Burnham V9 Installation and Operation Manual
INSTALLATION
AND
Price
-
$3.00
OPERATING
V-9
CAST
IRON HYDRONIC
INSTRUCTIONS
FOR
SERIES
HEATING
FORCED DRAFT
UNIT
LIGHT
OR GAS
FOR
OIL,
These Instructions have been
reviewed
suitable for use
Installation of
V-9
The ULC label or listed
marking on a product
only evidence provided
Underwriters' Laboratories
of Canada to identify products
which have been produced
under the listing and follow
service.
For service and repairs to the heating plant, call your Heating Contractor.
provide series and size designation shown on rating plate.
Boiler Number Type Firing Type System
Heating Con tractor
Address
Part
No.
8142927Rl-10/95-2,050f
AMERICA'S
Burnham Corporation
BOILER
Lancaster,
PA
17604-3079
When seeking information on the boiler,
COMPANY
by
ULC and found
in
Series Boilers.
ULC
.Phone No
the
labeled
is
the
by
-
up
-
IMPORTANT INFORMATION
PLEASE READ THIS PAGE CAREFULLY
1.
READ THIS MANUAL AND BURNER INSTALLATION MANUAL CAREFULLY BEFORE INSTALL
ING, OPERATING, OR SERVICING THIS UNIT.
ED AND PACKED IN THE BURNER CARTON.
BURNHAM AND ASK FOR APPROPRIATE BURNER MANUAL.
TO
BLE CONDITION AND POSTED NEAR HEATING UNIT FOR REFERENCE BY OWNER AND SERV
ICEMAN.
2.
ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WlTH NATIONAL, STATE AND LOCAL
PLUMBING, HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING
UTILITIES.
AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE INSTALLA
TIONS ARE MADE.
IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS:
USA BOILERS
A.
Current edition of American National Standard ANSWNFPA 31, "Installation of Oil Burning Equipment", for clearances
between boiler, vent connector and combustible material.
B. Current Edition of American National Standard
Appliances
tible materials.
C. Current Edition of American Society of Mechanical Engineers ASME CSD
ally Fired Boilers", for assembly and operations of controls and safety devices.
A. Current Edition of Canadian Standards Association CSA
mended Installation Practices.
B. The equipment shall be installed in accordance with the current installation code for gas burning appliances and equip
ment, CGA B149, and applicable provincial regulations for t%e class; which should be carefully followed in all cases. Auth
orities having jurisdiction should be consulted before installations are made.
"
, For Chimney requirements, type of venting material and clearances between vent connector pipe and combus
ANSI/NFPA 211, "Chimneys, Fireplaces, Vents, and Solid Fuel Burning
CANADA BOILERS
THE BURNER MANUAL FOR THIS UNIT IS PROVID
IF
YOU DO NOT HAVE A BURNER MANUAL, WRITE
KEEP INSTRUCTIONS IN LEGI
-
1, "Controls and Safety Devices for Automatic
B139, "Installation Code for Oil Burning Equipment", for recom
-
-
-
-
-
-
-
-
-
-
3.
ALL HEATING SYSTEMS SHOULD BE DESIGNED BY COMPETENT CONTRACTORS AND ONLY PER
SONS KNOWLEDGEABLE IN THE LAYOUT AND INSTALLATION OF HYDRONIC HEATING SYS
TEMS SHOULD ATTEMPT INSTALLATION OF ANY BOILER.
4.
THE BOILER MUST BE PROPERLY VENTED IN ACCORDANCE WITH NATIONAL AND LOCAL
CODES. SERIOUS PROPERTY DAMAGE COULD RESULT IF THE BOILER IS NOT PROPERLY
VENTED.
5.
READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESS
ORY DEVICES.
THESE ACCESSORY DEVICES MIJST BE INSTALLED AND USED ACCORDING TO
THE RECOMMENDATIONS OF THE MANUFACTURER.
6.
