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Burnham PF-5 Series Installation and Operation Manual

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1. 7 LKS e uy uuu a au ni 7 SECTION TI CAST IRON BLOCK ASSEMBLY Assembly of Sections Manual a a Osa aa 9 Assembly of Sections Hydraulie 18 Hydrostatic a RES i ane 14 SECTION III INSTALLATION INSTRUCTIONS OVER Platos didi ass adt O 15 Pressure Relef DOOR t nna E Da ta 15 Firewall Plates uyu un bla 15 Burner Mounting N R u oe sd 15 Canopy usan yuqa ee 16 Boiler at as m 18 Jacket ASsemDly u ACA hua a asus sas 22 Tankless Heater as s ep 24 Steam N cT sis a mana m EE Q maaa 24 Water NN a a an 28 r u tQ iw asides sis se i asis 28 SECTION IV OPERATING INSTRUCTIONS CS 29 PLOT USEING Controls uuu A S A 29 Adjustimg BUHE suce uyu 29 Testing COR EOS uuu sd as 29 Initial Cleaning Steam Boilers sa auts k 29 91 ImualCleanineg Water 81 Boiler Water Treatment u aise 31 OR LET Aan POS nasa uQ s SAD ut
2. WATER Er HOT WATER AUTOMATIC FAUCETS WASHERS ETC HOSE IN HOT WATER LINE FOR PERIODIC FLUSHING OF SEDIMENT GLOBE VALVE WATER OR HD COCK SUPPLY K W FLOW REGULATOR IN COLO WATER LINE AT LEAST 3 FEET AHEAD OF TANKLESS HEATER SC NOTE IT IS IMPORTANT THAT WATER HEATERS BE CENTRALLY LOCATED IN BOILER COPPER TEE XA COPPER TEE RN 2 4 5 9 O EIGHT HEATER MANIFOLD SEVEN HEATER MANIFOLD MINIMUM PIPING RECOMMENDATION FOR PF 5 TANKLESS WATER HEATER MANIFOLDS Fig 27 TANKLESS WATER HEATER RATINGS Steam and Water BOILER MODEL NUMBER OF 548 HEATERS INSTALLED co GO CO OD OO OO CO CO CO COO CO G9 C CO CO CO Ratings are given in gallons per minute continuous flow of water heated from 40 F to 1409F with 2009F boiler water TABLE 1 SURFACE BLOW OFF CONNECTION SAFETY VALVE STEAM BOILER FRONT VIEW STEAM BOILER SAFETY VALVE HOOK UP Fig 28 Fig 29 26 INSTALL DRAIN VALVE CONTROL APPLICATIONS SIZE OF WATER LOCATION TAPPINGS STEAM PROBE TYPE SE F LOW WATER CUT OFF ETHER F LOW WATER CUT OFF NOT USED 3 4 PRESSURE TEMPERATURE LIMIT CONTROL LIMIT CONTROL s OPERATING CONT OPERATING CONT TANKLESS HEATER TANKLESS HEATER PRESSURE COMB ALTITUDE REVERSE ACTING LOW WATER NOTE 3 TAPPING ON BACK SEC
3. FX jcr c Bx m Fx cr Bx 12 ex c ic cr 13 jexjer je jc cr m c er fe jerjexjerje c ox 15 rx c c jexjcr jc jc jer ax pe rx c cr cr c cr 1 jexje jer Jer cr jc 18 cT je c ferje cr 20 texte c cr jcx jetje jer je ferje ax m x fe fe ex fer ex je fer je fer ex Jere jc Fig 8 ud ab ME e EC Nd Ue CHANNEL BLOCK IN POSITION Fig 10 wet SAT gt d x SECTION ASSEMBLEDGE Fig 11 12 14 Excess length of tie rods must be sawed off so they will not extend beyond end sections Rods should project equally at each end to insure proper fit of the jacket See Figure 11 for complete boiler section assem blage Illustration shows boiler equipped with sec tions for built in water heater B Assembly of Sections Hydraulic Draw Up The entire assemblage may be drawn up at one time using hydraulic draw up equipment providing
4. 82 Warnings about Frequent Water Addition 32 SECTION V SERVICE INSTRUCTIONS Cleaning Boiler Heating Surfaces 88 Maintenance of Low Water Cutoff Devices 88 Checking Burner Controls iu aen ii ads 34 Kubr leji u Sa ahay 35 General Maintenance Considerations 35 Attention to Boiler while not in Operation LLL uqa ORA 85 SECTION VI REPAIR PARTS Regional Office Directory 85 Bare Boiler Assembly i nd sl ies oso eee 36 38 Steam W ter K 99 Jacket Assembly l i e 40 41 QU NUMBER SECTIONS 4 TOP FLOW TAPPINGS Fig 1 Dimensional Information TAPPED HOLE FOR BREECHING RATING PLATE PRESSURE SENSING LOWEST PERMISSIBLE S TER LEVEL ult Ue 81 DIA REMOVE LEFT E la a a SIDE PANEL FOR CLEANING ACCESS 3 RETURNS L H SIDE VIEW FRONT VIEW SECTION THRU BOILER WITH FLUSH JACKET TABLE 1 RATINGS DAT
