Burnham V7 SERIES manual

1 8142711R24-7/99 Price - $3.00 INST ALLA TION, OPERA TING AND SER VICE INSTRUCTIONS FOR V7 SERIES OIL FIRED BOILER KNOCKDOWN & P ACKAGED HEA TING UNITS The ULC label or listed marking on a product is the only evidence provided by Underwriters' Laboratories of Canada to identify products which have been produced under the listing and follo[...]

2 IMPOR T ANT INFORMA TION - PLEASE READ THIS P AGE CAREFULL Y 1. THIS BOILER HAS LIMITED WARRANTIES, COPIES OF WHICH ARE PRINTED ON THE BACK COVER OF THIS MANUAL. 2. THIS BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOORING. BOILER CANNOT BE IN- STALLED ON CARPETING. 3. ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL, STATE AND LO[...]

3 TABLE OF CONTENTS I. General Information ............................. 3 II. Knockdown Boiler Assembly ............... 7 III. Installation Instructions ...................... 12 IV. Operating Instructions ........................ 21 V. Boiler Cleaning .................................. 29 VI. Repair Parts ........................................ [...]

4 Figure 1B: V73 thru V79 Water Boiler with Tankless Heater (WBT) Figure 1C: V73 thru V79 Steam Boiler with or without Tankless Heater ("SBT" or "SB")[...]

5 Figure 1E: V713 and V714 Packaged Water Boiler with Tankless Heater (WBT) Figure 1D: V713 and V714 Packaged Water Boiler Less Tankless Heater (WB) Βυ ρ ν ηαµ Bur nham[...]

6 TABLE 2: Minimum Installation Clearances To Combustible Materials (Inches) 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 file[...]

7 SECTION II: KNOCKDOWN BOILER ASSEMBL Y A. REMOVAL OF BARE BOILER FROM SKID 1. Boiler is secured to base with 4 bolts, 2 on front and 2 on rear, see Figure 2. Remove all bolts. 2. Tilt boiler to right and to rear. Using right rear leg as pivot, rotate boiler 90° in a clockwise direction, and lower left side of boiler to floor. Tilt boiler and rem[...]

8 Figure 4: Boiler Tapping Locations and Usage (Knockdown Boilers Only) P U RP OS E OF T A P P I NGS T appi n g Loc at i on Si z e St e a m Bo i l e r W a t e r Bo i l e r Non- Heat er w/ He at er Non- Heat er Fr ont Heat er R ea r Heat er A¾ " P A 4 04A P re s s u r etro l ( P r obe L W CO ) P lugg ed ( F lo at L W C O ) L 81 48A O p era t i[...]

9 Figure 5: Knockdown Boiler Jacket Assembly b. Tapping “M” —Install ¾” x 8” long nipple into ¾” tapping located next to front section top supply tapping — all boiler sizes. I. INSTALL FLUSH JACKET (See Figure 5). 1. Remove burner swing door mounting plate. Loosen the bottom bolt three full turns. Remove (5) remaining 5/16” bolts [...]

10 manner as rating label. c. On steam boilers, install the Lowest Permissible Water Level Plate, Form No. 1204 (shipped in Steam Trim Carton), on the jacket right side panel. Align the two holes in the plate with the two 1/8” dia. holes located near the front edge, in line with the lower sight glass tapping, and secure with #8 x ½” lg. sheet [...]

11 the sight glass using the two ½” tappings to the right of the probe LWCO. 5. Install float-type Low Water Cutoff, if so equipped. See Figure below. a . Install nipples and unions in Tappings D. b. Mount hardware to low water cutoff body. Install assembly. c. Install water gage glass on low water cutoff assembly's tee fittings. 6. Install[...]

12 SECTION III: INST ALLA TION INSTRUCTIONS A. REMOVE CRATE — (Packaged Boilers) 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove draft regulator box and miscellaneous trim bag containing safety/relief valve, and pipe fittings. B. REMOVAL OF BOILER FROM SKID Fig. 7[...]

13 Fig 8: V73 Thru V79 Recommended Boiler Piping For Gravity Return Steam Boiler Fig. 9: V72 thru V79, V713 and V714 Recommended Boiler Piping for Series Loop Forced Hot Water System TS-39-17-D TS-39-4-C[...]

