IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR V 9 A S E R IE S B OIL E R 3050579 This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all instructions in this manual and all other information shipped with the boiler. Post all instructions and manuals near the boiler for reference by service personnel. Perform steps in the order given.
IMPORTANT INFORMATION READ and save these instructions for reference 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.
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas or fuel oil vapors, do not try to operate the burner/boiler system. Do not touch any electrical switch or use any phone in the building. Immediately call the gas or oil supplier from a remotely located phone.
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 water under high pressure.
Important Product Safety Information Refractory Ceramic Fiber Product 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 above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
TABLE OF CONTENTS SECTION I - GENERAL INFORMATION Dimensional Information ............................................................................................................................................... 9 Ratings/Data ................................................................................................................................................................. 10 Locating the Unit ................................................................................................
TABLE OF CONTENTS - Continued SECTION VI - BURNER SPECIFICATIONS Beckett Burners (Table V)............................................................................................................................................. 52 Power Flame Burners (Table VI)................................................................................................................................... 53 Webster Burners (Table VII).....................................................................................
Figure 1: Dimensional Information Section I - General Information
Table I: Boiler Ratings / Data (1) (2) (3) Heating Surface (Sq. Ft.) New Net I=B=R Rating Burner Input Boiler Horse- Gross Firebox Model Power Output Volume Oil Gas (MBH) Sq. Ft. MBH MBH Steam Water (Cu. Ft.) Steam Steam Water (GPH) (MBH) (4) Pressure Water Content Boiler Weight (Gal.) w/Water (Lbs.) in Firebox (In. Wtr. Clmn.) Steam Water Steam Water Vent Dia. (In.) V903A 10.3 347 1083 260 302 --- 447 34.2 37.0 3.2 .33 44.5 66.0 1439 1618 7 V904A 14.4 483 1508 362 420 4.
SECTION I - GENERAL INFORMATION (Continued) 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.
Figure 2: Boiler Foundation Failure to supply adequate air to the boiler will result in unsafe boiler operation. C. PROVIDE AIR SUPPLY AND VENTILATION 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.
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 UL1738, must be used (for example, Van-Packer model CS, Protech Model FasNSeal / FasNSeal W2, Heatfab Saf-T-Vent or equivalent).
A B C TEE TYPE RIGHT “A” CAP RIGHT RAIN CAP 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.
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”. Boiler sections must be drawn-up on perfectly level surface or improper assembly may result. B.
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).
NOTES: FOR BOILERS LESS TANKLESS HEATER, REPLACE THE "CT" SECTIONS WITH "C" SECTIONS. TANKLESS SECTIONS: IF BOILER CAN TAKE MULTIPLE TANKLESS COILS, BUT NOT ALL TANKLESS COILS WILL BE USED, INSTALL COILS TOWARDS BACK OF BOILER, FOLLOWING SECTION ARRANGEMENT CHART. 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. To facilitate assembly, it is advisable to enter the upper nipple first in its port.
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.
draw-up rod clamps on the other. These items are all located in the Draw-Up Kit. See Figure 12. 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. READ THE STATEMENTS BELOW BEFORE ATTEMPTING TO USE HYDRAULIC EQUIPMENT. • Release pressure in ram pumps before attempting to remove clamps.
Figure 12: 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.
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.
Figure 16: Bare Boiler Assembly
Figure 17: Left Side Canopy Intermediate Bracket on center section draw-up rod (hooks should face outward). Secure canopy with 5/16” flat 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 bolt between canopy body and casting. Slide carriage bolt into slot provided between castings. Lower carriage bolt until threaded end will pass through hole in bracket.
C. MOUNT REAR OBSERVATION PORT COVER 6. Jacket Top Panel Attachment Refer to Figure 16. a. On boilers with top flue outlet damper assembly, remove octagon shaped knockout. To remove knockout, use a single hacksaw blade with handle or aviation snips to cut metal tabs between slotted holes. b. Remove knockout(s) for necessary supply piping in a similar manner. c. Attach jacket top panel to the front panel, rear panel and upper tie bar panels with sheet metal screws. 7. Install Jacket side Panels 1.
