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Burnham operating and, Installation, Operating And Service Instructions

Burnham Operating and Service Instructions is a comprehensive manual designed to assist users with the installation, operation, and maintenance of their Burnham products. Easily downloadable for free at manualshive.com, this invaluable resource provides step-by-step guidance and troubleshooting tips to ensure optimal performance and longevity of your Burnham equipment.

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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

TABLE OF CONTENTS

Summary of Contents for operating and

Page 1: ...r o e c i v r e s r o F l e b a L g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b r e b m u N l e d o M r e l i o B r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I A _ _ 9 V _ _ _ _ _ _ _ _ 6 r o t c a r t n o C g n i t a e H l e u F f o e p y T s s e r d d A r e b m u N e n o h P 8142958R20 2 13 Price 5 00...

Page 2: ...2 ...

Page 3: ...mmended 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 ...

Page 4: ...on III of this manual for details This boiler is suitable for installation on combustible flooring Do not install boiler on carpeting Do not operate on floors 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 preferabl...

Page 5: ... safely and will contribute toward maintaining the boiler s efficiency 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 bo...

Page 6: ...ers 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 ...

Page 7: ...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 ...

Page 8: ...8 Section I General Information Figure 1 Dimensional Information ...

Page 9: ...n w Assembled Sections P Packaged F Packaged and Firetested Trim Suffix S Steam Boiler W Water Boiler Fuel Suffix N Natural Gas P LP Gas O Oil C Natural Gas Oil D LP Gas Oil M Less Burner Burner Suffix 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...

Page 10: ...ommended clearance for service may be reduced to minimum clearance to combustible material However increased service and maintenance difficulty will result WARNING Boilerissuitableforinstallationoncombustible floor Do not install boiler on carpeting Floor construction should have adequate load bearing characteristics to bear the weight of the boiler filled with water see Table 1 A boiler foundatio...

Page 11: ...hall 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...

Page 12: ...itive pressure Gas tight vent systems designed for pressure systems must be used to prevent flue 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 fire operation see breeching pressure sensing por...

Page 13: ... pipe at breeching and operate boiler This will determine if excessive down draft blocked or restricted flue etc is causing the problem 2 If using type shown in A above be sure cap is raised sufficiently above main pipe to allow flue 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 fluctuations in bac...

Page 14: ...Back Section Figure 4 Lifting Instruction 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 s...

Page 15: ...ve 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 afterproperlyapplyingsealantforbestresults 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 se...

Page 16: ...t to the 7 port and proceeding to the lower left lower right and finishing 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 s...

Page 17: ...sembly 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 t...

Page 18: ...must be installed Figure 10 Front and Rear Section Channel Block Positions Hydraulic Draw Up 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 9 long tie rods along with washers and nuts Continue installing the tie rods alt...

Page 19: ...ler 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 prot...

Page 20: ... 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 flue outlet damper assembly or rear outlet canopy cover to the canopy with the 5 16 flat wasters lock washers and brass nuts and tighten securely Attach the rear flue outlet damper assembly or cover to the back section with the four 4 5...

Page 21: ...21 Figure 16 Bare Boiler Assembly ...

Page 22: ... Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not clas...

Page 23: ...ue outlet damper assembly or top outlet canopy cover with 10 x 1 2 sheet metal screws B INSTALL FLUE COVER PLATES over cleanout openings on left side of boiler as shown in Figure 19 See Important Product Safety Information on Page 21 of this manual regarding refractory ceramic fiber product warning 1 Locate the cover plates carriage bolts nuts and washers in the boiler assembly carton s 2 Remove i...

Page 24: ...panel rear panel and upper tie bar panels with sheet metal screws 7 Install Jacket side Panels a Snap black thumb hole bushings into all side panel holes b Use the left side panel and right side panel usage charts to determine correct positions of side panels The three 3 digit panel identification numbers shown in the charts are also stamped along the bottom edge of each panel Refer to Figures 20 ...

Page 25: ...25 Figure 22 V9A Series Jacket Assembly Boiler Models V903A thru V912A ...

