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As an
ENERGY
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Partner,
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Burnham Hydronics
has determined that the
V83S, V83WM, V84S,
V84WM, V85S, V85WM,
V86S, V86WM and V87
meet the ENERGY STAR
guidelines for Energy
efficiency established by the
United States Environmental
Protection Agency (EPA).
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Table of Contents
Related Manuals for Burnham V8 Series
Summary of Contents for Burnham V8 Series
- Page 1 As an ENERGY STAR Partner, ® Burnham Hydronics has determined that the V83S, V83WM, V84S, V84WM, V85S, V85WM, V86S, V86WM and V87 meet the ENERGY STAR ® guidelines for Energy efficiency established by the United States Environmental Protection Agency (EPA).
- Page 2 IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating 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 and Electrical Codes and the regulations of the serving utilities.
- Page 3 i l i . l l f i l...
- Page 4 I. Pre-Installation ...10 II. Knockdown Boiler Assembly ...12 III. Packaged Boiler Assembly ...26 IV. Water Boiler Piping & Trim ...31 V. Steam Boiler Piping & Trim ...36 VI. Tankless & Indirect Water Heater Piping ..38 VII. Venting & Air Intake Piping ...41 VIII.
- Page 5 47-1/8" 47-1/8" 24-1/8" 24-1/8" NOTE: 1 The V82 Boiler is available as a packaged water boiler only. NOTE: 1 The V82 Boiler is available as a packaged water boiler only. 2 2 Maximum working Pressure: Steam: 15 PSI; Maximum working Pressure: Steam: 15 PSI;...
- Page 10 1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment. 2. V8 Series boilers can be installed in rooms with clearances from combustible material as listed SECTION I: PRE-INSTALLATION not level, or if water may be encountered on fl oor around boiler.
- Page 11 Outdoor air for combustion may be provided with an optional Burnham V8 Inlet Air Accessory Kit, Part Number 611280031 (ONLY AVAILABLE WITH BECKETT BURNER). See Section VII for installation details.
- Page 12 SECTION II: KNOCKDOWN BOILER ASSEMBLY A. REMOVAL OF BARE BOILER FROM SKID 1. Boiler is secured to skid with 4 bolts, 2 in front and 2 in rear of shipping skid, see Figure 3. Remove all bolts. Figure 3: Knockdown Boiler Removal from Skid 2.
- Page 13 Figure 5: Boiler Tapping Locations and Usage (Knockdown Boilers Only) ¾ " ¼ " ¾ " ¾ " ½ " ¾ " ½ " ¾ " ½ " ½ " " 2 " 2 ¾ " ¾ " l i x ¾...
- Page 14 H. INSTALL TRIM. The following steam or water trim will be concealed or inaccessible after boiler jacket is installed, see Figure 5 for boiler tapping locations and usage. 1. STEAM BOILER — Top tappings: a. Tapping "L" — Install 2" NPT plug in rear section top supply tapping on boiler sizes V83 thru V85, if only one supply riser is used.
- Page 15 Figure 7: Oil Burner Installation (Beckett Burner Shown) 6. Install jacket top panel. (See Figure 6, Item 2F). Place jacket top panel on boiler and secure to front, rear and left side panels with #8 x ½” long sheet metal screws.
- Page 16 Steam Boilers Only Knockdown V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same fi ring rate as the water boiler of the same size. a. Installation/Removal of Drawer Assembly Loosen screws, rotate latches and swing...
- Page 17 Knockdown V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same fi ring rate as the steam boiler of the same size. Inspect the installed nozzle and assure that the nozzle is the correct size and type as specifi...
- Page 18 Steam Boilers Only Steam boilers must use the lower input nozzle. The lower input nozzle will provide greater boiler effi ciency and for steam boilers, reduce boiler corrosion. However, boiler output will be reduced. Burners for knockdown V83 - V86 steam boilers are shipped with the lower (standard) fi...
- Page 19 fi ring rate nozzle installed. Knockdown V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same fi ring rate as the water boiler of the same size. a. Installation/Removal of Drawer assembly, refer to Figure 7B.
