Burnham V9A User Manual
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Commercial Boilers
3050579
8142958R19-2/11
www.burnhamcommercialcastiron.com
Price - $5.00
1
2
IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be installed in accordance with National, State and Local Plumbing, Heating
and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations
may differ from this instruction manual. Authorities having jurisdiction should be consulted
before installations are made.
In all cases, reference should be made to the following Standards:
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls
and safety devices.
E. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
B. The equipment shall be installed in accordance with the current Installation Code for Gas
Burning Appliances and Equipment, CSA B149, and applicable Provincial Regulations for
the class; which should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
CAUTION
NOTICE
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating
properly when the installation is complete. The warranty for this boiler is valid only if the boiler has been
installed, maintained and operated in accordance with these instructions.
3
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other
appliance.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or
death. Read and understand all instructions, including all those contained in component manufacturers
manuals which are provided with the appliance before installing, starting-up, operating, maintaining or
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance
for reference by owner and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled
and knowledgeable installer or service agency. All heating systems should be designed by competent
contractors and only persons knowledgeable in the layout and installation of hydronic heating systems
should attempt installation of any boiler. It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly when the installation is completed. Installation
is not complete unless a pressure relief valve is installed into the specied tapping located at the rear of
appliance - See Section III of this manual for details.
This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting. Do not
operate on oors where heat affected material is below.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to
assure that the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale.
The inside of combustion chamber should also be cleaned and inspected at the same time.
Have Burner and Controls must be checked at least once a year or as may be necessitated.
Do not operate unit with jumpered or absent controls or safety devices.
Do not operate unit if any control, switch, component, or device has been subject to water.
Return water cannot be lower than 135°F for prolonged periods of time. Operation under these conditions will
result in sustained condensing within the combustion chamber and potentially reduce boiler longevity.
In addition, the return water cannot be introduced into the boiler if it is more than 40°F less than the idle
boiler temperature. Continued operation under these conditions may result in premature boiler failure
through thermal shock.
Example: A boiler that has been idle for some time since the last heat demand cycle may have it’s boiler
water temperature reduced to 150°F. The return temperature from the next zone activation cannot be
less than 110°F.
If the above conditions exist, an RTC (or similar type of control) system must be installed to protect
the boiler from sustained condensing operation and thermal shock. See separate RTC Manual, P/N
8146382.
4
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which
can cause death or serious injury and which are known to the state of California to cause cancer, birth
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when
servicing or working nearby the appliance.
This boiler contains very hot water under high pressures. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
This appliance must be properly vented and connected to an approved vent system in good condition.
Do not operate boiler with the absence of an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of the
heating season and should be inspected periodically throughout the heating season for any obstructions.
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without
service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in
cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent
damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil, natural and/or LP gas only. Do not use gasoline, crankcase
drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to
any solid fuel (i.e. wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). 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 V9A 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 V9A
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 V9A are as
follows:
MAWP, Steam - 15 psi
MAWP, Water (USA) - 80 psi
MAWP, Water (Canada) - 45 psi
It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler
MAWP. Therefore, Burnham offers safety relief valves set at or below the MAWP of the boiler. See Table 1 for
available safety relief valve set pressures.