Page 26: ... ADAPTER PLATE TO BURNER MOUNTING PLATE Refer to Figures 16 and 23 ALSO REFER TO BURNER INSTALLATION MANUAL FOR INSTRUCTIONS SPECIFIC TO EACH BURNER 1 In all cases the burner adapter plate carton for the specified burner will be provided by Burnham 2 Open Adapter Plate carton and remove contents Apply four 4 small dabs of silastic on rear surface of adapter plate to temporarily hold gasket in plac...

Page 27: ...reely with its pointer directly over the index mark inside the back of the case 5 Install the steam gauge using the NPT x FPT hex bushing 6 Install the safety valve as shown in Figure 38a Safety valve must be installed in vertical position 7 For boilers with tankless heaters install the operating control in an unused tapping through one of the heater plates WARNING Safety valve discharge piping mu...

Page 28: ...h a lead lag panel lead lag controls will be shipped loose for header mounting The power can be supplied to the burner if equipped with a control panel If burner has no panel the power is supplied to the J box on the front jacket 2 SUPPLY CONNECTIONS Removal of top jacket is not required to connect the supply riser s however one may find it easier Refer to Figure 26 or 27 for water boilers and Fig...

Page 29: ...n to the front as an alternate location Some boiler sizes may require the use of additional supply and return tappings Check Figure 24 and applicable piping diagram for the boiler size you are installing WARNING Failure to properly pipe boiler may result in improper unsafe system operation and void manufacturer s warranty DO NOT improperly pipe boiler WARNING All steam and hot water pipes must hav...

Page 30: ...eat demand while the by pass diverts a portion of hot water back to the return Alternate minimum multiple boiler piping is shown in Figure 31 The blend pump will maintain constant flow through the boiler during every heat demand and provide a hot water blend back to the return f Glycol Antifreeze Solutions Many systems today use ethylene or propylene glycol antifreeze solutions as a measure for fr...

Page 31: ...31 Figure 26 V9A Series Minimum Piping Parallel Water Boiler ...

Page 32: ...32 Figure 27 V9A Series Minimum Piping Primary Secondary Water Boiler ...

Page 33: ...33 Figure 28 V9A Series Minimum Piping Details Bypass with Blend Pump Water Boiler ...

Page 34: ...34 Figure 29 V9A Series Minimum Piping Primary Secondary with Bypass Water Boiler ...

Page 35: ...35 Figure 30 Minimum Piping Details Multiple Boiler Application Primary Secondary Piping With Bypass ...

Page 36: ...36 Figure 31 Minimum Piping Details Multiple Boiler Application Parallel Piping With Blend Pump ...

Page 37: ...37 Figure 32 Minimum Piping Requirements For Gravity Return V9A Series Steam Boilers ...

Page 38: ...38 Figure 33 Typical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit ...

Page 39: ...vantageous in these applications because they provide both high temperature and tempered domestic hot water to the system eliminating the need to purge and waste water until it reaches the desired temperature In the case where the boiler is used for domestic production only and there is no space heating involved a destratification pump is utilized to provide flow within the boiler This flow acts a...

Page 40: ...In addition savings of hot water will be achieved since the user will not waste as much hot water while seeking desired water temperature 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 An electric hot water booster can also be used The mixing valve should be trapped by installing it b...

Page 41: ...kless heater quantities less than maximum allowable it is important that water heaters be centrally located in the boiler See Figure 8 for appropriate locations 3 Tankless heater pressure drop is 5 5 PSI at 7 5 GPM Boiler Model Number of V9 2 Tankless Heaters Installed 1 2 3 4 V903A 6 75 V904A 7 5 V905A 7 5 V905A 7 5 V906A 7 5 15 V908A 7 5 15 V909A 7 5 15 22 5 V910A 7 5 15 22 5 V911A 7 5 15 22 5 V...

Page 42: ...42 Figure 37b DHW Generation with Tankless Coils Storage Tank and Destratification Pump ...

Page 43: ...43 Figure 37c DHW Generation with Indirect Water Heater ...