- Page 20 Figure 7C: Nozzle Replacement Remove the nozzle adapter (2) from the drawer assembly by loosening the screw (1). ii. Remove existing nozzle from nozzle adapter. iii. Insert the proper nozzle into nozzle adapter and tighten securely (Do not over tighten). iv.
- Page 21 The lower (minimum) input nozzle will provide greater boiler effi ciency. However, boiler output will be reduced. Refer to Table 1B for fi ring rates. If the higher rate is desired, inspect the installed nozzle and assure that the nozzle is the correct size and type as specifi...
- Page 22 1½” NPT x 90° elbow (note - lower front section tapping “G” is used for standard return on water boilers). 5. If circulator (not supplied with boiler) is to be mounted directly to 1½" NPT boiler return tapping "G", use the piping arrangements outlined in steps a.
- Page 23 7. On units without a heater opening, install the well into the ¾” NPT tapping "A" located on the front of the boiler in the upper left corner. See Figures 1A and 5. Tighten the well and insert the control’s bulb into the well.
- Page 24 Refer to Paragraph S for details on use of burner disconnect junction box provided with all knockdown boiler builds. S. BURNERS SUPPLIED BY BURNHAM utilize a burner disconnect harness that is pre-wired into the burner junction box and primary control. Packed in the...
- Page 25 (3) pigtail wires connected to spade terminals on rear of power outlet receptacle. Make the connections as shown in appropriate wiring diagram based on boiler confi guration, refer to Figures 19 thru 23F. Figure 10: Burner Disconnect Junction Box with Power Outlet Receptacle (Mated to Burners with Disconnect Harness) lg.
- Page 26 Care should be exercised to prevent damage to jacket or burner. Figure 11A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured C. MOVE BOILER TO PERMANENT POSITION by sliding or walking.
- Page 28 Step 4. From this position the door can be swung clear of the vertical circulator return piping to provide full access to the combustion chamber and burner head (see Figure 11B, Position 3). 2. Perform routine inspection, service or cleaning as necessary.
- Page 29 Packaged V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same fi ring rate as the water boiler of the same size. Inspect the installed nozzle and assure that the nozzle is the correct size and type as specifi ed in Table 6 of this manual.
- Page 30 Packaged V87 - V89 boilers are provided with one nozzle, installed in the burner, that provides the same fi ring rate as the water boiler of the same size. Inspect the installed nozzle and assure that the nozzle is the correct size and type as specifi ed in Table 6 of this supplement.
- Page 31 Refer to the Alliance™ Installation, Operating, and Service Instructions for additional information. 4. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e.
- Page 32 To perform a long term pressure test including the boiler, ALL trapped air must fi rst be removed from the boiler. Figure 12: Recommended Piping for Combination Heating and Cooling (Refrigeration) System A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air.
- Page 36 A. EVALUATE THE EXISTING STEAM SYSTEM. The single most important factor in determining the expected life cycle of a steam boiler, is the amount of fresh water added to the boiler during operation. Fresh water brings minerals and oxygen into the boiler. These contaminants greatly accelerate corrosion of the cast iron boiler sections.
- Page 38 SECTION VI: TANKLESS AND INDIRECT WATER HEATER PIPING A. CONNECT TANKLESS HEATER PIPING as shown in Figure 15A. See Tables 2A and 2B for Tankless Heater Rating. THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER: 1. FLOW REGULATION — If fl 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.
- Page 39 TABLE 2A: TANKLESS HEATER DATA: Rear Mounted Heater on Steam and Water Boilers Figure 15A: Schematic Tankless Heater Piping TABLE 2B: TANKLESS HEATER DATA: Front Mounted Heater on Water Boilers...
- Page 40 Figure 15B: Alliance™ Water Heater Piping with V8 Boiler B. CONNECT ALLIANCE™ INDIRECT WATER 1. Refer to Alliance™ manual for additional HEATER PIPING as shown in Figure 15B. information.
- Page 41 Most homes have a chimney appropriate for the fuel and the era in which the home was built. That may have been a coal fi...
