Burnham V9A manuale d’uso

1 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S S E I R E S A 9 V R E L I O B n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o b o t s r i a p e r 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 [...]

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3 IMPORT ANT INFORMA TION - READ CAREFULL Y 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 fr om this instruction manual. Authorities having jurisdiction should be consulted before installations ar [...]

4 DANGER DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance. W ARNING Improper installa tion, 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 de[...]

5 W ARNING 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 [...]

6 SECTION I - GENERAL INFORMA TION Dimensional Information ............................................................................................................................................... 8 Ratings/Data ....................................................................................................................................[...]

7 T ABLE OF CONTENTS - CONTINUED SECTION VI - BURNER SPECIFICA TIONS Beckett Burners (T able V) ............................................................................................................................................ 52 Power Flame Burners (T able VI) ..............................................................................[...]

8 SECTION I - GENERAL INFORMA TION Figure 1: Dimensional Information[...]

9 T able I: Boiler Ratings / Data (1) (2) (3) (4) Boiler Model Horse- Power I=B=R Gross Output (MBH) Net I=B=R Rating I=B=R Burner Input Heating Surface (Sq. Ft.) New Firebox V olume (Cu. Ft.) Pressure in Firebox (In. Wtr . Clmn.) W ater Content (Gal.) Boiler Weight w/W ater (Lbs.) I=B=R V ent Dia. (In.) Sq. Ft. Steam MBH Steam MBH W ater Oil (GPH)[...]

10 SECTION I - GENERAL INFORMA TION (Continued) A. IN SP E CT SH I PM EN T c a re f ul ly fo r an y s ig n s 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 immediate[...]

1 1 W ARNING Failure to supply adequate air to the boiler will result in unsafe boiler operation. C. PROVIDE AIR SUPPL Y AND VENTILA TION 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 ad[...]

12 W ARNING 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 app roved for posi tive pre ssure appli catio n per UL 17 38 , mu st be use d (f or ex am pl e, V an -Pa ck er mod el CS, Prot ech Mode l Fas NSea l / FasN Sea l W2, He[...]

13 D C A B E RAIN CAP RIGHT “A” CAP RIGHT TEE TYPE RIGHT WRONG WRONG 90° ELBOW UP or DOWN 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. F AUL TY BOILER BURNER OPERA TION 1. If improper vent is suspected, remove pipe a[...]

14 SECTION II - CAST IRON BLOCK ASSEMBL Y A. F ACTOR Y 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, “HYDROST A TIC TEST”. CAUTION Boile[...]

15 W ARNING 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 [...]

16 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. T o 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 (crowba[...]

17 W ARNING When tightening the draw-up nuts, DO NOT EXCEED 150 FT -LB OF T ORQUE. If the maximum torque limit has been reached and a gap greater than .025” still exists between the sections, consult the regional ofce. KEEP NIPPLES ALIGNED WITH NIPPLE POR TS. If necessary , tap edge of nipples lightly with a blunt tool or rod to keep nipples f[...]

18 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 thre[...]

19 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 W A TER 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 th[...]

20 SECTION III - INST ALLA TION INSTRUCTIONS A. INST ALL CANOPY/FLUE OUTLET ASSEMBL Y , 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[...]

21 Figure 16: Bare Boiler Assembly[...]

22 Important Produc t Safety Informati on Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a kno[...]

23 Figure 17: Left Side Canopy Intermediate Bracket Figure 18: Right Side Canopy Intermediate Bracket on center section draw-up rod (hooks should face outward). Secure canopy with 5/16” at washers, lock washers and brass nuts. See Figure 17. d. Secure canopy right side bracket(s) with ¼ - 20 x 5” lg. carriage bolts. Insert head of carriage [...]

24 C. MOUNT REAR OBSER V A TION POR T COVER Refer to Figure 16. 1. With the silastic sealant, secure the 3/16” diameter rope gasket into the groove around the perimeter of the rear observation port cover . 2. Mount the rear observation port cover onto the rear section (with the word “T op” in the upright position) using the four (4) 5/16” -[...]

25 Figure 22: V9A Series Jacket Assembly (Boiler Models V903A thru V912A)[...]

26 8. Combination Label and Burnham Logo Plate were attached to jacket front panel at time of manufacture. If loose or peeling, apply pressure to reset adhesive. 9. On steam boilers, attach lowest permissible water level plate (from steam trim carton) to the front panel using sheet metal screws. 10. T ighten all sheet metal screws to complete jacke[...]