Page 44: ...ith the National Electric Code and Local Regulations Control voltage and or 3 phase line voltage must be supplied to the burner panel box through a fused disconnect Figure 38a Steam Boiler Safety Valve Hook up Figure 38b Water Boiler Pressure Relief Valve Hook Up ...

Page 45: ...rom system Use the following procedure on a Series Loop or Multi zoned System to remove air from system when filling a Close isolation valve in boiler supply piping b Isolate all circuits by closing zone valves or balancing valves c Attach a hose to bib cock located just below isolation valve in boiler supply piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor are...

Page 46: ...ing fill RESET OPERATING CONTROL CAUTION Probe and float type low water cutoff devices require annual inspection and maintenance 4 CHECK OPERATING CONTROL on boiler equipped with tankless heaters With burner off draw hot water until burner starts then turn off hot water and check burner shutdown F BOILER AND SYSTEM CLEANING STEAM BOILER NOTICE A qualified water treatment chemical specialist should...

Page 47: ...el in boiler Turn on burner and allow boiler to steam for 10 minutes then turn off burner Draw off one quart of water from bottom gauge glass fitting and discard Draw off another quart sample and if this sample is not clear repeat the cycle of draining the boiler and return main and refilling the boiler until sample is clear f If the boiler water becomes dirty again at a later date due to addition...

Page 48: ...ed minerals and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas Both can result in reduced boiler life The accumulation of sediment can eventually isolate the water from contacting the cast iron When this happens the cast iron in that area gets extremely hot and eventually cracks The presence of free oxygen in the b...

Page 49: ...s below While service or maintenance is being done electrical power to the boiler must be off B CLEAN THE BOILER HEATING SURFACES FLUE at least once each year preferably at the end of the heating season 1 CLEAN THE VENT SYSTEM Vent system should be checked annually for a Obstructions b Accumulations of soot c Deterioration of vent pipe or vent accessories due to condensation or other reasons d Pro...

Page 50: ...l and the probe d Dismount the low water cutoff control from the probe e Unscrew the probe from the boiler tapping f Inspect that portion of the probe that is exposed to the boiler water for a scale or sediment buildup g Light deposits may be removed by wiping the probe with a damp cloth Wiping the probe with a cloth soaked in vinegar will remove more tenacious lime deposits The most stubborn depo...

Page 51: ...o vent radiator hold small cup under air vent located near top of radiator open vent until water escapes and then close 3 If much water is added to system it is advisable to heat system to a high temperature and vent again This will make less venting necessary during the winter 4 Where an expansion tank is used make sure that neither the tank nor its drain pipe is exposed to freezing temperatures ...

Page 52: ...5 Hago 5 00 x 45 P V908A 9 6 Beckett CF 1400 CF66KEE 1 N A N A 3 5 8 5 150 300 Hago 5 50 x 45 P V909A 11 6 Beckett CF 2300A CF66KG 0 N A N A 2 0 4 0 150 275 Hago 7 00 x 45 P V910A 13 2 Beckett CF 2300A CF66KG 1 N A N A 2 0 6 0 150 275 Hago 8 00 x 45 P V911A 14 8 Beckett CF 2500 CF66KP 0 N A N A 0 5 3 0 275 275 Hago L 4 50 x 45 P V912A 16 4 Beckett CF 2500 CF66KP 0 N A N A 0 5 4 0 275 275 Hago H 5 ...

Page 53: ...06A 1010 Power Flame JR30A 12 J20615 1 16 1 8 13 16 7 8 2 1 2 1 4 3 4 3 V907A 1198 Power Flame JR50A 15 J20607 1 4 1 4 1 1 2 3 2 3 5 4 5 4 V908A 1386 Power Flame JR50A 15 J20607 Closed Closed 1 1 4 1 1 4 2 7 2 7 4 4 4 4 V909A 1674 Power Flame JR50a 15 J20599 5 16 1 8 3 4 7 8 2 4 2 4 5 0 5 0 V910A 1905 Power Flame C2 G 20A 1 4 3 8 1 4 7 8 1 2 1 8 1 8 5 2 5 2 V911A 2136 Power Flame C2 G 20B 1 4 1 2 ...