5. 9 O T TU N JE KC KI CI KC KI KC CI I K gt mi 0 IJ HORIZONTAL RUNS ON RISERS SECONDARY SUPPLY SUPPLY USE REDUCING ELBOW OR ATTACH EQUALIZER TO BOTTOM OF HEADER EQUALIZER GATE VALVE BOILER MAKE UP WATER via GLOBE VALVE DRAIN COCKS FORFLUSHING BOILER 8 SYSTEM CORRECT PHYSICAL ARRANGEMENT FOR STEAM HEADERS INCLUDING RECOMMENDED VALVING FOR EFFECTIVE CLEANING SUPPLY AT WRONG END END OF HEADER BUSHED DOWN HORIZONTALLY NO HORIZONTAL RUNS EQUALIZER ON RISERS EQUALIZER INCORRECT PHYSICAL ARRANGEMENT FOR STEAM HEADERS Secondary Supply connections illustrated in dotted lines are to be used only in addition to supply connections shown in solid lines not in lieu of Fig 22 ASSEMBLY OF JACKET A Open jacket carton and jacket hardware package Un less otherwise stated all jacket components are fasten ed with 8 x sheet metal screws Do not drive sheet metal screws tight until jacket assembly is com plete Install threaded plastic leg spacers 2 per panel into bottom of each jacket panel See Figure 1 Place the lower front jacket panel in place below the burner plate Install upper front panel by sliding it down behind the flanges of the front burner plate At tach the lower panel to the upper panel with two sheet metal screws Figure 23 shows the front panels assem bled to the boiler Assemble jack
6. QUANTITY CLEANING SOLUTION BOILER WATER CAPACITY CAUSTIC TRISODIUM O TO WATER LINE SODA PHOSPHATE bi GALS LBS LBS 504 PF 505 506 PF 507 PF 508 PF 509 PF 510 PF 511 PF 519 230 9 e 520 PF 521 253 Maintain 95 Sodium Chromate and 5 Sodium Borate water treatment compound at the following concentration after boiler is cleaned Steam Boilers 2 b per 100 gallons of boiler water Hotwater Boilers 1 Ib per 1400 gallons of heating system water NOTE THE USE OF THESE CHEMICALS MAY BE RESTRICTED IN SOME AREAS TABLE Ill 30 M Start burner and operate sufficiently the water without producing steam pressure Boil for about 5 hours Open boiler feed pipe sufficiently to permit a steady trickle of water from the surface blowoff pipe Continue this slow boiling and trickle of overflow for several hours until the water coming from the over flow is clear Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety Refill boiler to normal water line If water in gauge glass does not appear to be clear repeat steps A thru C and boil out the boiler for a longer time Remove temporary surface blowoff piping plug tap ping and reinstall safety valve Boil or bring water temperature to 180 F promptly in order to drive off the dissolved gases in the fresh water If unstead
7. Form 52003 5 TEST CONTROLS WARNING Before Installation of the boiler is considered complete the operation of the boiler controls should be checked particularly the low water cutoff and the high limit con trol A CHECK OPERATING CONTROL OPERATION Raise and lower operating control setting as required to start and stop burner B WARNING CHECK HIGH LIMIT CONTROL Jumper Operating Control Terminals Allow burner to operate until shutdown by limit Installation is not considered complete until this check has been made REMOVE JUMPER 29 CHECK LOW WATER CUTOFF control with water level at normal water line see Figure 1 Raise op erating control setting to allow burner to operate Open boiler drain to allow water level to drop to bottom of sight glass until burner operation is shut down by low water cutoff Close boiler drain and refill to normal water line Burner should automatically restart during fill Reset operating control IMPORTANT PROBE AND FLOAT TYPE LOW WATER CUT OFF DEVICES REQUIRE ANNUAL INSPECTION AND MAINTENANCE Refer to step of Service Instructions for proper cleaning instructions D CHECK OPERATING CONTROL on boiler equipped with tankless heaters With burner off draw hot water until burner starts then turn off hot water and check burner shutdown 6 CLEANING A NEW STEAM BOILER Oil greases amp sediments which accumulate in a new boiler and piping must be removed from
