANT: Jacket support bracket must be
facing left side of boiler — see Figure 3.
4. Secure canopy to boiler with two (2) 1/4" - 20 x 3"
lg. carriage bolts, 1/4" flat washers and 1/4" - 20
wing nuts provided.
H. INSTALL the following steam or water trim that
would be concealed or inaccessible after flush jacket is
installed, see Figure 4 for boiler tapping locations and
usage.
1. STEAM BOILER — Top tappings:
a. Tapping "L" — Install 2" plug in rear section
top supply tapping on boiler sizes V73 thru
V75.
b. Tapping “M” — Install ¾” coupling and ¾” x
8” long nipple into ¾” tapping located next to
front section top supply tapping — all boiler
sizes.
2. WATER BOILER — Top tappings:
a. Tapping “L” — Install 2” plug in rear section
top supply tapping on boiler sizes V73 thru
V79.
7
Figure 4: Boiler Tapping Locations and Usage (Knockdown Boilers Only)
g
PURPOSE OF TA PPINGS
Tappin
Location
Size
Steam Boiler Water Boiler
Non-Heater w/Heater Non-Heater Front Heater R ear Heater
A¾"
B ¼" P ressure /Vacuum G au g e Temp era ture/Press ure Gaug e
C¾"
C-C ¾ " Flus h Plug Flus h Plug Flus h Plug
D½"
F ¾" -----
G 1½" B us he d to ¾" for Drainc ock (O ptiona l Re turn ) R eturn
H 1½" R eturn Bus he d to ¾" for Drainc ock (O ptiona l Re turn )
J 1½ " Su rface Blow off - Plugged Flush Plu g
K 2" Front Su pply (3 thru 9 Section) Front Su pply (3 thru 9 Section)
L2"
M ¾" Safety Valve Re lief Valve
P ¾" Au xilia ry Tapping - Plugge d
R ¾" Au xiliary Tapping - Plu gge d Auxiliary Tapping - Plu gge d
Water Gaug e Glass, P ress uretrol, and LWC O (Flo at)
Plug ged, Optional Se co nd Supply (3 thru 5 Section)
PA4 04A Pr es suretrol (Probe LW CO)
Plugg ed (Float LW CO)
Pro be LWC O Std.
Plugg ed (Flo at LW CO)
Water Gauge Glass (Probe LWCO )
L40 06A O p eratin g
Control
R equired Se cond Su pply (6 thru 9 Section )
L8148A
Op era tin g C on trol
-- --- Di sreg ard
Plugge d (3 thru 9 Section)
Aux . Ta pping -
Plugge d
L81 24 C
Op era tin g C on trol
Flush Plug
Flush Plug
Disre gard
Op era tin g C on trol
Aux . Ta pping -
Flush Plug
L81 24 C
Plugge d
8
Figure 5: Knockdown Boiler Jacket Assembly
b. Tapping “M” —Install ¾” x 8” long nipple into
¾” tapping located next to front section top
supply tapping — all boiler sizes.
I. INSTALL FLUSH JACKET (See Figure 5).
1. Remove burner swing door mounting plate. Loosen
the bottom bolt three full turns. Remove (5)
remaining 5/16” bolts securing mounting plate to
boiler sections.
Lift up and remove plate.
2. Install rear jacket panel. Align two dimpled holes
on jacket panel with the cast iron lugs. Secure with
two #10 x 3/8” long self tapping screws.
3. JACKET FRONT PANEL
a. Install black plastic collar extension to jacket
front panels with 7-13/16" dia. heater opening.
Engage two (2) retaining tabs over raw edge of
opening. Provide support behind the panel with
one hand while applying pressure on collar to
snap each tab over edge of opening until all
eight (8) tabs are securing collar.
b. Install front jacket panel. Locate two 3/16”
diameter holes on front panel approximately 16”
up from the bottom of the panel and 4½” in
from each side. Align these holes with the
similarly located cast iron lugs on the front
section. Secure with two #10 x 3/8” long selftapping screws.