27 insulation and blast tube. If additional rope gasket is not provided with the burner , use 3/8” berglass rope rated for 2300°F (provided by others). Reinstall burner mounting plate when nished. CAUTION Failure to properly ll all gaps between the insulation and burner blast tube may result in damage to the burner . 5. For boilers with[...]

28 Figure 24: Purpose of T appings J. BURNER INST ALLA TION Refer to burner manufacturer ’ s installation manual for proper installation, fuel piping, wiring, burner adjustment, burner start-up and service instructions. Consult Section VI of this manual for burner specications and burner settings. K. P ACKAGED BOILER 1. The packaged boiler com[...]

29 Boiler Model Number of Section s Length A Width B* Height C** Approx. Center of Gravity D*** Approx. Shipping Weight LBS*** V903A 3 63-5/8 34-1/2 61 17-1/2 1478 V904A 4 69-5/8 34-1/2 61 20-1/2 1790 V905A 5 75-5/8 34-1/2 61 23-1/2 2102 V906A 6 81-5/8 34-1/2 61 27-1/2 2418 V907A 7 87-5/8 34-1/2 61 30-1/2 2734 V908A 8 93-5/8 34-1/2 61 33-1/2 3071 V[...]

30 i. If minimum return water temperature can be maintained at 135°F and temperature differential across the system is at 40°F or less, refer to Figure 26 or 27 for recommended minimum boiler piping details. ii. If minimum return water temperature cannot be maintained at 135°F or the temperature differential across the system varies, a blend pum[...]

31 Figure 26: V9A Series Minimum Piping - Parallel - Water Boiler[...]

32 Figure 27: V9A Series Minimum Piping - Primary Secondary - Water Boiler[...]

33 Figure 28: V9A Series Minimum Piping Details, Bypass with Blend Pump - Water Boiler[...]

34 Figure 29: V9A Series Minimum Piping - Primary Secondary/with Bypass - Water Boiler[...]

35 Figure 30: Minimum Piping Details - Multiple Boiler Application, Primary/Secondary Piping With Bypass[...]

36 Figure 31: Minimum Piping Details - Multiple Boiler Application, Parallel Piping With Blend Pump[...]

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

38 Figure 33: T ypical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit[...]

39 M. BOILER PIPING, DOMESTIC HOT W A TER (DHW) APPLICA TION – The V9A boiler can be used in many different piping applications to produce Domestic Hot W ater (DHW). In some applications, depending on the control strategy (outdoor reset, setpoint operation, etc.) and size of boiler , it is recommended to isolate the space heating load from the DH[...]

40 N. CONNECT T ANKLESS HEA TER PIPING as shown in Figure 37a. See T able IV for T ankless Heater Ratings. NOTICE The following guidelines should be followed when piping the tankless heater: 1. Install Flow Regulator If ow through the heater is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand. [...]

41 Figure 36: Minimum Piping Requirements for V9A T ankless Heater Manifolds Figure 37a: Schematic T ankless Heater Piping Notes: 1. Ratings are given in gallons per minute continuous ow of water heated from 40°F to 140°F with 200°F boiler water . 2. For tankless heater quantities less than maximum allowable, it is important that water heater[...]

42 Figure 37b: DHW Generation with T ankless Coils, Storage T ank and Destratication Pump[...]

43 Figure 37c: DHW Generation with Indirect W ater Heater[...]

44 O. ELECTRIC WIRING - Install all eld wiring in accordance with 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 V alve Hook-up Figure 38b: W ater Boiler - Pressure Relief V alve Hook-Up[...]

45  W ARNING If you do not follow these instructions exactly , a re or explosion may result causing property damage or personal injury . If any unusual or improper operation or site conditions are observed, turn the boiler off and[...]

46 4. ON W A TER BOILERS WITHOUT T ANKLESS HEA TERS, set high limit dial on L4006A at 210°F . This temperature may be varied to suit requirements of installation. 5. ON W A TER BOILERS WITH T ANKLESS HEA TERS, set low limit operating control dial at 190°F and high limit dial 210°F . Operating control must be a minimum of 20° below high limit se[...]

47 d. Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety . e. Rell boiler to normal water line. If water in gauge glass does not appear to be clear , repeat steps (a. thru e.), and boil out the boiler for a longer time. 2. Low pressure steam boilers such as the V9A Series should be maintained [...]

48 k. Drain the system in a manner and to a location that hot water can be discharged with safety . l. Remove plugs from all available returns and wash the water side of the boiler as thoroughly as possible, using a high-pressure water stream. m. Rell the system with fresh water . 3. Add appropriate boiler water treatment compounds as recommende[...]