8. Steel Mtg Plate Assy for G amp P R 8 Burner G amp P R 10 Burner Powerflame C2 Burner Powerflame C3 Burner Carlin 1050 FFD Burner Carlin 1150 FFD Burner Webster J B1 Bur PF504 Webster JB1 Bnr PF505 13 Webster JB2 Burner Observation Port Assy Cast Iron Mtg Plate Cover 1 each Shutter 1 each Glass 1 Shutter Handle 1 each Shutter Spring 1 each Shutter Spring Pin 1 ea Shutter Handle Knob 1 ea Outer Gasket 1 each Inner Gasket 1 each Sight Assembly Steel tg Plates except Webster bnr Pyrex Sight Glass 1 each Sight Glass Gasket 2 each Conduit Bushing Peep Sight Retainer 1 each Peep Sight Webster Burner Burner Mtg Plate Insulation Cast Iron Burner Mtg Plate Insulation Carlin 301 601 801 Powerflame C1 amp R 6 and ABC Bnrs Steel Mtg Plate Insulation Insulation depends on burner used Contact sales office for repair parts REPAIR PARTS FOR BARE PART NO 6172501 7172503 7172505 7172502 7066004 7066002 60861014 60861011 60861012 60861012 6112524 803250002 6032503 7032501 7032502 60225011 60225021 60225031 60225041 60225051 60225061 60225071 6022540 6022541 6022542 7026004 7026005 8026032 8026033 8026034 8206002 8026082 8026083 806600518 806600050 8202502 504 505 506 507 1 2 1 m m I lllllli i 1111 1 3 2 Gele 1 4 2 Kra
9. 1 8 l lll l 37 BOILER ASSEMBLY BOILER SIZE QUANTITY 508 509 510 511 512 513 514 1 1 1 1 1 1 1 6 7 7 8 9 10 10 3 4 4 4 5 5 5 1 1 1 1 2 1 1 1 1 1 1 1 7 8 9 10 11 12 1 14 16 18 20 22 24 96 do Q 2 xm Tl v 1 1 1 1 7 8 10 11 12 13 1 cs t PTS 1 1 i 1 1 1 o d do a cr B di L 1 1 1 1 1 1 NIB RM E 1 1 1 1 1 1 515 1 11 6 b Bat c 1 1 1 1 1 11 fet lel Gli elec l 516 1 12 6 5 517 13 518 gt TE n e D mm e ac sl e SZ S8r l 521 16 srl BOILER ASSEMBLY Continued BOILER SIZE QUANTITY NO DESCRIPTION NO 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 17 Firewall Plates 82025001 1 1 2 2 8 8 4 4 5 6 6 6 6 6 6 6 6 18 Pressure Relief Door Assembly 6112525 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 19 Canopy Assembly Assembly 504 61125042 1 Canopy Assembly 505 61125052 1 Canopy Assembly 506 61125062 1 Canopy Assembly PF 507 61125072 1 Canopy Assembly PF 508 61125082 1 Canopy Assembly 509 61125092 1 Canopy Assembly PF 510 61125102 1 Canopy Assembly PF 511 61
10. 1 806600018 1 806600008 1 806601501 1 1 806601514 1 806601516 1 806601517 Quantity PART 1 80160800 1 8056025 1 8056022 Pressuretrol 1 806603006 Water Gauge Set 2 806604501 Safety Valve 1 80660039 Syphon 1 806600508 Bottom Drain Tapping 1 Reverse Acting Control Tappings 2 806603512 Low Water Cut Off Tappings 2 806608517 Bottom Washout Tapping 1 806603514 1 806603001 1 81460009 2 80860000 505 508 512 515 504 to to to to 521 507 511 514 520 1 81660501 1 81660505 1 81660503 1 81660507 1 81660508 1 81660509 1 806601076 1 806601077 1 806601078 1 806601079 1 806601080 1 806601064 39 te 8I4 13NwYd INO43 H3MO1 L332VC IINvVd 2015 1 L332VC d3NVd 3015 2S 60S 1331 5 3Nvd IVHOJINI 3015 IH9I4 L3XOVvC 13Nwd L332VC O 339319 891113 3NVg 3015 1331 125 608 SJINVA 3015 1431 L13M2vC 3NVd HV3U 128 215 13NYd WHOSLNI 401 LAMI 115 05 NO 9NIN3dO 3113 13NYd 401 LM V 40 JACKET REPA PARTS ITEM PART BOILER QUANTITY NO DESCRIPTI
11. CODE AND LOCAL CODES SERIOUS PROPERTY DAMAGE COULD RESULT IF THE BOILER IS NOT PROPERLY VENTED READ THE LITERATURE ENCLOSED BY THE MANUFACTURER WITH THE VARIOUS ACCESS ORY DEVICES THESE ACCESSORY DEVICES MUST BE INSTALLED AND USED ACCORDING TO THE RECOMMENDATIONS OF THE MANUFACTURER IT IS THE RESPONSIBILITY OF THE INSTALLING CONTRACTOR TO SEE THAT ALL CONTROLS ARE CORRECTLY INSTALLED AND ARE OPERATING PROPERLY WHEN THE INSTALLATION IS COMPLETED FOR OPTIMUM PERFORMANCE FROM THIS UNIT SERVICE AS SPECIFIED IN SECTION V OF THIS MANUAL IN ALL CASES CLEARANCES BETWEEN BOILER AND OR SMOKE PIPE SURFACES AND COM BUSTIBLE MATERIALS MUST COMPLY WITH NATIONAL FUEL GAS CODE ANSI Z223 NFPA 54 DATED 1988 OR CURRENT EDITION AND FOR OIL 211 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 PROBE AND FLOAT TYPE LOW WATER CUTOFF DEVICES REQUIRE ANNUAL INSPECTION AND MAINTENANCE REFER TO SECTION V ITEM 4 FOR STEP BY STEP INSPECTION AND CLEAN ING INSTRUCTIONS WARNING HIGH WATER TEMPERATURES INCREASE THE RISK OF BURNS OR SCALDING INJURY INSTALL AN AUTOMATIC MIXING VALVE AT THE TANKLESS HEATER OUTLET TO AVOID EXCESSIVELY HOT WATER AT THE FIXTURES AS SHOWN IN FIGURE 26 TABLE OF CONTENTS SECTION I GENERAL INFORMATION Raons Dal y u m sans us ki 6 the