4. Install jacket left side panel. Fold panel at
perforation keeping insulation inward. Align left
side panel mounting holes with the front and rear
panel holes. Secure with #8 x ½” long sheet metal
screws.
5. Install jacket top panel. Place jacket top panel on
boiler and secure to front, rear and left side panels
with #8 x ½” long sheet metal screws.
6. Install jacket lower right side panel. Align right
side panel mounting holes with front and rear panel
holes. Secure with #8 x ½” long sheet metal screws.
7. Install jacket upper right side access panel. Using
the thumb holes, hold access panel 1” above lower
right side panel. Engage flanges on access panel
with surrounding panels and lower into position
until access panel is resting flush with top panel
and bottom flange is properly locked into position
with lower right side panel.
8. Attach the data labels shipped in the instruction
envelope as follows: (see Figure 5).
a. Place the Rating Label (serialized)
approximately 1/4" below the top edge and
3-1/2" from the right edge of the jacket front
panel as shown. Mark outline of label on jacket
with a pencil. Remove paper backing from
label, realign label with pencil marks and apply
label to jacket by using backing paper to rub
across face of label.
b. Locate the Combination Label (P/N 8142756)
on the front right corner of top panel,
approximately 3/8" from each edge as shown.
Mark the location and apply label in the same
9
Figure 6
manner as rating label.
c. On steam boilers, install the Lowest Permissible
Water Level Plate, Form No. 1204 (shipped in
Steam Trim Carton), on the jacket right side
panel. Align the two holes in the plate with the
two 1/8” dia. holes located near the front edge,
in line with the lower sight glass tapping, and
secure with #8 x ½” lg. sheet metal screws.
J. INSTALL OIL BURNER (See Figure 6).
1. Check target wall and cerafelt blanket in
combustion chamber. If any damage or movement
occurred during shipment, repair or replace as
needed.
2. Check the burner mounting plate and swing door
insulation pieces for damage and adhesion. If
damaged, replace insulation. If loose, re-attach with
RTV 732 or 736 silicone caulk.
3. Engage bottom slot on burner mounting plate with
matching bolt in bottom tapping of front section.
Align mounting holes and fasten the mounting
plate to the boiler sections with (5) five 5/16” bolts
and washers removed in step 8a. Fully tighten all
bolts.
4. Place burner flange gasket on burner swing door
and thread two 5/16” x ½” long bolts into vertical
set of holes approximately three full turns.
5. Insert oil burner air tube into the opening of the
burner swing door. Align keyhole slot with vertical
set of bolts, engage hex head of bolts and rotate
burner to the left. Install two remaining 5/16” x ½”
long bolts in horizontal sets of holes. Level burner
and fully tighten all bolts.
K. INSTALL STEAM BOILER TRIM AND CONTROLS
(See Figures 1C & 4).
1. Thread the combination pressure/vacuum gauge
into the ¼” tapping. Tighten with wrench applied
to the square shank of the gauge. Do not apply
pressure to the gauge case — this might destroy the
calibration of the gauge.
2. Thread 1½” x ¾” bushing and a ¾” drain cock into
the 1½” tapping located in the lower right corner of
the front casting. Tighten with wrench.
NOTE: Lower rear section tapping “H” is used for
standard condensate return on steam boilers.
3. Thread safety relief valve, as shown in Figure 1C,
into 3/4" coupling and 3/4” x 8” nipple previously
installed in step H. Tighten with wrench.
NOTE: Pipe discharge as shown in Figure 8.
4. Install probe type LWCO if so equipped. Thread
probe into ¾” tapping located on the front section
directly above the protectorelay on the oil burner.
Read the manufacturer’s instructions packed with
the probe LWCO for proper pipe dope application.
DO NOT use Teflon tape on probe threads. Use of
teflon can render the probe LWCO inoperational.
Slip the LWCO control over the probe and clamp in
place. Connect the wire(s) between the probe and
control per the manufacturer’s instructions. Install
10
the sight glass using the two ½” tappings to the
right of the probe LWCO.