IT IS THE RESPONSIBLJTY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS
ARE CORRECTLY INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION IS
COMPLETED.
7. DO NOT TAMPER WITH THE UNIT OR CONTROLS. RETAIN A COMPETENT SERVICEMAN TO
SURE THAT THE UNIT
8.
FOR OPTIMUM PERFORMANCE FROM THIS UNIT FOLLOW SERVICE INSTRUCTIONS
IS
PROPERLY ADJUSTED AND MAINTAINED.
AS
SPECIFI
ED IN SECTION V OF THIS MANUAL.
9.
PROBE AND FLOAT TYPE LOW WATER CUTOFF DEVICES REQUIRE ANNUAL INSPECTION AND
299
MAINTENANCE. REFER TO INSTRUCTIONS ON PAGE
ITEM 4 FOR STEP BY STEP IN
SPECTION AND CLEANING INSTRUCTIONS.
10.
ALL FLAMMABLE DEBRES, 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.
-
-
-
A$-
-
-
HIGH WATER TEMPERATURES INCREASE THE RISK OF BURNS OR SCALDING INJURY. INSTALL AN
AUTOMATIC MIXING VALVE AT THE
TANKLESS HEATER OUTLET TO AVOID EXCESSIVELY
HOT
WATER AT THE FIXTURES.
TABLE
OF CONTENTS
SECTION I - GENERAL INFORMATION
SECTION
SECTION
SECTION
SECTION
SECTION
PI
--CAST IRON BLOCK ASSEMBLY
111
-
INSTALLATION INSTRUCTIONS
IV
-
OPERATING INSTRUCTIONS
V
--
SERVICE INSTRUCTIONS
VI
-
REPAIR PARTS
SECTION
.............................................................................
I
GENERAL INFORMATlON
........................................................
............................................
........................................
..............................................
........................................................
SAFETY/RELIEF
VALVE
Page
Page
Page
Page
Page
Page
4
7
12
24
27
29
+DOES NOT INCLUDE BURNER MOUNTING PLATE.
ADO
45
LBS.
FOR
M
O
U
N
T
I
NG PLA
T
E
(SHIPPED
L
PRESSURE
DOOR MOUNT I NG
RELIEF
ASSEMBLY
LEFT
SIDE
vlmy
SEPARATELY
BURNER
PLATE
-3"
TAPPING
(TYPICAL ALL
S
U
P
PLI
E
S
).
GAUGE
RATING
PLATE
-
-
PRESSURETROL
(STEAM ONLY)
PERMISSIBLE
)
BURNER
DETAIL
t
-im
in
a
COCK
RIGHT SIDE VIEW
CAST IRON
SECT l ONS
Fig.
1
.
l
)
GHT
I
WATER
BOILER
(LBS.
WE
W/
I
)
S
N
O
LL
FULL
WATER
RATINGS
-
I
TABLE
A
G
CONTENT
(
NG
I
FT.)
HEAT
SURFACE
(SQ.
T
U
P
N
I
BURNER
CO',
12.5%
.lo" water column pressure at boiler
+
£301 ler ratings are based on
flue outlet.
MAXIMUM ALLOWABLE WORKING PRESSURE:
(3)
-
"W"
,
"G"
x
l
PSI
45
15 PSI
-
-
WATER
PSI
70
-
PSI
15 PSI STEAM
50
-
-
(USA) (CANADA)
STEAM
WATER
OPTIONAL SPECIAL ORDER
cated,
I
nd
i
feet on
2000
feet above sea leve
1000
tudes above those
i
t
l
feet on oil and
1000
for each
4%
the ratings should be reduced at the rate
gas. For a
up to
-
of
Ratings shown above apply at altitudes
BTU
based
is
140,000
GPH
RATING
I=B=R
NET
indicates oil
Suf f
.