- Page 42 Figure 16: Recommended Vent Pipe Arrangement and Chimney Requirements Figure 17: Proper and Improper Locations of Draft Regulator...
- Page 43 2. After determining location, cut a hole in the wall to accept 4 inch air intake pipe. See Figure 18. 3. Remove the metal knockout in right side of burner cover. Install Burnham Inlet Air Accessory Kit, Part Number 611280031. 4. Mount the Vacuum Relief Valve Tee Assembly (Part Number 8116268 included with Kit) or 90°...
- Page 44 SECTION VIII: ELECTRICAL . f f B. INSTALL A ROOM THERMOSTAT on an 7. If boiler is installed in Canada, a blocked vent safety switch must be installed. Refer to Blocked Vent Safety Switch Instruction Supplement provided with boiler (Canada only).
- Page 45 When the high limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The probe low water cut-off will shut down the burner after a 10-15 second delay, if the water level in the boiler drops below the probe level.
- Page 46 Figure 19A: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Carlin Burners...
- Page 47 Figure 19B: Wiring Diagram, Steam, Hydrolevel CG450 Probe LWCO for Riello Burners...
- Page 48 The probe low water cut-off will shut down the burner after a 10-15 second delay, if the water level in the boiler drops below the probe level.
- Page 49 Figure 20A: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Carlin Burners...
- Page 50 Figure 20B: Wiring Diagram, Steam, McDonnell & Miller PS-801 Probe LWCO for Riello Burners...
- Page 51 The low water cut-off will shut down the burner if the water level in the boiler drops too low. The control resets and restarts the burner with a call for heat a few seconds after the water is returned to its normal level.
- Page 52 Figure 21A: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Carlin Burners...
- Page 53 Figure 21B: Wiring Diagram, Steam, McDonnell & Miller 67 Float LWCO for Riello Burners...
- Page 54 If the thermostat is not satisfi ed and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high limit is closed by a drop in boiler water temperature.
- Page 55 Figure 22A: Wiring Diagram, Water without Tankless Heater for Carlin Burners...
- Page 56 Figure 22B: Wiring Diagram, Water without Tankless Heater for Riello Burners...
- Page 57 10 seconds. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low limit in the L8124C control.
- Page 58 Figure 23B: Wiring Diagram, Water with Front Tankless Heater for Carlin Burners...
- Page 59 Figure 23C: Wiring Diagram, Water with Front Tankless Heater for Riello Burners...
- Page 60 10 seconds. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low limit in the L8124C control.
- Page 61 Figure 23D: Wiring Diagram, Water with Rear Tankless Heater for Carlin Burners Figure 23E: Wiring Diagram, Water with Rear Tankless Heater for Carlin Burners...
- Page 62 Figure 23F: Wiring Diagram, Water with Rear Tankless Heater for Riello Burners...
- Page 63 . GENERAL 1. Use fl exible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil fi lter is recommended as a minimum for all fi ring rates but a pleated paper fuel oil fi...
- Page 64 . TWO PIPE OIL LINES 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 3 (two-stage) and Table 4 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 25.
- Page 65 Open full port ball valve in boiler system piping. k. Remove hose from purge valve. l. Confi rm that the boiler and system have no water leaks. BURNER to be sure that all connections are tight and burner is rigid, that all electrical connections have been completed and fuses installed, and that oil tank is fi...
- Page 66 OPEN FLAME OBSERVATION PORT COVER on burner swing door. e. Beckett burners for boiler models V83 thru V86 are factory equipped with (2) nozzles for dual fi ring rates. On packaged boiler models PV83W thru PV86W, the higher fi...
- Page 67 Table 6 and, 3) check the oil pump pressure and adjust if necessary to the setting specifi ed in Table 6, refer to Paragraph F for details. 5. Riello Burners a. OPEN ALL OIL LINE VALVES. b. Provide a pan to catch oil. c.
- Page 68 Figure 27A: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG) Figure 27B: "L1" and "V1" Head Electrode Figure 27C: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG) Positioning and Gun Setting (Beckett AFG) Figure 27D: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)
- Page 69 Install gauge port/bleeder plug and tighten. Start burner again. 6. FLAME FAILURE The V8 boiler controls operate the burner automatically. If for unknown reasons the burner ceases to fi re and the reset button on the primary control has tripped, the burner has experienced ignition failure.