49 SECTION V - SER VICE INSTRUCTIONS DANGER This boiler uses ammable gas, high voltage electricity , moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. More than one gas shut-off valve and electrical dis[...]

50 5. REASSEMBLE BOILER CAUTION Do not start the burner unless canopy , smokepipe, burner mounting plate and all ue plates are secured in place. a. If removed, install the canopy taking care to align the cerafelt strips. If strips are damaged replace as needed. b. Reinstall burner mounting plate to front section making sure 3/16” diameter rope[...]

51 and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc., and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly . Give special attention to solder joints on bellows and oat when thi[...]

52 SECTION VI - BURNER SPECIFICA TIONS NOTICE V9A boiler ratings and capacities are based upon the following burners, pump pressures, nozzle sizes and manifold pressures. Refer to instructions furnished with burner for additional information regarding proper installation, fuel piping, wiring details, burner adjustments, service instructions and bur[...]

53 Boiler Model Burner Input (GPH) Burner Mfr . Burner Model Diffuser Blade Setting Damper Settings T op / Bottom Damper Pump Pressure (PSI) Nozzle Make Nozzle Data Low Fire High Fire Low Fire High Fire GPH x Angle-T ype V904A 4.2 Power Flame C1-OS 1/8 1/4” / Closed 3/4” / 1/4” 100 270 Delavan 2.50 x 90° - B V905A 5.6 Power Flame C1-OS 1/4 C[...]

54 Boiler Model Burner Input (GPH) Burner Mfr . Burner Model Burner Settings Air Inlet Settings Pump Pressure (PSI) Nozzle Make Nozzle Data Nozzle to Diffuser Drawer Assembly Inner Fire Cylinder Low Fire High Fire Low Fire High Fire GPH x Angle-T ype V903A 3.1 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A V904A 4.2 N/A N/A N/A N/A N/A N/A N/A N/A N/A[...]

55 OIL BURNERS T able VIII: Carlin Burner Specications Boiler Model Burner Input (GPH) Burner Mfr . Burner Model Air T ube Comb. Burner Settings Pump Pressure (PSI) Nozzle Make Nozzle Data Head Air Band Air Damper Low High Low Fire High Fire V903A 3.1 Carlin 301CRD 8” - Style ‘B’ 1/4” 60% N/A N/A --- 150 Delavan 2.50 x 80° - B V904A 4.2[...]

56  [...]

57 JACKET REP AIR P ARTS (Models V903A Thru V912A) ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY P ART NO. V903A V904A V905A V906A V907A V908A V909A V910A V91 1A V912A 1 Jacket Front Panel Assembly 1 1 1 1 1 1 1 1 1 1 6042926 2 Jacket Rear Panel Assembly 1 1 1 1 1 1 1 1 1 1 6042927 3 Jacket Upper Tie Bar Panel Assemblies: 3A Jacket Upper T ie Bar Pan[...]

58 [...]

59 REP AIR P ARTS FOR BARE BOILER ASSEMBL Y ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY P ART NO. V903A V904A V905A V906A V907A V908A V909A V910A V91 1A V912A 1 Front Section 1 1 1 1 1 1 1 1 1 1 7172936 2 “C” Center Section - Steam Boiler 1 2 3 4 5 6 7 8 9 10 7172940 W ater Boiler 1 2 3 4 5 6 7 8 9 10 7172940 3 Optional - “CT” Center Sectio[...]

60 ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY P ART NO. V903A V904A V905A V906A V 907A V908A V 909A V910A V91 1A V912A 21B T op Outlet Canopy Cover , 7 & 8” Dia. Opening 1 1 1 1 1 71 12638 T op Outlet Canopy Cover , 10” Dia. Opening 1 1 1 71 12639 T op Outlet Canopy Cover , 12” Dia. Opening 1 1 71 12640 22 Burner Mounting Plate Assemblie[...]

61 STEAM TRIM / W A TER TRIM STEAM TRIM BOILER SIZE / QUANTITY P ART NO. V903A/ V904A V905A/V908A V909A/V912A Pressuretrol: Honeywell L404F1060 1 1 1 80160942 Honeywell L4079B1033 (Pkgd. Boiler) 1 1 1 80160943 Low W ater Cutoff, M&M 63M (Pkgd. Boiler Only) 1 1 1 80160509 Steam Gauge, 3½” Dia. Ametek #144350 1 1 1 8056022 Gauge Glass Set, Con[...]

62 SER VICE RECORD DA TE SER VICE PERFORMED[...]

63 SER VICE RECORD DA TE SER VICE PERFORMED[...]

64[...]