"0"
ler
i
fired,
-
indicates steam boi ler
indicates comblnat ion gas-
"
'5**
Suffix
)
(I
GO
"
indicates gas
indicates water bo
fired,
oil fired.
net ratings shown are based on
I=B=R
(2)
piping and pickup allowances which vary
for water.
from 1.333 to 1.315 for steam and 1.15
burner capacity in
on.
l
I=B=R
ments, such as intermittent system oper-
Consult manufacturer for installations
having unusual piping and pickup require
at ion, extensive piping systems, etc.
per gal
The
on oil having a heat value of
@INSPECT SHIPMENT carefully for any signs of damage.
A. ALL EQUIPMENT is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery of
crated Boiler to the carrier in good condition.
B.
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.
A. PROVIDE
so
as
CLEARANCE -Locate the unit in the boiler room
to
provide
ease
of venting and adequate clearance for
maintenance, serviceability, and installation of piping.
-
FRONT
Provide 48" service clearance for removal, main
tenance, and servicing or burner and controls.
REAR
-
jacket of 36
Provide a minimum clearance from the boiler
"
for access to pressure relief door, flame ob
servation, port and flue damper.
LEFT SIDE
boiler jacket of 35
-
Provide a minimum clearance from the
"
for installation and removal of the
tankless heaters and for cleaning of flueways.
RIGHT SIDE
boiler jacket of
TOP
-
Refer to Figure
B.
For
minimum
C.
PROVIDE ADEQUATE FOUNDATION for the unit.
1.
CAUTION
PETING.
-
Provide a minimum clearance from the
9.
F'rovide a minimum
1
for boiler dimensional data.
clearances
to
-
DO NOT INSTALL BOILER ON CAR
Boiler is suitable for installation on com
clearance
from the boilerpcket of 21".
combustible materials,
See
Figure
Ik
bustible floors.
2. Floor construction should have adequate load bear
ing characteristics to bear the weight of the boiler
filled with water (see Table
1).
A boiler foundation
similar to the one shown in Figure 2 is recommended
if the boiler room floor is weak or uneven or if a wa
ter condition exists.
"r
1.
Where communicating by means of vertical ducts, each
opening shall have a free area of not less than
per 4,000 Btuh (35 sq in. per
(
CONTINUED
)
1
sq in.
gph) (5.5 cm2 per kw) of
total input rating of all appliances in the enclosure.
2. If horizontal ducts are used, each opening shall have
free area of not less than 1 sq in per 2,000 Btuh
gph.) (11 cm2 per kw) of total input of all appli
in per
(70
a
sq.
-
ances in the enclosure.
@
CHIMNEY OR VENT
V-9
The
Series boiler is designed for forced draft firing and
may be used with a conventional natural draft stack or a stub
vent, sometimes called a diesel stack (see Figure 3). See Table
1
for the proper vent size. 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
"
-
pressure in the vent connector box during burner operation.
Figure
1A
damper which should be adjusted to maintain a positive 0.1
WC.
-
-
-
-
Boiler Above Fronk nector Rear Sides
A
B
C
Chimney
Con
-
D
E
@
PROVIDE AIR SUPPLY
Am
vENTILATIoN to accom
modate proper combustion.
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
hr.
(35 sq. in. per gal. per hr.) (5.5 cm2per kw.) of total input
rating of the burner or burners and in no case less than 35
sq. in. (0.425 m
2
).
1
sq. in. per 4,000 Btu per
For boiler rooms not adjacent to outside walls, the com
bustion air shall be supplied in a manner acceptable to the
authority having jurisdiction.
A. In the absence of local requirements, the confined 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 communi
cate with the outdoors.
-
1:
NOTE
Standard
ment.
NOTE
clearances from combustible material as listed above. Listed
clearances can not be reduced for alcove or closet installations.