- Page 70 T-T Jumper: Select models have pre- installed T-T jumper resistor. To remove, use side-cutting pliers to cut jumper (See Figure 28). vi. Diagnostic LED: The indicator light on oil primary control provides lockout, recycle and cad cell indications as follows: •...
- Page 71 Close boiler drain and refi ll to normal water line. Burner should automatically restart during fi ll. Lower thermostat setting.
- Page 72 On a call for heat, the relay contacts make to complete the line voltage circulator circuit and also the burner circuit if the boiler water temperature is below the high limit setting. The high limit switch shuts off the burner if boiler water temperature exceeds the high limit setting.
- Page 73 Warning: This product contains refractory ceramic fi bers (RCF). RCF has been classifi ed as a possible human carcinogen. After this product is fi red, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health.
- Page 74 Add boiler water treatment compound as needed (refer to Paragraph B.). o. Restore electric service to the boiler. p. Fire burner to bring the water in the boiler to a boil to drive off free oxygen. q. WARNING — BEFORE RETURNING...
- Page 75 If the condensate can temporarily be wasted, operate boiler only for the length of time it takes for condensate to run clear. If the latter cannot be achieved or if the...
- Page 76 Both can result in reduced boiler life. The accumulation of sediment can eventually isolate the water from contacting the cast iron. When this happens the cast iron in that area gets extremely hot and eventually cracks.
- Page 77 2. With steam boilers, at end of season add suffi cient water to fi ll boiler to top of water column and leave it that way until fall when water should be drained again to proper level. If at this time boiler water is dirty, drain water, fl...
- Page 78 2. For access to combustion chamber remove two (2) 5/16" - 18 cap screws, one on the right (1¼" long) and one on the left (3¼" long). If boiler is equipped with fl exible fuel line(s), swing door open. 3. For cleaning from the side: a.
- Page 79 Figure 30: Cleaning of Boiler Flueways l l i...
- Page 80 The selection of the nozzle supplied with the V8 boiler is the result of extensive testing to obtain the best fl ame shape and effi cient combustion. Other brands of the...
- Page 81 Oil valve stuck open or closed. All V8 Series Boiler Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require as- sistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.
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- Page 85 i r c ) y l - " " 4 t a l - " " 8 t n I " 6 - " " 2 " 6 t a l - " - " ½ " n i l ½...
- Page 87 l l o . t r . r t . r t . r t . r t . r t - - - . r t ) . r ) . r - - - . r t ) . r - - - ) .
- Page 88 V83 Thru V89 Steam Boilers - Trim and Controls...
- Page 89 " 6 " 7 , f f , f f ¾ " " 3 ¾ " ¾ " ¼ " ¼ " " 4 ° 0 , t i , " , f f ½ " ¾ " ¾ " ¾...
- Page 90 V82 Thru V89 Water Boilers - Trim and Controls...
- Page 91 6" 7" & ¼ ¼ ½ " " 3 ° 0 ½ " ¾ " ½ " " 8 ½ " " 6 " 6 ¾ " " 8 ¾ " ½ " ½ " " 2 " 4 ¼ "...
- Page 93 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. s ' t - - - - - - r i f...
- Page 94 BECKETT OIL BURNER PART NOS. FOR V8 SERIES BOILERS (continued) 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.
- Page 95 CARLIN OIL BURNER PART NUMBERS FOR V8 SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Installation and Operation Instructions For Carlin Model 102 CRD Oil Burner (Form No. 96858) for an exploded view of the burner and a list of spare parts.
- Page 97 The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.
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Page 98: Service Record
SERVICE RECORD DATE SERVICE PERFORMED... -
Page 99: Limited Warranty
NOTE: If the heat exchanger model involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the Burnham Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger. - Page 100 Boiler Co., Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Co., Inc., to ship said parts prepaid to Burnham Hydronics at the above address for inspection or repair. In addition, the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with his claim before resorting to legal remedies in the courts.