5. Install float-type Low Water Cutoff, if so equipped.
See Figure below.
a. Install nipples and unions in Tappings D.
b. Mount hardware to low water cutoff body. Install
assembly.
c. Install water gage glass on low water cutoff
assembly's tee fittings.
6. Install Limit Control.
a. Probe LWCO: Install Limit in Tapping A using
¾ NPT x 2" nipple, ¾ NPT elbow, ¾ NPT x ¼
NPT bushing, and syphon. See Figure below
right.
b. Float LWCO: Remove ¼ NPT plug from top of
Low Water Cutoff. Install Syphon and Limit into
this tapping. See Figure below.
7. On units equipped with a tankless heater, install the
aquastat controller well in the ¾” tapping in tankless
heater plate. Slip the bulb of the aquastat into the well
and secure the control in place with the set screw.
8. Connect the field wiring to the pressure limit, the
LWCO, the burner J-box, and from the aquastat
control (if equipped with tankless heater) to the oil
burner primary control's "T-T" terminals. Make the
wiring connections as shown in Figures 17 thru 20.
L. INSTALL WATER TRIM AND CONTROLS
(See Figures 1B and 4).
1. Thread ½” pipe plugs into gauge glass tappings in
the upper right side of front section.
2. Thread ¾” pipe plug in probe low water cut off
tapping (just left of gauge glass tappings).
3. Thread combination pressure/temperature gauge into
¼” tapping. Tighten with wrench applied to the
square shank of the gauge. Do not apply pressure to
the gauge case - this might destroy the calibration of
the gauge.
4. Screw drain valve into 1½” tapping in lower rear
section using 1½” x ¾” bushing (note - lower front
section tapping “G” (see Figure 4) is used for
standard return on water boilers).
5. If CIRCULATOR (not supplied with boiler) is to be
mounted directly to 1½" boiler return tapping "G",
use the piping arrangements outlined in steps a. thru
e. as follows:
a. Thread 1½” x 3” long nipple and 1½” x 90°
elbow into the return tapping and tighten with a
pipe wrench.
b. Thread 1½” NPT x 15” long pipe nipple into the
90° elbow and tighten with a pipe wrench.
c. Thread one of the circulator flange onto the pipe
nipple and tighten with a pipe wrench. Position
flange so that the bolt slots are perpendicular to
the boiler front.
d. Place a flange gasket in the flange groove on the
circulator and mount the circulator on the flange
installed in step 3. Note that this is the return
piping and the flow arrow on the circulator should
point down ê. Fasten circulator with 7/16” nuts
and bolts.
e. Bolt second circulator flange and gasket to the
circulator with 7/16” nuts and bolts.
6. Install pressure relief valve, as shown in Figure 1B,
onto ¾” x 8” nipple previously installed in Step H.
Tighten with wrench.
NOTE: Pipe discharge as shown in Figure 9.
7. On units without a tankless heater, install the control
well into the ¾” tapping located on the front of the
boiler in the upper left corner. Tighten the well and
insert the control’s bulb into the well. Secure the
control with set screw on the control.
8. On units with a tankless heater, install the control
well in the ¾” tapping on the tankless heater plate.
Tighten the well and insert the control’s bulb into the
well. Secure the control with set screw on the control.
9. Connect the field wiring from the circulator to the
control and from the control to the burner J-Box.
Make the wiring connections as shown on Figures 21
and 22.
NOTE: Proceed to Installation Instructions Section
III, step E, to continue.
Float-type Low Water Cutoff Installation
11
Limit Installation for Probe LWCO Equipped
Boilers
SECTION III: INSTALLATION INSTRUCTIONS
A. REMOVE CRATE — (Packaged Boilers)
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other inside
protective spacers and bracing. Remove draft
regulator box and miscellaneous trim bag
containing safety/relief valve, and pipe fittings.
B. REMOVAL OF BOILER FROM SKID
TS-39-26-A
Fig. 7
1. Boiler is secured to base with 4 bolts, 2 on left side
and 2 on right side, see Figure 7. Remove all bolts.