NOTE
protection must
NFPA 31
Listed clearances comply with American National
ANSIINFPA 31, Installation
2:
V-9
Series boilers can be installed in rooms with
3:
For reduced clearances to combustible material,
be
standard.
provided as described
of
oil burning equip
in
the above ANSI/
-
-
-
6
U8.2 STEEL CHANNEL
-
h-2
NOTE: IF THE BOILER ROOM FLOOR IS WEAK OR UNEVEN
EJL0iz6H'?MFL"fR"1T;:NT5":"01t
IS
RECOMMENDED.
~%'G~RSE~
Fig.
2
SECTION
@
FACTORY ASSEMBLED SECTIONS - If the boil
9
SECT.
I1
CAST
er was ordered with factory assembled sections, the assem
blage should be set in the proper location as outlined in
'Section
Figure
1.
Lifting arrangement and weights are given in
4.
The tie-rod nuts should then be loosened until finger
tight. Now proceed to part
"
HYDROSTATIC TEST.
3
of this section on page 12,
"
FIELD ASSEMBLED SECTIONS - If the boiler
was ordered to be field assembled, follow the assembly
procedure outlined on the following pages.
-
A. Assembly of Sections (Manual Draw
Up)
WHEN ASSEMBLING SECTIONS WITHOUT HY
DRAULIC DRAW-UP EQUIPMENT, NEVER AS
SEMBLE MORE THAN ONE 'SECTION AT A
TIME.
IR
-
-
-
-
1
TYPICAL
FOR
N
BLOCK ASSEMBLY
IMPORTANT
-
AS DIRECTED TO INSURE TIGHT JOINTS.
MOST NIPPLE LEAKS ARE CAUSED
ED OR COCKED NIPPLES.
6. IMPORTANT
-
FIRED BOILER AND SEALANT MUST BE AP
PLIED WHERE SPECIFIED FOR PROPER AND
SAFE PERFORMANCE. THE
PORATION HAS APPROVED A SECTION
JOINT SEALANT
ED BY DOW-CORNING UNDER THE PRODUCT
NUMBERS OF 732-RTV, 732-BLll AND 781. ALL
THREE NUMBERS ARE THE SAME MATER
IAL.
ARRANGEMENT
STUB
VENT
Fig.
3
NIPPLES MUST
BE
BY
DRIVEN
TILT
THIS IS A FORCED DRAFT
BURNHAM COR
(SILASTIC) MANUFACTUR
WUYWR
SECTIONS
4
SECT
LENOTH
-
-
-
-
-
A
"
Manual Draw-Up Kit" is available through Burn
ham
by
ordering part num'ber 6082901.
1.
Place the rear section in its approximate final posi-
tion,
as
suitable prop. 'See Figure
outlined in 'Section 1, and support it with a
5.
903 ONLY - Open target wall carton, apply silastic
to back of target wall and secure target wall to rear
section.
2.
Open the Boiler Assembly Carton (s)
3.
Clean nipples and nipple ports thoroughly
.
degreasing solvent and apply nipple lubricant pro
vided.
4.
Drive nipples squarely into section using block of
wood and hammer, or preferably an aluminum
headed hammer, if available.
5.
A special nipple setting gauge is provided for the
nipples.
Gauge nipple in both directions to insure
that it is driven to the proper depth into the nipple
opening. Cut
-
out in gauge must rest on nipple, with
legs of gauge touching finished face of section,
when nipple is properly driven. See Figure 6.
with
-
Fig.
4
LIFTING INSTRUCTIONS
a
-
The grooves in the gound joint along the edge
the section should be cleaned with a wire brush.
Then using a cartridge of sealant in a caulking gun,
apply
Y4"
bead of Silastic to one side of each joint
to be mated. Touch up any missed spots before
-
up. Touch-up after draw-up has no value. See
draw
Figure
All sections must be drawn-up iron-to-iron at all
three nipple ports.