5
TABLE OF CONTENTS
SECTION I - GENERAL INFORMATION
Dimensional Information ............................................................................................................................................... 8
Ratings/Data .................................................................................................................................................................. 9
Locating the Unit . ........................................................................................................................................................ 10
Air Supply/Venting ....................................................................................................................................................... 11
SECTION II - CAST IRON BLOCK ASSEMBLY (Knockdown Only)
Assembly of Sections, Manual Draw-up ..................................................................................................................... 14
Assembly of Sections, Hydraulic Draw-up ................................................................................................................. 17
Hydrostatic Test ........................................................................................................................................................... 18
SECTION III - INSTALLATION INSTRUCTIONS
Knockdown
Canopy ......................................................................................................................................................................... 20
Flue Cover Plates ......................................................................................................................................................... 23
Rear Observation Port Cover ........................................................................................................................................ 24
Inspect All Boiler Seals ................................................................................................................................................ 24
Jacket Assembly .......................................................................................................................................................... 24
Burner Mounting Plate / Burner Adapter Plate ........................................................................................................... 26
Steam Trim .................................................................................................................................................................. 27
Water Trim . .................................................................................................................................................................. 27
Burner Installation ....................................................................................................................................................... 28
Package Boilers
Preparation for Installation ........................................................................................................................................... 28
Common Installation Requirements
Boiler Piping - Water Heating Applications ................................................................................................................ 29
Boiler Piping - Steam Heating Applications ................................................................................................................ 30
Boiler Piping - Domestic Hot Water (DHW) Applications .......................................................................................... 39
Tankless Heater Piping ................................................................................................................................................ 40
Electric Wiring .............................................................................................................................................................. 44
SECTION IV - OPERATING INSTRUCTIONS
Filling System ............................................................................................................................................................... 45
Adjusting Controls ....................................................................................................................................................... 45
Adjusting Burner ......................................................................................................................................................... 46
Test Controls ................................................................................................................................................................ 46
Initial Cleaning, Steam Boilers .................................................................................................................................... 46
Initial Cleaning, Water Boilers ....................................................................................................................................47
Frequent Water Addition .............................................................................................................................................. 48
Oxygen Corrosion ........................................................................................................................................................ 48
SECTION V - SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces ............................................................................................................................... 49
Maintenance of Low Water Cutoff Devices ................................................................................................................ 50
Checking Burner & Controls ........................................................................................................................................ 51
Lubrication ................................................................................................................................................................... 51
General Maintenance Considerations ........................................................................................................................... 51
Attention to Boiler While Not in Operation ................................................................................................................. 51
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TABLE OF CONTENTS - CONTINUED
SECTION VI - BURNER SPECIFICATIONS
Beckett Burners (Table V) ............................................................................................................................................ 52
Power Flame Burners (Table VI) .................................................................................................................................. 53
Webster Burners (Table VII) ........................................................................................................................................54
Carlin Burners (Table VIII) .......................................................................................................................................... 55
SECTION VII - REPAIR PARTS
Customer Service Contact Information ........................................................................................................................ 55
Jacket Assembly .......................................................................................................................................................... 56
Bare Boiler Assembly ................................................................................................................................................... 58
Steam/Water Trim ......................................................................................................................................................... 61
WARRANTY ....................................................................................................................................................... REAR COVER
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8
Figure 1: Dimensional Information
SECTION I - GENERAL INFORMATION
Table I: Boiler Ratings / Data
(1) (2) (3) (4)
Boiler
Model
HorsePower
Gross
Output
(MBH)
V903A 10.3 347 1083 260 302 3.1 447 34.2 37.0 3.2 .33 44.5 66.0 1439 1618 7
V904A 14.4 483 1508 362 420 4.2 606 48.6 54.3 4.8 .38 53.0 75.0 1811 1995 7
V905A 19.3 646 2021 485 562 5.6 808 63.0 71.5 6.4 .31 61.5 84.0 2184 2372 8
V906A 24.1 808 2525 606 703 7.0 1010 77.5 88.8 7.9 .38 70.0 93.0 2557 2749 8
I=B=R
V907A
V908A 33.2 1110 3471 833 965 9.6 1386 106.3 123.3 11.0 .35 87.0 111.0 3303 3503 10
V909A 10.1 1342 4225 1014 1167 11.6 1674 120.7 140.5 12.6 .35 95.5 120.0 3676 3880 10
V910A
V911A
V912A
(1) Type of Build Prex: K = Knockdown, A = Knockdown w/Assembled Sections, P = Packaged, F = Packaged and Firetested
Trim Sufx: S = Steam Boiler, W = Water Boiler
Fuel Sufx: N = Natural Gas, P = LP Gas, O = Oil, C = Natural Gas/Oil, D = LP Gas/Oil, M - Less Burner
Burner Sufx: B = Beckett, C = Carlin, J = Power Flame JR, P = Power Flame C, W = Webster, L = Less Burner
(2) I=B=R net ratings shown are based on piping and pick-up allowances which vary from 1.333 to 1.289 for steam and 1.15 for water. Consult manufacturer for
installations having unusual piping and pick-up requirements, 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)
listed above.
(4) Boiler ratings are based on 12.5% CO2 (oil) and 9.7% CO2 (natural gas), + .10” (inches) water column pressure at boiler ue outlet. Ratings shown above apply at
altitudes up to 1000 feet on oil and 2000 feet on gas.