14 There are many possible causes of oxygen contamina- tion such as: 1. Addition of excessive make-up water as a result of system leaks. 2. Absorption through open tanks and fittings. 3. Oxygen permeable materials in the distribution system. CAUTION Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and c[...]

15 TABLE 3: TANKLESS HEATER DATA: Rear Mounted Heater on Steam and Water Boilers TABLE 3A: TANKLESS HEATER DATA: Front Mounted Heater on Water Boilers WARNING Install an automatic mixing valve at the tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at the fixtures. Adjust and maintain the mixing valve in accord[...]

16 Fig. 14: Proper and Improper Locations of Draft Regulator Fig. 13: Recommended Smokepipe Arrangement and Chimney Requirements 3. For the same reasons as in (2.) above, heat extractors mounted into the breeching are not recommended. H. INSTALL ELECTRIC WIRING in accordance with National Electrical Code and local regulations. A separate ELECTRICAL[...]

17 Lift "H" (See Fig. 16) Max im u m L e ng th o f Tu bi n g "H" + "R" (See Figure 16) 3/8" O D Tubing (3 GPH) 1/2" OD Tubing (3 GPH) 0' 93' 100' 2' 85' 100' 4' 77' 100' 6' 69' 100' 8' 60' 100' 10' 52' 100' 12' 44&a[...]

18 Fig. 18: Wiring Diagram for Steam Boilers with Optional McDonnell & Miller PS-801 Probe LWCO, Beckett AFG Burner and Controls, with or without Tankless Heater Fig. 17: Wiring Diagram for Steam Boilers with Standard Hydrolevel CG-450 Probe LWCO, Beckett AFG Burner and Controls, with or without Tankless Heater BOILER SEQUENCE OF OPERATION WITH[...]

19 NOTE: The McDonnell Miller low water cut off incorporates a 10 second delay to prevent nuisance burner cut-off due to rapid water level fluctuations. The LWCO also has a time delay of 15 seconds which allows additional fill time after water touches the probe. Red LED indicates a low water condition. BOILER SEQUENCE OF OPERATION WITH FLOAT LWCO W[...]

20 Fig. 22: Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls, with Tankless Heater Fig. 21: Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls, without Tankless Heater SEQUENCE OF OPERATION A call for heat by the thermostat energizes the L8148A control which in turn energizes the R4184D primary control to tur[...]

21 SECTION IV : OPERA TING AND SER VICE INSTRUCTIONS WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be su[...]

22 F. REMOVE GUN ASSEMBLY 1. Items to be checked are nozzle size, type, and angle; head size (and setting on MD(V1)head); gun setting; and positioning of electrodes. This informations is shown in Figures 23 and 24 and Table 6 (at rear of manual). 2. Reinstall gun assembly. G. ADJUST OIL BURNER BEFORE STARTING. 1 . SET BURNER AIR BAND AND AIR SHUTTE[...]

23 5 . TURN “ OFF ” BURNER and remove pressure gauge. Install gauge port plug and tighten. Start burner again. 6 . CAD CELL LOCATION AND SERVICE The burner is supplied with a cadmium sulfide flame detector mounted at the factory, mounted on the bottom of the ignitor. See Figure 25. To service cad cell or to replace the plug in portion, swing op[...]

24 K. CHECK FOR CLEAN CUT OFF OF BURNER. 1. AIR IN THE OIL LINE between fuel unit and nozzle will compress when burner is on and will expand when burner stops, causing oil to squirt from nozzle at low pressure as burner slows down and causing nozzle to drip after burner stops. Usually cycling the burner operation about 5 to 10 times will rid oil li[...]

25 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 t[...]

26 v . When boiler has cooled down sufficiently (crown sheet of sections are not too hot to touch), close the drain cocks at boiler and in return main and feed water slowly up to normal level in boiler. Turn on oil 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 [...]

27 recommended boil out compound. iii . Replace safety relief valve. iv . Fill the entire system with water. v . Start firing the boiler. vi . Circulate the water through the entire system. vii . Vent the system, including the radiation. viii . Allow boiler water to reach operating temperature, if possible. ix . Continue to circulate the water for [...]

28 10 . START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode settings, flame shape, air or water in the fuel lines. 11 . SHUT DOWN NOISE — If the flame runs out of air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, o[...]

29 AQUASTAT SWITCHING ACTION WITHIN L8124C CONTROL The switching action within the L8124C control has three settings: 1. high limit 2. low limit 3. adjustable differential HIGH LIMIT OPERATION — - The high limit opens and turns off the burner when the water temperature reaches the set point. The high limit automatically resets after the water tem[...]