12. ing a heat exchanger TO SYSTEM BYPASS VALVE THERMOME TER BOILER SUPPLY VALVE ORAIN COCK RECOMMENDED BYPASS PIPING WATER BOILERS Fig 19 61 PF 504 AND 505 506 PF 509 510 THRU PF 513 514 THRU 517 518 THRU PF 521 Secondary Supply Connections illustrated in dotted lines are to be used only in addition to supply connections shown in solid lines not in lieu of MINIMUM PIPING REQUIREMENTS STEAM BOILERS Fig 20 OPTIONAL SECONDARY ha SUPPLY SUPPLY RISER SPACING INCHES BOILER 312 UN ili MO fN In NIN a I U U 1 ol O O E N N a 59 Lets ili a NE WE EN 4 NE TK E 2382 x al N e M 0c SUPPLY SUPPLY FRONT FRONT BACK 3 RETURN RETURN HEADER BACK RETURN PF 504 THRU PF 507 508 THRU PF 513 SUPPLY 3 SUPPLY HEADER FRONT BACK 3 RETURN HEADER PF 514 THRU PF 521 MINIMUM PIPING REQUIREMENTS WATER BOILERS SUPPLY BOILER AND NUMBER RETURN HN 2 1 2 2 2 Ti 506 507 508 F 509 F 51 PF 51 512 PF 5 5 PF 5 5 F 5 5 F 519 F 520 72170 U O E O 5 T m 9
13. water cutoff control and the probe 4 Dismount the low water cutoff control from the probe 5 Unscrew the probe from the boiler tapping 6 Inspect that portion of the probe that is exposed to the boiler water for a scale or sediment buildup 7 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 tenacious lime deposits The most stubborn deposits may be re moved from the probe by using a diluted amount part of water to 1 part of phosphoric acid CAUTION Exercise caution when handling phosphoric acid and fol low the instruction label on its container 8 Wire brushing of the probe is not recommended as the soft platinum guard ring sandwiched between the ceramic insulators may be damaged Care must be taken not to damage this ring in any way or the useful life of the probe may be shortened 9 Clean the pipe threads of the probe to remove old hardened pipe dope and other foreign matter 10 Apply a moderate amount of good quality pipe dope to the pipe threads on the probe leaving the two end threads bare Do not use PTFE Teflon tape 11 Screw the probe into the boiler tapping 12 Mount the low water cutoff control on the probe 13 Reeonnect the control to probe wiring 14 Fill the boiler to its normal waterline 15 Add boiler water treatment compound as needed see Table 8 16 Restore electric service to
14. 2 2 2 2 8 8 8 8 4 4 4 4 5 5 Paper Containing Sheet Metal Serews 8 x 1 2 Lg Phillips Truss Hd Type AB Pit d 80860000 46 46 52 52 52 62 72 72 72 72 78 78 78 78 84 84 84 84 12 Leg Spacer 806603518 8 8 8 8 8 12 12 12 12 12 12 12 12 12 12 12 12 12 4 THIS PAGE LEFT INTENTIONALLY BLANK 42 THIS PAGE LEFT INTENTIONALLY BLANK 43 SS AAA AA PA Red Roe HR 62407 GOS ES RS FO 2 FS GS IGS FS GES GES ITN AGES ITN TES GING to Limited Warranty SERIES 5B SERIES 8B PF 5 SERIES V 9 SERIES FD SERIES WOODLANDER DUO RAD AND CAST IRON RADIATION SAHARA INDIRECT WATER HEATER CP N hae A LIMITED WARRANTY Except as provided below with respect to products or parts not manufactured by Burnham Corporation Burnham Corporation warrants to the original owner at the original installation site that products manufactured bv Burnham America s Boiler Company comply at the time of manufacture with recognized Hvdronics industry regulatory agency standards and requirements then in effect and will be free from defects in materials and workmanship for a period of one vear after the date of installation ADAPA AQ 4 S LVS GUS The remedy for breach of this warranty is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use and does not extend to liability for incidental special or consequential damages
15. Controller Honeywell L4006A2015 Immersion Well Honey well 1238714 NPT Temperature Pressure Gauge Ametek 144840 0 100 PSI Pipe Plug Square Head Black Pipe Plug Square Head Black Pipe Plug 1 NPT Countersunk Black Pipe Plug 3 NPT Square Head Black Bottom Washout Tapping and Low Water Cut Off Tapping Hex Bushing 3 NPT x 4 FPT Black Drain Cock ConBraCo 31 606 01 4 NPT Specific Parts Relief Valves set at 50 PSI ConBraCo 10 303 10 4 NPT x 24 NPT ConBraCo 10 214 10 1 NPT x 1 NPT Watts 740 1 NPT x 14 Watts 740 114 NPT x 1 NPT Watts 740 1 NPT x 2 NPT Safety Valve Piping Hex Bushing 3 NPT x 34 FPT Black Hex Bushing 3 NPT x 1 FPT Black Hex Bushing 3 NPT x 114 Black Hex Bushing 3 NPT x 1 Black Pipe Nipple 4 NPT x Close Black Pipe Nipple 1 NPT x Close Black Pipe Nipple 1 x Close Black Pipe Nipple 1 x Close Black Street Elbow 34 NPT x 90 Black Street Elbow 1 NPT x 90 Black Street Elbow 1 NPT x 90 Black Street Elbow 142 NPT x 90 Black REPAIR PARTS Quantity PART NO STEAM TRIM REPAIR PARTS Common Parts Boiler Sizes 504 thru 521 Pressuretrol Honeywell PA404A 1009 Water Gauge Set ConBraCo 20 104 10 w 812 Lg glass Steam Pressure Gauge Ametek 144350 3 Dia Syphon x 90 4 leg Extension Adapter 2 NPT x Pipe Nipple 3 NPT