For altitudes above those indicated, the ratings should be reduced at the rate of 4% for each 1000 feet above sea level.
Safety (Relief) Valve Set Pressure: USA Steam Boiler - 15 PSI, USA Water Boiler - 50 PSI
Optional USA Water Boiler - 30 PSI, 80 PSI (special order)
Canadian Steam Boiler - 15 PSI, Canadian Water Boiler - 45 PSI
Optional Canadian Water Boiler - 30 PSI (special order)
28.6 959 2996 719 834 8.3 1198 91.9 106.0 9.5 .36 78.5 102.0 2930 3126 8
45.6 1528 4867 1168 1329 13.2 1905 135.1 157.8 14.2 .40 104.0 129.0 4048 4257 10
51.2 1714 5513 1323 1490 14.8 2136 149.5 175.0 15.7 .45 112.5 138.0 4421 4634 12
56.8 1900 6142 1474 1652 16.4 2367 164.0 192.3 17.3 .49 121.0 147.0 4794 5011 12
Firebox volume does not include added volume of 8” extended burner mounting plate (BMP). If 8” BMP is specied (refer to Figure 1), add 0.7 cu. ft. to volume
Net I=B=R Rating
Sq. Ft.
Steam
MBH
Steam
MBH
Water
I=B=R
Burner Input
Oil
(GPH)
(MBH)
Gas
Heating
Surface
(Sq. Ft.)
Steam Water Steam Water Steam Water
New
Firebox
Volume
(Cu. Ft.)
Pressure
in Firebox
(In. Wtr.
Clmn.)
Water Content
(Gal.)
Boiler Weight
w/Water (Lbs.)
I=B=R
Vent
Dia.
(In.)
9
SECTION I - GENERAL INFORMATION (Continued)
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 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
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.
FRONT — Provide 43” service clearance for
removal, maintenance, and servicing of burner and
controls.
REAR — Provide a minimum clearance from the
boiler jacket for access to ame observation port,
rear ue damper and vent piping, relief valve, and
boiler return piping. See Table III.
LEFT SIDE — Provide a minimum clearance from
the boiler jacket of 26” for cleaning of ueways and
installation and removal of tankless heater(s).
RIGHT SIDE — Provide a minimum clearance from
the boiler jacket of 12”.
TOP — Provide a minimum clearance from the
boiler jacket of 24”
NOTICE
Recommended clearance for service may be
reduced to minimum clearance to combustible
material. However, increased service and
maintenance difculty will result.
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.
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table II.
3. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
Table II: Minimum 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
NOTES:
1. Listed clearances comply with American
National Standard ANSI/NFPA 31, Installation of
Oil Burning Equipment.
2. V9A Series boilers can be installed in rooms with
clearances from combustible material as listed
above. Listed clearances cannot be reduced for
alcove or closet installations.
3. For reduced clearances to combustible material,
protection must be provided as described in the
above ANSI/NFPA 31 Standard.
Table III: Recommended Rear Service Clearance
Flue
Outlet
Size
7” Dia. 18” 37” 22”
8” Dia. 38” 23”
10” Dia. 40” 25”
12” Dia. 43” 28”
Top
Flue
Outlet
Combustible
Surfaces
Rear Flue Outlet
Non-Combustible
Surfaces
10
Figure 2: Boiler Foundation
WARNING
Failure to supply adequate air to the boiler will
result in unsafe boiler operation.
C. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate 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 1 sq. inch per
4,000 Btu per hr. (35 sq. inch per gallon per hour)
(5.5 cm2 per kw.) of total input rating of the burner or
burners and in no case less than 35 sq. inch (0.425m2).
For boiler rooms not adjacent to outside walls, the
combustion air shall be supplied in a manner acceptable
to the authority having jurisdiction.
1. In the absence of local requirements, the conned
space shall be provided with two permanent
openings, one in or near the top of the room and one
near the bottom. The openings shall communicate
by means of ducts, with the outdoors or to such
spaces (crawl or attic) that communicate with the
outdoors.
a. Where communicating by means of vertical
ducts, each opening shall have a free area of not
less than 1 sq. inch per 4,000 Btuh (35 sq. inch
per gph) (5.5 cm2 per kw) of total input rating of
all appliances in the enclosure.
b. If horizontal ducts are used, each opening shall
have a free area of not less than 1 sq. inch
per 2,000 Btuh (70 sq. inch per gph.) (11 cm2
per kw) of total input of all appliances in the
enclosure.