Page 54: ...JB1 03 1 8 1 1 4 1 16 2 2 6 V909A 1674 Webster JB1 05 1 8 1 3 4 1 16 2 3 2 V910A 1905 Webster JB1 05 3 16 1 1 1 16 2 4 1 V911A 2136 Webster JB1 07 3 16 1 3 4 1 16 2 4 8 V912A 2367 Webster JB1 07 3 16 1 3 4 1 16 2 4 2 NOTES 1 Straight oil burner drawer assembly is 420007 with direct spark ignition straight gas drawer assembly is 420005 and gas oil drawer assembly is 420010 with proven gas pilot For...

Page 55: ...x 60 P V908A 9 6 Carlin 702CRD 10 Std 3 4 N A 1 2 Open 100 300 Hago 5 50 x 60 P V909A 11 6 Carlin 801CRD 10 Std 1 4 N A 1 4 Open 150 150 Hago L 5 50 x 45 H H 4 00 x 45 H V910A 13 2 Carlin 801CRD 10 Std 9 16 N A 1 4 Open 150 150 Hago L 6 50 x 45 H H 4 50 x 45 H V911A 14 8 Carlin 801CRD 10 Std 3 4 N A 1 2 Open 150 150 Hago L 6 00 x 45 H H 6 00 x 45 H V912A 16 4 Carlin 801CRD 10 Std 3 4 N A 1 2 Open ...

Page 56: ...56 SECTION VII REPAIR PARTS Continued Figure 39 V9A Series Jacket Assembly Boiler Models V903A thru V912A ...

Page 57: ...4 I Jacket Lower Tie Bar Panel Assy V911A 2 60429118 4J Jacket Lower Tie Bar Panel Assy V912A 2 60429128 5 Jacket Top Panel Assemblies 5A Jacket Top Panel Assembly V903A 1 604290331 5B Jacket Top Panel Assembly V904A 1 604290431 5C Jacket Top Panel Assembly V905A 1 604290531 5D Jacket Top Panel Assembly V906A 1 604290631 5E Jacket Top Panel Assembly V907A 1 604290731 5F Jacket Top Panel Assembly V...

Page 58: ...58 Figure 40 Bare Boiler Assembly ...

Page 59: ...Tankless Heater Assembly Includes gasket mounting hdwe One Required for each CT Section 6032901 OR 60429048 12B Blank Heater Cover Plate One Required for each CT Section 7036020 13 Tankless Heater Cover Plate Mounting Hardware 3 8 17 7 8 Lg Eight Required for each CT Section 80361337 Cap Screw SA 307B ASME Code Mat l 14 Canopy Assemblies 1 6112903001 1 6112904001 1 6112905001 1 6112906001 1 611290...

Page 60: ...8026032 Observation Port Inner Gasket 1 1 1 1 1 1 1 1 1 1 8206002 26 8 Extended Burner Mounting Plate Insulation 1 1 1 8202905 OR 4 Standard Burner Mounting Plate Insulation 1 1 1 1 1 1 1 1 8202904 27 3 16 Dia Rope Gasket 1 1 1 1 1 1 1 1 1 1 72026021 28 Burner Adapter Plate Assembly w Gasket and Hardware Beckett CF BAP No 920 4 3 4 Dia Hole 1 1 1 602292201 Beckett CF BAP No 921 6 1 8 Dia Hole 1 1 ...

Page 61: ...1 806603010 Pkgd Boiler 2 2 2 806603010 Plug Extra Tappings Pipe Plug NPT Countersunk Black 1 1 1 806603504 Pipe Plug 1 NPT Countersunk Black 1 1 1 806603517 Pipe Plug NPT Square Head Black 2 2 2 806603512 Pipe Plug 1 NPT Square Head Black 4 3 3 806603501 Lowest Permissible Water Level Plate Form No 1203 1 1 1 81460009 WATER TRIM V903A V907A V908A V909A V910A V912A PART NO Aquastat Controller Hone...

Page 62: ...62 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 63: ...63 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 64: ...64 ...

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