16. 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 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 discard Draw off another quart sample and if this sample is not clear repeat the cycle of draining the boiler and and return main and refilling the boiler until samp le is clear 6 If the boiler water becomes dirty again at a later date due to additional sediment loosened up in the piping close gate valve in Hartford Loop open drain cock in return main turn on burner and allow eondensate to flow to drain until it has run clear for at least 30 minutes while feeding water to boiler so as to maintain norma water level Turn off burner drain boiler open gate valve in Hart ford Loop then repeat step 1 above 3l CLEANING WATER BOILER The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner A Remove safety relief valve using extreme care to avoid damaging it B NOTICE Certain state and local codes may restrict the use of some of the chemicals listed for cleaning and main taining the boiler Check with local authorities before proceeding to use these chemicals Partially fill boiler and add caustic soda or trisodium phosphate to the boi
17. for burner tests and adjustments 6 LUBRICATE BOILER COMPONENTS according to manufacturer s instructions Generally this involves the oil burner and circulator This includes the type of lubricant to use frequency of lubrication and points to lubricate 34 1 GENERAL MAINTENANCE CONSIDERATIONS A Keep radiators and convectors clean B If a hot water radiator is hot at the bottom but not at the top it indicates that air has accumulated inside and should be vented To vent radiator hold small cup under air vent located near top of radiator open vent until water escapes and then close C If much water is added to system it is advisable to heat system to a high temperature and vent again This will make less venting necessary during the winter D Where an expansion tank is used make sure that neith er the tank nor its drain pipe is exposed to freezing temperatures Never place valves in piping leading to or from expansion tank E Boiler and system cleaning will help assure trouble free operation See Item under Operating In structions for procedure ATTENTION TO BOILER WHILE NOT IN OP ERATION A IMPORTANT IF BOILER IS NOT USED DURING WINTER TIME IT MUST BE FULLY DRAINED TO PRE VENT FREEZE DAMAGE B Spray inside surfaces with light lubricating or crank case oil using gun with extended stem so as to reach all corners C With steam boilers at end of season add sufficient water to fill boiler to top
18. regulator also limits the flow of supply water regardless of inlet pressure vari ations in the range of 20 to 125 psi B Tempering of Hot Water WARNING Install a mixing valve at the tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at the fixture Refer to Figure 26 for piping recommendations Adjust and maintain the mixing valve in accordance with manufacturers instructions Installation of a tempering or mixing valve will also lengthen the delivery of the available hot water by mixing some cold water with the hot In addition sav ings of hot water will be achieved since the user will not waste as much hot water while seeking water tem peratures to his liking Higher temperature hot water required by dishwashers and automatic washers is pos sible by piping the hot water from the heater prior to entering the mixing valve The mixing valve should be trapped by installing it below the cold water inlet to heater to prevent lime formation in the valve C Flushing of Heater All water contains some sediment which settles on the inside of the coil Consequently the heater should be periodically backwashed This is accomplished by in stalling hose bibs as illustrated in Figure 26 and al lowing water at city pressure to run into hose bib A through the heater and out hose bib B until the dis charge is clear The tees in which the hose bibs are located should be the same size heater c