D. CHIMNEY OR VENT
NOTICE
When a V9A 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 V9A oil red or combination gas/oil
red boiler is connected to a venting system
that is designed so that it will operate under
a negative pressure, the use of Type C, L or
other manufactured vent systems designed
for negative pressure is acceptable.
Unlined masonry chimneys are not acceptable. Lined masonry chimneys are acceptable
with the appropriate vent connectors using
materials described above.
11
WARNING
When a V9A 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 V9A 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 V9A 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 Arrangement for Stub Vent
If the venting system is designed for positive or forced
draft venting, the boiler, vent connector and stack will
operate under positive pressure. Gas tight vent systems
designed for pressure systems must be used to prevent
ue by-product leakage. The vent height is usually
limited to prevent negative draft, typically three (3)
feet above the roof line (see Figure 3a). The damper
shall be adjusted to maintain a positive pressure of
0.1” W.C. in the vent connector box during burner high
re operation (see breeching pressure sensing port in
Figure 1).
If the venting system is designed for negative pressure
(natural draft), the boiler still operates with positive
pressure in the chamber and up to the xed damper on
the ue collar. However, if the venting system is larger
than what is required, the stack will provide a surplus
draft (or negative pressure) that may require the use of
a barometric damper to maintain the positive 0.1” W.C.
pressure at the ue outlet. Multiple forced draft boiler
stacks should always be designed as negative to ensure
the products of combustion do not exit a boiler that is
not ring.
WARNING
Venting instructions are recommendations only. Consult a venting expert on the design of a specic
vent system for your application. The ASHRAE Venting Guide and The National Fuel Gas Code, NFPA
54 should be considered in all venting systems.
Conventional vent material may not be suitable for the application. Flue gases can leak carbon
monoxide from the joints on these materials and can result in severe personal injury or death.
Installations having long horizontal runs or an excessive amount of tees or elbows will restrict the ow
of combustion gases and can result in condensation, ue gas leakage of carbon monoxide, resulting in
severe personal injury or death.
12
A
B
C
RAIN CAP
RIGHT
D
WRONG
VENT SIZING - Area must be the same as or greater than the boiler breeching (Smoke Outlet). A barometric damper may be required on
installations with a high draft condition.
1. If improper vent is suspected, remove pipe at breeching and operate boiler. This will determine if excessive down draft,
blocked or restricted ue, etc. is causing the problem.
2. If using type shown in A above, be sure cap is raised sufciently above main pipe to allow ue gases to vent unimpeded.
3. A popular type cap is shown in B.
4. The tee is frequently used as shown in C.
5. D and E should not be used due to possible uctuations in back pressure.
“A” CAP
RIGHT
E
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
13
SECTION II - CAST IRON BLOCK ASSEMBLY
A. FACTORY ASSEMBLED SECTIONS — If the
boiler was ordered with factory assembled sections,
the assembly should be set in the proper location as
outlined in Section I. Lifting arrangement and weights
are given in Figure 4.
1. Proceed to Paragraph C of this Section,
“HYDROSTATIC TEST”.
CAUTION
Boiler sections must be drawn-up on perfectly
level surface or improper assembly may result.
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 DRAWUP)
These sections are designed to be drawn together,
one section at a time, using the 9¾” long draw-up
rods (provided) and ordinary hand tools.
Tools required:
(1) ¾” Drive Ratchet
(1) 1-1/16” Socket
(1) 1-1/16” Combination or Open End Wrench
(1) Container of grease, oil or other appropriate
lubricant.
CAUTION
When assembling sections without 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 and wedges. See Figure 5.
Figure 4: Lifting Instruction
Figure 5: Positioning of Back Section
b. On size V903A only— Open target wall carton,
apply Silastic to back of target wall and secure
target wall to rear section.
c. Clean the groove in the ground joint along the
edge of the section with the wire brush.
d. Open the Boiler Assembly Carton(s) and remove
the bottle of adhesive. Using the dauber supplied
in the bottle, apply the adhesive to the groove.