30 WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season f[...]

31 SECTION VI: REP AIR PAR TS All V7 Series Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact your Burnham Regional Sales Office as listed below. [...]

32 BARE BOILER ASSEMBLY[...]

33 Item No. Description Part No. V72 V713 V73 V714 V74 V75 V76 V77 V78 V79 BARE BOILER ASSEMBLY (See Page 32 for Illustration) 1 Front Section (Non-Htr.), Machined Water 71727019 1 --- 1 --- 111111 Front Section (Non-Htr.), Machined Water 71727015 --- 1 --- 1 --- --- --- --- --- --- 1A Front Section (Non-Htr.), Machined Steam 71727018 --- --- 1 ---[...]

34 BARE BOILER ASSEMBLY (CONTINUED)[...]

35 CON T IN UE D FR O M P A GE 33 Item No. D es cripti on P art No. V 72 V713 V 73 V 714 V 74 V 75 V 76 V 77 V 78 V 79 B A R E B O I LE R A SSE MB L Y ( See P a ge 3 4 f or Ill us t ra t ion) 1 0 F l u e C o v e r P l a t e A s s e m b l y 6 1 1 2 2 1 4 1 2 2 3 345678 1 1 H e a t e r C o v e r P l a t e G a s k e t - F r o n t H e a t e r 8 0 3 6 0[...]

36 TS-39-112-D V713 and V714 FLUSH JACKET[...]

37 Item No. Description Part No. V71 3 V714 V713 and V714 Flush Jacket Components - Items 1 thru 6 Include Insulation As Part of Assembly 1 Jacket Front P anel A s sembly 604270 97 1 1 2 Jacket Re ar P ane l Assem b l y 604270 96 1 1 3 Jacket Left Side/Top Panel As sembly 6042703 14 1 --- 6042704 14 --- 1 4 Jack et Top Panel Ass embly 6042703 22 1 [...]

38 V72 Thru V79 FLUSH JACKET TS-39-109-D[...]

39 Item No. Description Part No. V72 V73 V74 V75 V76 V77 V78 V79 V72 Thru V79 Flush Jacket Components - Items 1 thru 7 Include Insulation As Part of Ass'y 1 Jacket Front Panel Ass'y w/o Htr. Op g . (Wtr. Blr.) 60427090 1 1 111111 Jacket Front Panel Ass'y w/o Htr. Op g . (Stm. Blr.) 60427091 --- Jacket Front Panel Ass'y w/Htr. Op[...]

40 V73 Thru V79 STEAM BOILERS - TRIM AND CONTROLS[...]

41 Ite m No . De s cri pt i o n P a r t No . V 73 V 74 V 75 V 76 V 77 V 78 V 79 V7 3 Th r u V7 9 STEA M B OIL ER S - T R I M A N D C ONTR O LS ( Se e Pag e 4 0 fo r I ll us t r a tio n) 1 . D ra f t R egula t or 1A DR - 6 Draft R egula tor 81 16029 1 1 1 1 - - - -- - -- - 1B DR- 7 D ra f t Reg ul a t or 8 1 1 60 01 --- --- --- --- 1 1 1 2 . Ins t r[...]

42 V72 Thru V79, V713 and V714 WATER BOILERS - TRIM AND CONTROLS[...]

43 IT E M NO. DE S CR IP T I ON Pa r t No . V 72 V 7 13 V 73 V 7 14 V 74 V 75 V 76 V 77 V 78 V 79 V 7 2 Thr u V 79 , V 7 13 an d V 7 14 WA TE R B O I LER S - TR IM A N D CO NTR OLS ( See Page 42 f or Ill us t ra t ion) 1. DR AF T R EG UL A T O R 1A DR -6 Dr af t Re g u l at or 8 1 16 0 29 1 1 1 1 1 1 1 -- -- -- -- -- -- 1B DR -7 Dr af t Re g ul a t[...]

44 Beckett AFG Burner[...]

45 BECKETT OIL BURNER P ART NOS. FOR V7 SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Bo iler Model V72 V 7 13 V73 V 7 1 4 V 74 V75 V76 V77 V78 V79 Air T u be Com bination AFG70M B AF72YH AF44XN AF72YY AF44 WH AF[...]

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