Burnham V7 SERIES Manuel

8142711R24-7/99

Price - $3.00

INSTALLATION,

OPERATING AND SERVICE

INSTRUCTIONS FOR

V7 SERIES OIL FIRED BOILER

KNOCKDOWN & PACKAGED

HEATINGUNITS

TheULClabelorlisted

markingonaproductisthe

onlyevidenceprovidedby

Underwriters'Laboratoriesof

Canadatoidentifyproducts

whichhavebeenproduced

underthelistingandfollow-up

service.

Theseinstructionshavebeen

reviewedbyULCandfound

suitableforuseinthe

installationofULClabeled

V-7SeriesBoilers.

As an

ENERGY

STAR®Partner,

Burnham Corporation

has determined that the

V73WR (0.60 GPH),

V74WR (0.80 GPH),

V75WR (0.90 GPH),

and V76WR (1.15 GPH)

meet the ENERGY STAR®

guidelines for Energy

efficiency established by the

United States Environmental

Protection Agency (EPA).

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

_V7 ____-____ 6_ _ _ _ _ _ _

Heating Contractor Phone Number

Address

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY

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 LOCAL PLUMBING,

HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES WHICH MAY

DIFFER FROM THIS MANUAL. AUTHORITIES HAVING JURISDICTION SHOULD BE CONSULTED BEFORE

INSTALLATIONS ARE MADE.

IN ALL CASES, REFERENCE SHOULD BE MADE TO THE FOLLOWING STANDARDS:

USABOILERS

A. CurrentEditionofAmericanNationalStandardANSI/NFPA31,“InstallationofOilBurningEquipment”,forclearancesbetweenboiler,ventconnectorand

combustiblematerial.

B. CurrentEditionofAmericanNationalStandardANSI/NFPA211,“Chimneys,Fireplaces,Vents,andSolidFuelBurningAppliances”,ForChimneyrequire-

ments,typeofventingmaterialandclearancesbetweenventconnectorpipeandcombustiblematerials.

C. CurrentEditionofAmericanSocietyofMechanicalEngineersASMECSD-1,“ControlsandSafetyDevicesforAutomaticallyFiredBoilers”,forassemblyand

operationsofcontrolsandsafetydevices. CANADABOILERS

A. CurrentEditionofCanadianStandardsAssociationCSAB139,“InstallationCodeforOilBurningEquipment”,forrecommendedInstallationPractices.

4. 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.

5. 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 HEAT-

ING SEASON AND SHOULD BE INSPECTED PERIODICALLY THROUGHOUT THE HEATING SEASON FOR ANY

OBSTRUCTIONS. A CLEAN AND UNOBSTRUCTED CHIMNEY FLUE IS NECESSARY TO ALLOW NOXIOUS

FUMES THAT COULD CAUSE INJURY OR LOSS OF LIFE TO VENT SAFELY AND WILL CONTRIBUTE TOWARD

MAINTAINING THE BOILER’S EFFICIENCY.

6. READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESSORY DEVICES.

THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS

OF THE MANUFACTURER.

7. IT IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS ARE COR-

RECTLY INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION IS COMPLETED.

8. FOR OPTIMUM PERFORMANCE AND SERVICEABILITY FROM THIS BOILER ADHERE TO THE FOLLOWING

RECOMMENDATIONS:

A. DO NOT TAMPER WITH THE BOILER OR CONTROLS. Retain your contractor or a competent serviceman to assure that the boiler is properly adjusted and

maintained.

B. Cleanflueways atleastoncea year-preferably attheendof theheatingseason toremovesoot and scale.Insideof fireboxshouldalso be cleanedatthe same

time.

C. Haveoil burner andcontrolschecked at leastonceayear orasmaybe necessitated.

WARNING

High water temperatures increase the risk of burns or scalding injury. Install an automatic tempering

(mixing) valve at the tankless heater outlet to avoid excessively hot water at the fixtures.

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 sure to tighten swing door

fastener completely when service is completed.

WARNING

This boiler is designed to burn No. 2 fuel oil 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) or gaseous fuel (i.e. natural gas, LP/propane). All flammable debris, rags, paper, wood scraps,

etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of fire hazards.