7.
of
SECTION'S MUST BE DRAWN
WITHIN FOUR HOURS OF THE TIME WHEN
SILASTIC IS FIRST APPLIED. SILASTIC
CURES IN FOUR HOURS AND WILL NOT
FLOW INTO SEAL GROOVES AFTER FOUR
HOURS FROM APPLICATION, REGARDLESS
OF THE PRESSURE APPLIED.
Tie bolts must be applied immediately after
up. If any joint springs apart it must be re-drawn
tight within four hours of the time of application
of the 'Silastic to that joint.
On long boiler assemblies, it may be necessary to
draw
-
up a partial block if the entire boiler is not
ready to be drawn
first application of Silastic. If the block assembly
time extends overnight, the partial block completed
must be drawn
overnight. If a joint springs out, it must be re
drawn tight within four hours of first application
of Silastic to the joint.
7.
From arrangement of sections chart (see Figure
select next section according to code letters on sec
tion.
IMPORTANT
BLED IN PROPER ORDER.
-
up tight within four hours of the
-
up tight before leaving the boiler
-
SECTIONS MUST BE ASSEM
-
UP TIGHT
draw-
8)
-
-
-
SETTING
OF
Fig.
NIPPLES
6
Clean nipple ports and place section on nipples in
rear section. To facilitate assembly, it is advisable
to enter the upper nipple first in its port, then enter
the lower nipples in their respective ports.
8.
Insert the three
ports in the intermediate section extending them
through the tapped holes in the rear section.
CA.UTION: Care must be exercised to avoid applying
pressure directly on threaded tappings on front and
rear sections with Draw
bly procedures.
Refer to figs.
channel block during assembly procedures.
Place a
upper draw
on each end of the lower draw
nuts and washers. These items are all located in the
Draw
9.
Drive
striking blows as squarely as possible over nipples.
3
"
-
Up Kit. See Figures 9 and 10.
section in place with a heavy block of wood,
%"
draw-up rods through the nipple
-
up channels during assem
9
and 10 for proper placement of
x
12
"
Ig. steel channel on each end of the
-
up rod and an
3
"
x
8%"
1g. steel channel
-
up rods along with
-
APPLICATION
Fig.
OF
7
SEAM
V9
SECTION ARRANGEMENT
F - FRONT SECTION w/3"TOP SUPPLY TAPPING
C
-
CENTER SECTION
CT
-
CENTER SECTION w/HEATER OPENING
CX
-
CENTER SECTION w/3"TOP SUPPLY TAPPING
B
-
BACK SECTION w/3" TOP SUPPLY TAPPING
10. DRAW
tightening each draw
that sections are equally spaced, starting with
UP
SECTION SLOWLY AND EVENLY,
-
up rod a little at a time so
low-
draw-up rods.
KEEP NIPPLES A'LIGNED WITH NIPPLE
PORTS. If necessary, tap nipples lightly with
a
!blunt tool or rod to keep nipples from cocking while
-
section are being drawn
SECTION WHEN NIPPLES ARE COCKED. Con
up. DO NOT DRAW UP
tinue tightening draw-up rods equally, periodically
bumping the section with the heavy block of wood
to relieve tension on
meet iron
-to-
11. KEEP DRAW
iron on the ground surfaces.
the draw-up rods, until sections
-
UP ROD THREADS, NUTS AND
WASHERS LUBRICATED with grease or heavy
oil to prevent damage to rods and threads and to
make assembling easier.
12. CONTINUE ASSEMBLING SECTIONS IN
THEIR RESPECTIVE ORDER.
Fig.
8
1.
FOR BOILERS LESS TANKLESS HEATER, REPLACE THE "CT" SECTIONS
NOTES:
WlTH
"C"
2.
3.
SECTIONS.
THE SECTIONS MUST
SHOWN TO INSURE PROPER OPERATION AND ALIGNMENT OF PIPING
WlTH JACKET KNOCKOUTS.