Be sure to use enough adhesive to sufciently
coat the entire groove surface. If so desired,
a multi-purpose spray adhesive (supplied by
others) may be used instead. HOWEVER,
GREAT CARE MUST BE TAKEN TO
ENSURE THAT THE ADHESIVE DOES
NOT COME IN CONTACT WITH THE
NIPPLES OR NIPPLE PORTS.
e. While the adhesive is becoming tacky, clean
nipples and nipple ports thoroughly with a degreasing solvent. Use the Loctite #592 provided
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 the 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
number 8052601). Place block over entire
nipple edge and hit the wood with the hammer.
14
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 legs of gauge touching
nished face of section, when nipple is properly
driven. See Figure 6.
Figure 7: Afxing the Fiberglass Rope
Figure 6: Setting of Nipples
h. Remove a 96” length of berglass rope from
the assembly carton. Starting with the area
around the upper 7” nipple port, rmly press
the rope into the groove, so that the adhesive
holds it in place. (If more than 25 minutes have
passed since the adhesive was applied, it may
be necessary to reapply.) Continue to afx the
rope to the groove in this fashion around the
perimeter of the section. Make sure that the rope
does not droop or hang outside of the groove.
When the end of the groove is reached, cut off
the excess rope. Push the length of 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.
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.
i. From the “Section Arrangement” chart, select
the next section according to the “Identication
Code” at the top of the chart. See Figure 8. Use
a wire 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 silastic sealant.
Touch-up any missed spots before draw-up.
Touch-up after draw-up has no value.
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.
15
NOTES: FOR BOILERS LESS TANKLESS HEATER, REPLACE THE "CT" SECTIONS WITH "C" SECTIONS.
Figure 8: V9A Section Arrangement
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.
k. Drive sections in place with a heavy block of
wood, striking blows as squarely as possible over
nipple port.
l. The large draw-up rod lugs with dual holes
are cast in the four (4) corners of each casting.
STARTING WITH THE UPPER HOLES,
install four (4) 5/8” x 9¾” long draw-up rods
along with washers and nuts (see Figure 9).
CAUTION
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.
m. DRAW UP SECTION SLOWLY AND
EVENLY using an alternating pattern starting
with the upper right lug (closest to the 7” port)
and proceeding to the lower left , lower right
and nishing with upper left lug. When you
start, grind surfaces between adjoining sections
should be approximately 3/8” apart. Use
three (3) or four (4) passes at tightening the
four (4) draw-up rods a little at a time so that
sections are pulled up evenly. During the last
pass, pay close attention to the silastic sealant
as it squeezes when the sections come in close
contact. The silastic sealant should continue
to squeeze out wafer thin until the sections are
connected metal to metal. If the silastic has
stopped squeezing out from the connection and
the sections still do not appear to be drawn metal
to metal, use a feeler gauge to measure any gaps
at the locations identied in Figure 9. (Unless
specied otherwise, gaps should be measured at
these locations on both sides of the sections.) A
maximum gap of .025” is acceptable. Measure
gaps at the outer edge of the connection only,
making sure not to puncture the gasket created
by the silastic and rope.
16
Figure 9: Connection Inspection Locations and
Manual Draw-Up Tie Rod Pattern
WARNING
When tightening the draw-up nuts, DO NOT
EXCEED 150 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 regional ofce.
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.
n. CONTINUE ASSEMBLING SECTIONS IN
THEIR RESPECTIVE ORDER alternating
draw-up rods from the upper to lower set of
holes in draw-up lugs (see Figure 13). Be certain
that all sections are drawn up iron-to-iron at all
three (3) nipple ports.
BE SURE TO APPLY THE SEALANT to
the groove in the ground joints between
adjacent sections as the boiler operates with a
positive pressure in the rebox 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 assembly.
o. If a joint springs apart it must be redrawn tight
within four (4) hours of the time of application of
Silastic to that joint.
p. EXCESS LENGTH OF DRAW-UP RODS must
not extend beyond front and rear section to
ensure proper t of jacket, adjust accordingly.
q. After all sections have been drawn up, the
draw-up rod nuts should be loosened until
nger tight and then tightened ½ turn with a
wrench.
r. Now Proceed to Paragraph C of this Section,
Hydrostatic Test.