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 ........................................ 31

Burner Specifications ......................... 46

SECTION I: GENERAL INFORMATION

Figure 1A: V72 thru V79 Water Boiler Without Tankless Heater (WB)

TABLE 1: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1E)

IMPORTANT

Before startin

to install this oil boiler, read these instructions carefull

. Kee

instructions in le

ible condition and

osted near oil boiler for reference b

owner and service technician.

Boiler

Model

No.

Dimensions Minimum

Chimney Size

Water Content -

Gallons

Heat Transfer

Surface Area -

Sq. Ft. Approximate

Shippin

Wei

(LB.)

"A" "B" "C" Steam

Boiler Water

Boiler Steam Boiler

V72 11-3/8" 6-3/8" 5" 8" x 8" x 15' ---- 10.6 ---- 381

V713 16" 8-3/4" 6" 8" x 8" x 15' ---- 13.5 ---- 524

V73 15-3/8" 8-3/8" 6" 8" x 8" x 15' 10.8 13.2 13.8 478

V714 20" 10-3/4" 6" 8" x 8" x 15' ---- 15.9 ---- 580

V74 19-3/8" 10-3/8" 6" 8" x 8" x 15' 13.5 15.9 19.7 575

V75 23-3/8" 12-3/8" 7" 8" x 8" x 15' 16.1 18.5 25.6 674

V76 27-3/8" 14-3/8" 7" 8" x 8" x 15' 18.6 21 31.4 773

V77 31-3/8" 16-3/8" 8" 8" x 12" x 15' 21.2 23.6 37.3 872

V78 35-3/8" 18-3/8" 8" 8" x 12" x 15' 23.8 26.2 43.1 971

V79 39-3/8" 20-3/8" 8" 8" x 12" x 15' 26.4 28.8 49.0 1070

NOTE: 1. Maximum Working Pressure 15 PSI (Steam) and 30 PSI (Water)

2. The V72, V713 and V714 Boilers are available as packaged water boilers only

3. The V713 and V714 are not ULC listed Models

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")

Figure 1E: V713 and V714 Packaged Water Boiler with Tankless Heater (WBT)

Figure 1D: V713 and V714 Packaged Water Boiler Less Tankless Heater (WB)

Βυρνηαµ

Burnham

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 filed 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 receipt of goods.

B. LOCATE BOILER in front of final position before

removing crate. See Figures 1A thru 1E.

1. LOCATE so that smoke pipe connection to

chimney will be short and direct. BOILER IS

SUITABLE FOR INSTALLATION ON

COMBUSTIBLE FLOOR. Boiler cannot be

installed on carpeting.

2. FOR BASEMENT INSTALLATION, provide a

solid base, such as concrete, if floor is not level, or

if water may be encountered on floor around boiler.

3. PROVIDE SERVICE CLEARANCE of at least 24”

on right side of boiler for removal of rear tankless

heater. Provide at least 24” clearance from front

jacket panel for servicing and removal of front

tankless heater (increase to 30" for #A54 heater).

Provide at least 24" clearance from right side of

boiler or top of boiler for cleaning flueways. Boiler

flueways may be cleaned either from the top or

from the side.

4. For minimum clearances to combustible materials.

See Table 2.

C. PROVIDE AIR SUPPLY AND VENTILATION to

accommodate proper combustion. If natural ventilation

is inadequate, provide a screened opening or duct from

the boiler room to the outside. The opening or duct

must be sized so the boiler input will not exceed 4,000

BTUH/Sq. In. of free area. If other air consuming

appliances are near the boiler, the air inlet should be

larger. Consult respective manufacturers.

Boiler A

Above B

Front

Chimney

Connector D

Rear E

Sides

V7 6 24 18 6 6

NOTE 1: Listed clearances comply with American

National Standard ANSI/NFPA 31, Installation of Oil

Burning Equipment.

NOTE 2: V7 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.

NOTE 3: For reduced clearances to combustible

material, protection must be provided as described in

the above ANSI/NFPA 31 standard.

SECTION II: KNOCKDOWN BOILER ASSEMBLY

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

remove crate skid.

Note: If Boiler is Packaged Go To Section III

Figure 2

B. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

C. TEST BOILER FOR LEAKS before installing

controls, trim, and jacket, and before connecting to

heating system.