2. Tilt boiler to right and to rear. Using right rear leg
as pivot, rotate boiler 90° in a clockwise direction,
and lower left side of boiler to floor. Tilt boiler and
remove crate skid. Care should be exercised to
prevent damage to jacket or burner.
C. MOVE BOILER TO PERMANENT POSITION by
sliding or walking.
D. INSPECT COMBUSTION TARGET WALL AND
COMBUSTION CHAMBER LINER
1. OPEN FLAME OBSERVATION DOOR AND/OR
BURNER SWING DOOR on front of boiler. Use
flashlight to inspect target wall secured to rear
section with silastic sealant. Inspect ceramic fiber
blanket secured to floor of boiler with water glass
adhesive. If either is damaged they must be
replaced.
E. CONNECT SUPPLY AND RETURN PIPING TO
HEATING SYSTEM.
CLEARANCES — Steam and hot water pipes shall
have clearances of at least ½” from all combustible
construction.
1. With STEAM HEATING, see Figure 8. Consult I =
B = R Installation and Piping Guide No. 200.
2. With Forced Circulation HOT WATER HEATING,
see Figure 9. Consult I = B = R Installation and
Piping Guide No. 200.
3. Packaged boilers. Install Safety Valve in Tapping
M. Use ¾ NPT x 8" nipple and ¾ NPT coupling
included in trim bag. Safety Valve must be
installed with spindle in vertical position.
4. Packaged boilers with Probe style LWCO. Install
Limit in Tapping A using ¾ NPT x 2" nipple, ¾
NPT elbow, ¾ NPT x ¼ NPT bushing, and syphon
included in trim bag. See Figure on previous page.
Connect wiring harness from Low Water Cutoff.
See Figure below.
TS-39-126-A
5. If this boiler is used in connection with
refrigeration systems, the boiler must be installed so
that the chilled medium is piped in parallel with the
heating boiler using appropriate valves to prevent
the chilled medium from entering the boiler, see
Figure 10. Also consult I = B = R Installation and
Piping Guides.
6. If this boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, the boiler piping must be equipped
with flow control valves to prevent gravity
circulation of boiler water during the operation of
the cooling system.
7. Use a boiler bypass if the boiler is to be operated in
a system which has a large volume or excessive
radiation where low boiler water temperatures may
be encountered (i.e. converted gravity circulation
system, etc.).
Remove the circulator and install a pipe tee
between the circulator and boiler return along with
a second tee in the supply piping as shown in
Figure 11. The bypass should be the same size as
the supply and return lines with valves located in
the bypass and supply outlet as illustrated in Figure
11 in order to regulate water flow for maintenance
of higher boiler water temperature.
Set the by-pass and boiler supply valves to a half
throttle position to start. Operate boiler until the
system water temperature reaches its normal
operating range.
Adjust the valves to maintain 180°F boiler water
temperature. Adjust both valves simultaneously.
Closing the boiler supply valve and opening the bypass valve will raise the boiler water temperature
and lower the supply temperature. Opening the
boiler supply valve while closing the by-pass valve
will lower the boiler water temperature and raise
the supply temperature.
8. A hot water boiler installed above radiation level
must be provided with a low water cutoff device as
part of the installation.
12
TS-39-17-D
Fig 8: V73 Thru V79 Recommended Boiler Piping For Gravity Return Steam Boiler
TS-39-4-C
Fig. 9: V72 thru V79, V713 and V714 Recommended Boiler Piping for Series Loop Forced Hot Water System
13
TS-O-62-B
Fig. 10: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
Water Boilers
In order to insure long product life, oxygen sources
should be eliminated. This can be accomplished by taking
the following measures:
1. Repairing system leaks to eliminate the need for
addition of make-up water.
2. Eliminating open tanks from the system.
3. Eliminating and/or repairing fittings which allow
oxygen absorption.
4. Use of non-permeable materials in the distribution
system.