Figure 22: V9A Series Jacket Assembly (Boiler Models V903A thru V912A)
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. Tighten all sheet metal screws to complete jacket assembly. F. BURNER MOUNTING PLATE - Refer to Figures 16 and 23. 1.
insulation and blast tube. If additional rope gasket is not provided with the burner, use 3/8” fiberglass rope rated for 2300°F (provided by others). Reinstall burner mounting plate when finished. Failure to properly fill all gaps between the insulation and burner blast tube may result in damage to the burner. 5. For boilers without tankless heaters, proceed to Paragraph H (Install Steam Trim) or I (Install Water Trim). 6.
Figure 24: Purpose of Tappings J. BURNER INSTALLATION 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 specifications and burner settings. K. PACKAGED BOILER 1. The packaged boiler comes on it’s own shipping skid (see Figure 25) and the assembled block is hydrostatically tested at the factory.
Boiler Model Number Length of A Sections Width B* Approx. Approx.
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 pump is recommended as a minimum to help protect the boiler from flue gas condensation and/or thermal shock. See piping details in Figure 28.
Figure 26: V9A Series Minimum Piping - Parallel - Water Boiler
Figure 27: V9A Series Minimum Piping - Primary Secondary - Water Boiler
Figure 28: V9A Series Minimum Piping Details, Bypass with Blend Pump - Water Boiler
Figure 29: V9A Series Minimum Piping - Primary Secondary/with Bypass - Water Boiler
Figure 30: Minimum Piping Details - Multiple Boiler Application, Primary/Secondary Piping With Bypass
Figure 31: Minimum Piping Details - Multiple Boiler Application, Parallel Piping With Blend Pump
Figure 32: Minimum Piping Requirements For Gravity Return V9A Series Steam Boilers
Figure 33: Typical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit
M. BOILER PIPING, DOMESTIC HOT WATER (DHW) APPLICATION – The V9A boiler can be used in many different piping applications to produce Domestic Hot Water (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 DHW load.
N. CONNECT TANKLESS HEATER PIPING as shown in Figure 37a. See Table IV for Tankless Heater Ratings. The following guidelines should be followed when piping the tankless heater: 1. Install Flow Regulator If flow through the heater is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand. For this reason a FLOW REGULATOR matching the heater rating should be installed in the cold water line to the heater. Refer to Figure 37a for piping recommendations.
Figure 36: Minimum Piping Requirements for V9A Tankless Heater Manifolds Table IV: Tankless Heater Ratings Boiler Model Figure 37a: Schematic Tankless Heater Piping 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 --- V912A 7.5 15 22.5 30 Notes: 1.
Figure 37b: DHW Generation with Tankless Coils, Storage Tank and Destratification Pump
Figure 37c: DHW Generation with Indirect Water Heater
O. ELECTRIC WIRING - Install all field 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.
SECTION IV - OPERATING INSTRUCTIONS If you do not follow these instructions exactly, a fire 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 contact an experienced and skilled service agency. Follow component manufacturer’s instructions. Component manufacturer’s instructions were provided with the boiler. Contact component manufacturer for replacement if instructions are missing.
4. ON WATER BOILERS WITHOUT TANKLESS HEATERS, set high limit dial on L4006A at 210°F. This temperature may be varied to suit requirements of installation. 5. ON WATER BOILERS WITH TANKLESS HEATERS, 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 setting. Set differential at 25°. D. ADJUST BURNER according to the Burner Manual. Probe and float type low water cutoff devices require annual inspection and maintenance. 4.
d. Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety. e. Refill 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 with appropriate water treatment compounds.
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. Refill the system with fresh water. 3. Add appropriate boiler water treatment compounds as recommended by your local qualified water treatment company. 4. Make pH or Alkalinity Test.
SECTION V - SERVICE INSTRUCTIONS This boiler uses flammable 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 disconnect switch are used on the boiler. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service.