2. ASSEMBLY OF SECTIONS (HYDRAULIC
DRAW-UP)
The entire boiler assembly may be drawn up at one
time using hydraulic draw-up equipment providing
the operation is completed within two (2) hours after
application of the sealant.
a. Repeat steps 1a through 1k under “Field
Assembled Sections (Manual Draw-Up).”
b. Continue driving sections in place (in their
respective order) until all sections are in the
assembly. 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 boiler
joints. Failure to properly seal the boiler joints
will result in combustion gas leaks through to
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 two (2) hours
of the rst application of Silastic. If the block
assembly time extends overnight, the partial
block completed must be drawn-up tight before
leaving the boiler overnight. If a joint springs
out, it must be redrawn tight within four (4)
hours of rst application of Silastic to the joint.
c. Insert the three (3) ¾” 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 3” x 12” lg. steel channel on each end of
the upper draw-up rod and a 3” x 8½” lg. steel
channel on each end of the lower draw-up rods.
Refer to Figures 10 and 11 for proper placement
of channel block during assembly procedures.
Install nuts and washers on one end of the drawup rods and the hydraulic rams, washers and
17
draw-up rod clamps on the other. These items
are all located in the Draw-Up Kit.
See Figure 12.
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 draw-up rods
should be covered while sections are being
drawn in case rods should snap while under
tension.
• Do not operate ram against draw-up coupling.
• Do not operate pump after ram has reached
stroke limit.
Figure 11: Center Section Channel Block Position
(Partial Block Draw-Up)
The large draw-up rod lugs with dual holes cast
in the four (4) corners of each casting. Starting
with the upper holes in the back section, install
four (4) 5/8” x 9¾” 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.
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 nger tight. Then tighten them an
additional ½ turn with a wrench.
Figure 10: Front and Rear Section Channel
Block Positions (Hydraulic Draw-Up)
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.
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 9¾” long tie rods must be installed.
18
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 IV gives
the maximum number of heaters permissible per
assembly and the heater ratings.
2. Plug all boiler tappings and ll boiler completely
with cold water.
CAUTION
DO NOT install gauge until after hydrostatic
testing the boiler. Gauge failure may result.
3. All completed boilers must satisfactorily pass the
prescribed hydrostatic test.
Figure 12: Hydraulic Draw-Up Sections
Figure 13: Boiler Section Assembly
a. STEAM BOILERS: The assembled boiler must
be subjected to a hydrostatic test of 45 psig to 55
psig.
b. HOT WATER BOILERS: The assembled boiler
must 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 operation.
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.
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SECTION III - INSTALLATION INSTRUCTIONS
A. INSTALL CANOPY/FLUE OUTLET ASSEMBLY,
Refer to Figures 14, 15 and 16.
1. Open canopy carton.
2. Attach the two (2) canopy brackets to the front end
cap of canopy with four (4) #10 x 1/2” sheet metal
screws each.
3. 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 rear surface of back section. Cut off
excess.
4. Place the canopy on the sections.
5. Position rear ange (end with studs) of canopy ush
with rear surface of back section.
6. Loosely attach the canopy brackets to the lugs on
the front section of the block assembly with 5/16”
carriage bolts, at washers and locknuts.
7. Check to see if rear ange of canopy is still ush
with raised ange on back section.
8. Open either the rear ue outlet carton (standard) or
top ue outlet carton (optional).
9. 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.
10. Attach either the rear ue outlet damper assembly
or rear outlet canopy cover to the canopy with the
5/16” at wasters, lock-washers and brass
nuts and tighten securely. Attach the rear ue
outlet damper assembly or cover to the back section
with the four (4) 5/16” at washers and cap screws
and tighten securely.
11. Tighten front canopy carriage bolt until canopy is
secure.
12. On the longer canopy sizes, Intermediate Mounting
Brackets are provided, two (2) are required on sizes
V907A thru V909A and four (4) are required on
sizes V910A thru V912A. Refer to Figures 17 and
18.
a. Intermediate brackets are shipped at. Bend
side anges down approximately 90° as shown.
Adjust bends until holes in bracket match hole
pattern on canopy.
b. Secure brackets to both sides of canopy with
three (3) #10 x ½” sheet metal screws per
bracket.
c. Secure canopy left side bracket(s) with
appropriate canopy ‘J’ bolt(s). Insert threaded
20
end through holes in brackets and hook ‘J’ bolt
Figure 14: Canopy with Rear Flue Outlet Damper
Assembly (Shown on optional steel shipping skid)
Figure 15: Canopy with Top Flue Outlet Damper
(Shown on optional steel shipping skid)
Assembly (Rear Cover Removed)
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