5. Isolating the boiler from the system water by installing
a heat exchanger.
F. CONNECT TANKLESS HEATER PIPING AS
SHOWN IN Figure 12. See Tables 3 and 3A for
Tankless Heater Ratings.
TS-39-7-A
Fig. 11: Recommended Bypass Piping
Water Boilers
CAUTION
Oxygen contamination of 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.
There are many possible causes of oxygen contamina-
tion such as:
1. Addition of excessive make-up water as a result of
system leaks.
2. Absorption through open tanks and fittings.
3. Oxygen permeable materials in the distribution
system.
TS-0-63-B
Fig. 12: Schematic Tankless Heater Piping
THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER:
1. FLOW REGULATION — If flow 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 water line to the heater. The flow regulator
should preferably be located below the inlet to the
heater and a minimum of 3’ 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 flow regulator also
limits the flow of supply water regardless of inlet
pressure variations in the range of 20 to 125 psi.
2. TEMPERING OF HOT WATER — Installation of
an automatic mixing valve will lengthen the
delivery of the available hot water by mixing some
14
TABLE 3: TANKLESS HEATER DATA: Rear
Mounted Heater on Steam and Water
Boilers
Pressure Drop
thru Heater
(PSI)
Boiler
Model
Heater
No.
Heater Rating
(GPM)
Steam Water Steam Water
WARNING
Install an automatic mixing valve at the tankless
heater outlet to avoid risk of burns or scalding
due to excessively hot water at the fixtures.
Adjust and maintain the mixing valve in
accordance with the manufacturer's instructions.
V713 V1-2 --- 3.25 --- 5.6
V73 V1-2 2.75 3 3.9 4.7
V714
V74 V1-2 3 3.25 4.7 5.6
V75 V1-2 3.25 3.5 5.6 6.4
V76 V1-2 3.75 3.75 7.2 7.2
V77 V1-2 3.75 4 7.2 8
V78 V1-2 4 4.5 8 9.8
V79 V1-2 4 4.5 8 9.8
V1-1 --- 3.5 --- 4.4
V1-2 --- 4 --- 8
TABLE 3A: TANKLESS HEATER DATA: Front
Mounted Heater on Water Boilers
Boiler
Model
V73 222 3 22
V74 222 3.5 22
V75 222 4 30.5
V76 222 4.5 33
V77
V78
V79
Heater
No.
222 4.6 33
A54 5.5 36
222 4.75 40
A54 6 39.5
222 4.75 40
A54 6 39.5
Heater Rating
(GPM)
Pressure Drop
Thru Heater (PSI)
cold water with the hot. This prevents excessive
and possibly scalding hot water at the fixtures. In
addition, savings of hot water will be achieved
since the user will not waste as much hot water
while seeking water temperature 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 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
beneficial to the tankless heater but to piping and
fixtures plus the many other benefits derived from
soft water.
NOTE: STEAM BOILERS
a. During summertime operation, the normal water
line should be raised 1”, from 22-5/8” to
23-5/8” (see Figure 1C) for improved tankless
heater performance.
G. INSTALL SMOKEPIPE — The V7 should be vented
into a fireclay tile-lined masonry chimney or chimney
constructed from type L vent or a factory built chimney
that complies with the type HT requirements of
UL103. The chimney and vent pipe shall have a
sufficient draft at all times, to assure safe proper
operation of the boiler. See Figure 13 for recommended
installation.
1. Install a draft regulator (supplied with boiler)
following the instructions furnished with the
regulator. See Figure 14 for alternate draft regulator
locations.
2. Consider the chimney overall. Chimneys that have
a high heat loss may become less suitable as the
heat loss of the home goes down and the efficiency
of the boiler installed goes up. Most homes have a
chimney appropriate for the fuel and the era in
which the home was built. That may have been a
coal fired or an inefficient oil fired boiler built into
a home without insulation or storm windows. With
increasing fuel prices that home probably has been
insulated and fitted with storm windows so that the
heat loss of the home has been reduced. This
15
Loading...