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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
V9ASERIES BOILER
3050579
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number Boiler Serial Number Installation Date
_V9_ _ A 6_ _ _ _ _ _ _
Heating Contractor Type of Fuel
Address Phone Number
Commercial Boilers
www.burnhamcommercialcastiron.com
842958R 9-2/
Price - $5.00
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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, “
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DANGER DO NOT store or use gasoline or other flammable 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 b
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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 wate
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TABLE OF CONTENTS SECTION I - GENERAL INFORMATION Dimensional Information ............................................................................................................................................... 8 Ratings/Data .................................................................................................................................................................. 9 Locating the Unit . ............................................................................
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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) ...................................................................
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8 SECTION I - GENERAL INFORMATION Figure : Dimensional Information
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Table I: Boiler Ratings / Data () (2) () (4) Heating I=B=R Water Content Boiler Weight I=B=R New Pressure I=B=R Net I=B=R Rating Surface Burner Input (Gal.) w/Water (Lbs.) Boiler Horse- Gross Firebox in Firebox Vent (Sq. Ft.) Model Power Output Volume (In. Wtr. Dia. Sq. Ft. MBH MBH Oil Gas (MBH) (Cu. Ft.) Clmn.) (In.) Steam Water Steam Water Steam Water Steam Steam Water (GPH) (MBH) V90A 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
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SECTION I - GENERAL INFORMATION (Continued) 2. FOR MINIMUM CLEARANCES to combustible A. INSPECT SHIPMENT carefully for any signs of materials, See Table II. damage. 3. PROVIDE ADEQUATE FOUNDATION for the 1. ALL EQUIPMENT is carefully manufactured, unit. Refer to Figure 2. inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good Table II: Minimum Clearances To Combustible condition. Materials (Inches) 2. ANY CLAIMS for damage or shorta
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Figure 2: Boiler Foundation less than 1 sq. inch per 4,000 Btuh (35 sq. inch WARNING 2 per gph) (5.5 cm per kw) of total input rating of all appliances in the enclosure. Failure to supply adequate air to the boiler will b. If horizontal ducts are used, each opening shall result in unsafe boiler operation. have a free area of not less than 1 sq. inch 2 per 2,000 Btuh (70 sq. inch per gph.) (11 cm C. PROVIDE AIR SUPPLY AND VENTILATION to per kw) of total input of all appliances in the acc
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WARNING When a V9A gas fired 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 UL 8, must be used (for example, Van-Packer model CS, Protech Model FasNSeal / FasNSeal W2, Heatfab Saf-T-Vent or equivalent). When a V9A oil fired or combination gas/oil fired boiler is connected to a venting system that is designed so that it will operate un- Fi
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A B C TEE TYPE “A” CAP RAIN CAP RIGHT RIGHT RIGHT D E 90° ELBOW UP or DOWN WRONG 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. FAULTY BOILER BURNER OPERATION 1. If improper vent is suspected, remove 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
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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 field
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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 t
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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 m. DRAW UP SECTION SLOWLY AND to be assembled and place on nipples previously EVENLY using an alternating pattern starting installed in rear section. To facilitate assembly, with the upper right lug (closest to the 7” port) it is advisable to enter the upper nipple first in and proceeding to the lower left , low
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p. EXCESS LENGTH OF DRAW-UP RODS must not extend beyond front and rear section to ensure proper fit of jacket, adjust accordingly. q. After all sections have been drawn up, the draw-up rod nuts should be loosened until finger tight and then tightened ½ turn with a wrench. 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 opera
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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 befo
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Figure 2: Hydraulic Draw-Up Sections 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
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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 sur