19. the rear section extending them through the tapped holes in the front section Be sure to screw draw up rods into couplings far enough to prevent stripping threads 4 Place a 12 lg steel channel on each end of the upper draw up rod and an 8 lg steel channel on each end of the lower draw up rods Install nuts and washers on one end of the draw up rods and the hydraulic rams washers and draw up rod clamps on the other See Figure 12 NOTICE Rods should be approximately centered in openings so that rods and couplings when used do not drag on pipe thread in end section tappings 13 5 Draw up Sections WARNING READ THE STATEMENTS BELOW BEFORE AT TEMPTING TO USE HYDRAULIC EQUIPMENT RELEASE PRESSURE IN RAM PUMPS BE FORE ATTEMPTING TO REMOVE CLAMPS DO NOT STAND IN LINE WITH DRAW UP RODS AT EITHER END WHEN HYDRAULIC PRESSURE IS BEING APPLIED AS A SAFE TY MEASURE ENDS OF DRAW UP RODS SHOULD BE COVERED WHILE SECTIONS ARE BEING DRAWN IN CASE RODS SHOULD SNAP WHILE UNDER TENSION DO NOT OPERATE RAM AGAINST DRAW UP COUPLING DO NOT OPERATE PUMP AFTER RAM HAS REACHED STROKE LIMIT Use hydraulic rams to draw up sections by applying pressure alternately on the draw up rods When rams reach stroke limit release pressure in ram pumps and then move clamps to new position NOTICE KEEP NIPPLES ALIGNED WITH NIPPLE PORTS If necessary tap nipples lightly with a blunt tool or rod to keep nipples from cock
20. the rear section in its approximate final posi tion as outlined in Section I and support it with a suitable prop See Figure 5 2 Open the Boiler Assembly Carton s 3 Clean nipples and nipple ports thoroughly with a degreasing solvent and apply nipple lubricant pro vided 4 Drive nipples squarely into section using block of wood and hammer or preferably an aluminum headed hammer if available 5 A special nipple setting gauge is provided for the nipples Gauge nipple in both directions to insure that it is driven to the proper depth into the nipple opening Cut out in gauge must rest on nipple with legs of gauge touching finished face of section when nipple is properly driven See Figure 6 NOTICE NIPPLES MUST BE DRIVEN AS DIRECTED TO INSURE TIGHT JOINTS MOST NIPPLE LEAKS ARE CAUSED BY TILTED OR COCKED NIPPLES CAUTION 6 THIS IS A FORCED DRAFT FIRED BOILER amp SEALANT MUST BE APPLIED WHERE SPECI FIED FOR PROPER AND SAFE PERFORM ANCE THE BURNHAM CORPORATION HAS APPROVED A SECTION JOINT SEALANT SI LASTIC MANUFACTURED BY DOW CORN ING UNDER THE PRODUCT NUMBERS OF 192 RT V 732 BL11 AND 781 ALL THREE NUM BERS ARE THE SAME MATERIAL POSITIONING OF BACK SECTION Fig 5 SETTING OF NIPPLES Fig 6 10 11 12 The grooves in the ground joint along the edge of the section should be cleaned with a wire brush Then using a cartridge of sealant in a caulking gun apply 4 bead of Silast
21. the system in order to prevent an unsteady water line and carry over of the water into the supply main above boiler Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler 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 condensate is re turned to the boiler boil out the boiler using the SUR FACE BLOWOFF connection See Figure 29 A Drain boiler until water is just visible in gauge glass Run temporarily 1 pipe line from the surface blow off connection to an open drain or some other location where hot water may be discharged safely Do not in stall valve in this line NOTICE Certain state local codes may restrict the use of some of the chemicals listed for cleaning and main taining the boiler Check with local authorities before proceeding to use these chemicals Drain about 5 gallons of hot water from boiler into a container and dissolve into it 1 pound of caustic soda and 1 pound of trisodium phosphate for each 50 gal lons of boiler water See Table 3 Remove safety valve and add solution to boiler water thru exposed tapping CAUTION Use extreme care in handling these chemicals Caustic Soda is harmful to skin clothing and eyes Do not permit the dry material or the concentrated solution to come into contact with skin or clothing