WATER BOILER ONLY. REPLACE "CX" SECTION WlTH
BE
ASSEMBLED ACCORDING TO THE ARRANGEMENT
"C"
SECTION
Be sure to apply the sealant to the groove joints
between adjacent sections as the boiler operates
with a positive pressure in the firebox and products
of combustion will escape between sections unless
the sections are properly sealed. The sealant should
be applied before each section is placed on the
as-
sem'blage.
CHANNEL BLOCK IN POSITION
Fig.
9
a. Locate
Boiler Assembly Carton
b.
Locate the Tie-Rod Bundle.
c. Insert tie
V-911
rods must be assembled with tie-rod couplings to
achieve the proper length tie
the coupling is too large to fit through the lugs
on the sections, insert the (2) tie
the lugs before joining with the coupling.
d.
Place a %"-11 hex nut and washer on
of
e. Remove draw-up rods from the section assem
blage.
f. Excess length of tie
they will not extend beyond front and rear
sections. Rods should project equally at each end
to insure proper fit of the jacket.
See Figure
blage. Illustration shows 'boiler equipped with
sections for built
(8)
%"-I1 hex nuts and washers in the
(s)
.
-
rods through lugs on sections. On the
and the V-912, (2) different length tie
-
rod assembly. Since
-
rods through
the tie-rods and
11
turn
until finger tight.
-
rods must be sawed off so
for complete boiler section assem
-
in water heaters.
each
end
-
-
-
13.
After all sections have been drawn up, but before
removing draw
stalled.
-
up rods, the tie-rods must be in
14. If any joint springs apart it must be redrawn with
in four hours of the time of application of the Sil-
astic to that joint.
-
15. Now proceed to part
'%HYDROSTATIC TEST.
3
of this section on page
"
-
12,
SECTION
Fig.
ASSEMBLAGE
11
B. Assembly of Sections (Hydraulic Draw-Up)
The entire assemblage may be drawn up at one time
using hydraulic draw
eration is completed within four hours after applica
tion of the sealant.
"
Hydraulic Draw-Up Equipment" is available through
Burnham by ordering part number 6196008.
1.
Repeat steps 1 through 7 under "Assembly of Sec
tions (Manual Draw-Up)
2. Continue assembling sections in their respective or
der until all sections are in the assemblage. Be sure
to apply the sealant to the groove in the ground
joints 'between adjacent sections as the boiler op
erates with a positive pressure in the firebox and
products of combustion will escape between sections
unless the sections
should be applied before each section is placed on
the assemblage.
%"
3. Use
the sections (extra rods and couplings are provided
with hydraulic draw
CA-UTION: Care must be exercised to avoid applying
pressure directly on threaded tappings on front and
rear sections with Draw
bly procedures.
diameter rod (s) and coupling(s) to draw-up
-
up equipment providing the op
."
are properly sealed. The sealant
-
up equipment).
-
up channels during assem
Refer to figs. 9 and 10 for proper placement of
-
-
-
-
-
-
channel block during assembly procedures.
4.
Use two
rod, which is inserted through the upper tappings
and nipple ports. See Figure 12.
5.
Use four
rods, which are inserted through the lower tappings
and nipple ports.
6.
Use hydraulic rams to draw up sections by applying
pressure alternately on the draw
to draw
ground joints.
7.
Repeat steps 13 through 15 under "Assembly of Sec
tions (Manual Draw
12
"
lg. steel channel blocks for the upper
8%"
lg. steel channel blocks for the lower
-
up rods. Continue
-
up until all sections make contact at the
-
Up) ."
-
"HEX
T
-
6
3"
R
X
NUT
E
Q
8l/2"
'D.
LG.
a.
s-
STEE
3"
X
8%''
S
T
E
E
L
CHANNEL^
BLOCK
LL
LVI*J
.L CHANNEL BLOCK
/'
LONG
7
/
-/
ROD
CLAMP
-
PUMP AND
RAM
SET
HYDRAULIC DRAW-UP
Fig.
12
OF
SECTIONS
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