1. Loosen nuts on tie rods until only finger tight.

2. Install pressure gauge (at least 30 P.S.I. capacity), a

hose to the city water and a valve in the supply

tapping. Plug remainder of tappings.

3. Fill boiler with water and apply a pressure of at

least 10 pounds but no more than 30 pounds gauge

pressure.

4. Examine Boiler carefully inside and outside for

leaks or damage due to shipment or handling.

D. DRAIN WATER FROM BOILER. Remove gauge,

valve and plugs from those tappings to be used. Leave

other tappings plugged or bushed according to Figure

E. INSPECT JOINTS BETWEEN SECTIONS. All joints

are factory sealed. If there are any spaces due to

shipment or handling, seal them with boiler putty.

F. INSPECT FLUE COVER PLATES for tightness. If

loose, retighten mounting hardware. If flue plate or

sealing insulation is damaged repair or replace as

needed.

G. INSTALL AND SECURE CANOPY with cerafelt

gasket and hardware provided to ensure gas tight seal

— see Figure 3.

1. Cut two (2) strips 13 ¾” lg. from the roll of cerafelt

gasket insulation. Place one (1) strip across the top

of the front section and the other across the rear

section as shown in Fig. 3. Place gaskets so as not

to allow any flueway blockage.

2. Cut the remainder of the roll into two (2) equal

pieces. Place each piece along the sides, allowing

the ends to overlap the front and rear pieces.

Do not allow any flueway blockage.

3. Position canopy body within the retaining bar

which borders the flueway openings on top of the

bare boiler block assembly.

IMPORTANT: Jacket support bracket must be

facing left side of boiler — see Figure 3.

4. Secure canopy to boiler with two (2) 1/4" - 20 x 3"

lg. carriage bolts, 1/4" flat washers and 1/4" - 20

wing nuts provided.

H. INSTALL the following steam or water trim that

would be concealed or inaccessible after flush jacket is

installed, see Figure 4 for boiler tapping locations and

usage.

1. STEAM BOILER — Top tappings:

a. Tapping "L" — Install 2" plug in rear section

top supply tapping on boiler sizes V73 thru

V75.

b. Tapping “M” — Install ¾” coupling and ¾” x

8” long nipple into ¾” tapping located next to

front section top supply tapping — all boiler

sizes.

2. WATER BOILER — Top tappings:

a. Tapping “L” — Install 2” plug in rear section

top supply tapping on boiler sizes V73 thru

V79.

Figure 3

Figure 4: Boiler Tapping Locations and Usage (Knockdown Boilers Only)

PURPOSE OF TAPPINGS

Tappin

Location Size Steam Boiler Water Boiler

Non-Heater w/Heater Non-Heater Front Heater Rear Heater

A¾" PA404A Pressuretrol (Probe LWCO)

Plugged (Float LWCO) L8148A

Operating Control L8124C

Operating Control Flush Plug

B ¼" Pressure/Vacuum Gauge Temperature/Pressure Gauge

C¾" Probe LWCO Std.

Plugged (Float LWCO) Flush Plug

C-C ¾" Flush Plug Flush Plug Flush Plug

D½" Water Gauge Glass (Probe LWCO)

Water Gauge Glass, Pressuretrol, and LWCO (Float) Flush Plug

F ¾" ----- L4006A Operating

Control ----- Disregard L8124C

Operating Control

G 1½" Bushed to ¾" for Draincock (Optional Return) Return

H 1½" Return Bushed to ¾" for Draincock (Optional Return)

J 1½" Surface Blowoff - Plugged Flush Plug

K 2" Front Supply (3 thru 9 Section) Front Supply (3 thru 9 Section)

L2"

Plugged, Optional Second Supply (3 thru 5 Section)

Required Second Supply (6 thru 9 Section) Plugged (3 thru 9 Section)

M ¾" Safety Valve Relief Valve

P ¾" Auxiliary Tapping - Plugged Aux. Tapping -

Plugged Disregard Aux. Tapping -

Plugged

R ¾" Auxiliary Tapping - Plugged Auxiliary Tapping - Plugged

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 securing mounting plate to

boiler sections.

Lift up and remove plate.

2. Install rear jacket panel. Align two dimpled holes

on jacket panel with the cast iron lugs. Secure with

two #10 x 3/8” long self tapping screws.