22. x Close Black Hex Bushing 34 NPT x FPT Black Hex Bushing 3 NPT x Black Pipe Plug 34 NPT Square Head Black Pipe Plug 1 NPT Countersunk Black Pipe Plug 3 NPT Square Head Black Drain Cock ConBraCo 31 606 01 4 Lowest Permissible Water Level Plate Form 1204 Sheet Metal Screw 8 x Lg Phillips Truss Head AB Plated Specific Parts Safety Valves set at 15 PSI ConBraCo 13 202 08 1 NPT x 1 NPT ConBraCo 18 213 08 114 NPT x 12 ConBraCo 13 214 08 1 NPT x 2 NPT ConBraCo 12 205 08 2 NPT x 2 NPT ConBraCo 12 206 08 2 NPT x 2 NPT ConBraCo 12 208 08 3 NPT x 3 NPT Black Tees For Safety Valve 3 NPT x 3 NPT x 1 NPT 3 NPT x 3 NPT x1 NPT 3 NPT x 3 NPT x 1 NPT 3 NPT x 3 NPT x 2 NPT 3 NPT x 3 NPT x 2 NPT 8 NPT 1 80160400 1 80160452 1 8056028 Gauge Glass Tappings 2 806603507 Reverse Acting Control Tappings 3 806603512 Low Water Cut Off Tappings 2 806603517 2 806603514 Bottom Drain Tapping 1 806600509 806603001 Boiler Size 504 506 509 512 519 and to to to to 505 508 511 518 521 1 381660302 1 81660330 1 81660805 1 81660808 1 81660309 1 806600509 1 1 806600559 1 806600560 1 806600542 1 806600022 1 1 806600004
23. 0 pounds EXAMINE BOILER CAREFULLY INSIDE AND OUTSIDE to insure against leaks from cocked nipples or through concealed breakage caused in shipping and handling This precaution is for your protection and will simplify handling of necessary replacements and adjustment claims After making certain that there are no leaks drain boiler and remove plugs for boiler trim and other con nections SECTION 111 INSTALLATION INSTRUCTIONS 1 INSTALL FLUE COVER PLATES over cleanout openings on left side of boiler as shown in Figure 13 CLEANOUT COVER COVER GASKET A Locate the cover plates carriage bolts nuts and wash ers in the miscellaneous parts carton B Attach the carriage bolts to the top and bottom of the flue openings with washers and hex nuts to provide a fixed stud INSULATION C Install flue cover plates amp gaskets over studs and secure with washers and nuts CLEANOUT NUT AND WASHER BOLT 2 MOUNT PRESSURE RELIEF DOOR TOP VIEW CLEANOUT COVER ASSEMBLV WASHERS A Apply a 14 bead of Silastic along the groove on the inside face of the pressure relief door Fig 13 B Mount the pressure relief door onto the rear section with the word Top in the upright position using the 4 s 18 x 1 cap screws located in the miscell aneous parts carton 3 Install the refractorv firewall plates on the right side of the center sections The plates should be installed toward the front of the boile
24. 125112 1 Canopy Assembly PF 512 61125122 1 Canopy Assembly PF 513 61125132 1 Canopy Assembly PF 514 61125142 1 Canopy Assembly PF 515 61125152 1 Canopy Assembly PF 516 61125162 1 Canopy Assembly 517 61125172 1 Canopy Assembly 518 61125182 1 Canopy Assembly PF 519 61125192 1 Camopy Assembly PF 520 61125202 1 Canopy Assembly 521 61125212 1 20 Canopy Insulation Canopy Insulation PF 504 7202504 1 Canopy Insulation PF 505 7202505 1 Canopy Insulation PF 506 7202506 1 Canopy Insulation PF 507 7202507 1 Canopy Insulation PF 508 7202508 1 Canopy Insulation PF 509 7202509 1 Canopy Insulation PF 510 72025010 1 Canopy Insulation PF 511 72025011 1 Canopy Insulation PF 512 72025012 1 Canopy Insulation PF 513 72025013 1 Canopy Insulation PF 514 72025014 1 Canopy Insulation PF 515 72025015 1 Canopy Insulation PF 516 72025016 1 Canopy Insulation PF 517 72025017 1 Canopy Insulation 518 72025018 1 Canopy Insulation PF 519 72025019 1 Canopy Insulation 520 72025020 1 Canopy Insulation PF 521 72025021 21 Cerafelt Gasket 10 Foot Roll 7206018 1 1 15 Foot Roll 7206014 b d d 25 Foot Roll 9206003 1 1 1 1 1 1 1 1 1 1 1 22 Flue Damper Assembly Flue Damper Assy 10 Dia 61125011 1 1 1 1 1 Flue Damper Assy 14 Dia 61125021 1 1 1 1 1 1 1 1 Flue Damper Assy 18 Dia 61125031 1 1 l 1 38 WATER TRIM Common Parts Boiler Sizes 504 thru 521 Aquastat