5. REASSEMBLE BOILER Do not start the burner unless canopy, smokepipe, burner mounting plate and all flue 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 gasket is in place and forms gas tight seal. If gasket is damaged, replace. c. Bolt burner to burner mounting plate. Inspect gasket to assure adequate seal.
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 float when this type of control is used. Check float for evidence of collapse and check mercury bulb (where applicable) for mercury separation or discoloration.
SECTION VI - BURNER SPECIFICATIONS 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 burner start-up. Table V: Beckett Burner Specifications OIL BURNERS Boiler Model Burner Burner Input Mfr. (GPH) V903A 3.
Table VI: Power Flame Burner Specifications Boiler Model Burner Input (GPH) Burner Mfr. V904A V905A V906A V907A V908A V909A V910A V911A V912A 4.2 5.6 7.0 8.3 9.6 11.6 13.2 14.8 16.
Table VII: Webster Burner Specifications OIL BURNERS Burner Boiler Input Burner Mfr. Model (GPH) Burner Model Pump Pressure (PSI) Low High Fire Fire Air Inlet Settings Burner Settings Nozzle to Drawer Inner Fire Diffuser Assembly Cylinder Low Fire High Fire Nozzle Data Nozzle Make GPH x Angle-Type 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 N/A N/A V905A 5.
Table VIII: Carlin Burner Specifications OIL BURNERS Boiler Model Burner Input (GPH) Burner Mfr. Burner Model Air Tube Comb. Pump Pressure (PSI) Burner Settings Air Head Band Air Damper Low High Low Fire High Fire Nozzle Make Nozzle Data 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 Carlin 301CRD 8” - Style ‘B’ 1/2” 100% N/A N/A --- 150 Hago 3.50 x 80° - SS V905A 5.
Figure 39: V9A Series Jacket Assembly (Boiler Models V903A thru V912A) SECTION VII - REPAIR PARTS (Continued)
JACKET REPAIR PARTS (Models V903A Thru V912A) ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY V903A V904A V905A V906A V907A V908A V909A V910A V911A V912A PART NO. 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 Tie Bar Panel Assy., V903A 2 3B Jacket Upper Tie Bar Panel Assy., V904A 60429037 2 3C Jacket Upper Tie Bar Panel Assy.
Figure 40: Bare Boiler Assembly
REPAIR PARTS FOR BARE BOILER ASSEMBLY ITEM NO. BOILER SIZE / QUANTITY DESCRIPTION V903A V904A V905A V906A V907A V908A V909A V910A V911A V912A PART NO. 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 Water Boiler 1 2 3 4 5 6 7 8 9 10 7172940 1 1 1 2 2 2 3 3 3 4 7172941 1 7172942 7172938 3 Optional - “CT” Center Section w/Tankless Heater Opening Max. No.
REPAIR PARTS FOR BARE BOILER ASSEMBLY (Continued) ITEM DESCRIPTION NO. 21B Top Outlet Canopy Cover, 7 & 8” Dia. Opening BOILER SIZE / QUANTITY V903A V904A V905A V906A V907A V908A V909A V910A V911A V912A 1 1 1 1 1 Top Outlet Canopy Cover, 10” Dia. Opening 7112638 1 1 1 Top Outlet Canopy Cover, 12” Dia. Opening 22 PART NO. 7112639 1 1 7112640 Burner Mounting Plate Assemblies (Incl. Items 23-27 & Mtg.
STEAM TRIM / WATER TRIM BOILER SIZE / QUANTITY V903A/ V904A V905A/V908A V909A/V912A STEAM TRIM PART NO. Pressuretrol: Honeywell L404F1060 1 1 1 80160942 Honeywell L4079B1033 (Pkgd. Boiler) 1 1 1 80160943 Low Water Cutoff, M&M 63M (Pkgd. Boiler Only) 1 1 1 80160509 Steam Gauge, 3½” Dia.
SERVICE RECORD DATE 62 SERVICE PERFORMED
SERVICE RECORD DATE SERVICE PERFORMED 63