3. JACKET FRONT PANEL

a. Install black plastic collar extension to jacket

front panels with 7-13/16" dia. heater opening.

Engage two (2) retaining tabs over raw edge of

opening. Provide support behind the panel with

one hand while applying pressure on collar to

snap each tab over edge of opening until all

eight (8) tabs are securing collar.

b. Install front jacket panel. Locate two 3/16”

diameter holes on front panel approximately 16”

up from the bottom of the panel and 4½” in

from each side. Align these holes with the

similarly located cast iron lugs on the front

section. Secure with two #10 x 3/8” long self-

tapping screws.

4. Install jacket left side panel. Fold panel at

perforation keeping insulation inward. Align left

side panel mounting holes with the front and rear

panel holes. Secure with #8 x ½” long sheet metal

screws.

5. Install jacket top panel. Place jacket top panel on

boiler and secure to front, rear and left side panels

with #8 x ½” long sheet metal screws.

6. Install jacket lower right side panel. Align right

side panel mounting holes with front and rear panel

holes. Secure with #8 x ½” long sheet metal screws.

7. Install jacket upper right side access panel. Using

the thumb holes, hold access panel 1” above lower

right side panel. Engage flanges on access panel

with surrounding panels and lower into position

until access panel is resting flush with top panel

and bottom flange is properly locked into position

with lower right side panel.

8. Attach the data labels shipped in the instruction

envelope as follows: (see Figure 5).

a. Place the Rating Label (serialized)

approximately 1/4" below the top edge and

3-1/2" from the right edge of the jacket front

panel as shown. Mark outline of label on jacket

with a pencil. Remove paper backing from

label, realign label with pencil marks and apply

label to jacket by using backing paper to rub

across face of label.

b. Locate the Combination Label (P/N 8142756)

on the front right corner of top panel,

approximately 3/8" from each edge as shown.

Mark the location and apply label in the same

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 metal screws.

J. INSTALL OIL BURNER (See Figure 6).

1. Check target wall and cerafelt blanket in

combustion chamber. If any damage or movement

occurred during shipment, repair or replace as

needed.

2. Check the burner mounting plate and swing door

insulation pieces for damage and adhesion. If

damaged, replace insulation. If loose, re-attach with

RTV 732 or 736 silicone caulk.

3. Engage bottom slot on burner mounting plate with

matching bolt in bottom tapping of front section.

Align mounting holes and fasten the mounting

plate to the boiler sections with (5) five 5/16” bolts

and washers removed in step 8a. Fully tighten all

bolts.

4. Place burner flange gasket on burner swing door

and thread two 5/16” x ½” long bolts into vertical

set of holes approximately three full turns.

5. Insert oil burner air tube into the opening of the

burner swing door. Align keyhole slot with vertical

set of bolts, engage hex head of bolts and rotate

burner to the left. Install two remaining 5/16” x ½”

long bolts in horizontal sets of holes. Level burner

and fully tighten all bolts.

K. INSTALL STEAM BOILER TRIM AND CONTROLS

(See Figures 1C & 4).

1. Thread the combination pressure/vacuum gauge

into the ¼” tapping. Tighten with wrench applied

to the square shank of the gauge. Do not apply

pressure to the gauge case — this might destroy the

calibration of the gauge.

2. Thread 1½” x ¾” bushing and a ¾” drain cock into

the 1½” tapping located in the lower right corner of

the front casting. Tighten with wrench.

NOTE: Lower rear section tapping “H” is used for

standard condensate return on steam boilers.

3. Thread safety relief valve, as shown in Figure 1C,

into 3/4" coupling and 3/4” x 8” nipple previously

installed in step H. Tighten with wrench.

NOTE: Pipe discharge as shown in Figure 8.

4. Install probe type LWCO if so equipped. Thread

probe into ¾” tapping located on the front section

directly above the protectorelay on the oil burner.

Read the manufacturer’s instructions packed with

the probe LWCO for proper pipe dope application.

DO NOT use Teflon tape on probe threads. Use of

teflon can render the probe LWCO inoperational.

Slip the LWCO control over the probe and clamp in

place. Connect the wire(s) between the probe and

control per the manufacturer’s instructions. Install

Figure 6

Ce manuel convient aux modèles suivants

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