25. 5 COVER 4 T CAST IRON SLIP NIPPLE TANKLESS HEATER d R 3 16 XI LG X2 CERAFELT STRIP b HEX HD CAP SCREWS W FLAT WASHERS 2 or 3 HEATER COVER PLATE BURNER MOUNTING PLATE INSULATION OBSERVATION PORT OR PEEP SIGHT ASSEMBLY CT CENTER SECTION FIREWALL PLATES FRONT SECTION C CENTER SECTION K DIA ROPE GASKET STEEL MOUNTING PLATES ONLY BURNER MOUNTING PLATE ASSEMBLY 3 4710 TIE ROD W WASHERS 8 NUTS Fig 33 ITEM NO a Qo V 10 11 12 13 14 15A 15B 15 16 DESCRIPTION Front Section C Center Section Optional CT Center I L O Max Center Section with Tankless Heater CX Center Section with 3 Supply Tapping Rear Section 7 Cast Iron Slip Nipple 3 Cast Iron Slip Nipple Tie Rod Sets Tie Rod Bundle 26 34 LG Tie Rod Bundle 37 34 LG Tie Rod Bundle 49 14 LG Tie Rod Bundle 67 134 LG Cleanout Cover Assembly Tankless Htr Cover Plate Gskt 1 each Section Tankless Htr 1 ea Sctn OR Blank Heater Cover Plate 1 opa CT Steam only Tapped Heater Cover Plate 1 each CT Water only Burner Mounting Plate Assy w Observation Port Assy and Mtg Plate Insulation Cast Iron Burner Mounting Plate Assembly for Carlin 301 Burner Carlin 701 Burner Carlin 801 Burner Powerflame C1 Burner G amp P R 6 Burner
26. 8 CANOPY ASSEMBLY SECURED amp SEALED SECTIONS 17 2 If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air the boiler piping must be equipped with flow control valves to prevent gravity circula tion of boiler water during the operation of the cooling system If the boiler will be operated where low boiler water temperatures may be encountered i e converted gravity circulation systems etc the use of a boiler water bypass is recommended to maintain optimum operation Remove the circulator and install a pipe tee be tween the circulator and boiler return along with a second tee in the supply piping as shown in Figure 19 The bypass should be the same size as the sup ply and return lines with valves located in the by pass and supply outlet as illustrated in Figure 19 order to regulate water flow for maintenance of higher boiler water temperature Set the by pass and boiler supply valves to a half throttle position to start Operate boiler until the System water temperature is at a normal operating RETURN MAIN COMBIN FROM COMBINEO HEATING 8 CIRCULATOR HEATING COOLING COOLING SYSTEM SYSTEM range Adjust the valves to provide 180 to 200 F supply water temperature Opening the boiler supply valve will raise the system temperature while opening the by pass valve will lower the system supply tem perature WAR
27. A Number T BURNER Gos 3 stis NET l B R RATING INPUT Pressure eight Required ie Gross inches iler 1 1 Boiler MBh Oil Gas Ibs P F 504 505 PF 506 PF 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 G N Q O LH o N 1 Suffix S indicates steam boiler W indicates water boiler Suf 3 Minimum gas pressure required at std gas train inlet for maxi fix G indicates gas fired O indicates oil fired indicates mum burner input based on 1000 Btu cu ft 0 60 specify gravity combination gas oil fired gas 2 I B R net ratings shown are based on piping and pickup allow 4 Boiler ratings are based on 121406 CO 10 water column pres ances which vary from 1 333 to 1 288 for steam and 1 15 for sure at boiler flue outlet water MAXIMUM ALLOWABLE WORKING PRESSURE Consult manufacturer for installations having unusual piping and USA CANADA pickup requirements such as intermittent system operation exten sive piping systems etc STEAM 15 PSI STEAM 15 PSI Net ratings for water square feet are based on 170 F average MAIER WATER Water t mpsrat ro In System rag OPTIONAL SPECIAL ORDER 70 PSI For higher water temper
28. Fig ure 1 shows correct placement of the plates Install the Lowest Permissible Water Level Plate located in the steam water trim carton on the jacket left panel using sheet metal screws See Figure 1 509 510 1 512 iu 01000 fig E gta 515 514 515 49 8 50 0 36 0 TANKLESS HEATER KNOCKOUT 1 KNOCKOUT NOT USED LJ PF 5 JACKET RIGHT SIDE PANEL ARRANGEMENT COMPLETELV ASSEMBLED JACKET Fig 25 23 For boilers with no tankless heaters proceed to Step Steam Trim or Step Water Trim Install the tankless heater manifolds according to Figure 27 1 CONNECT TANKLESS PIPING AS SHOWN IN Fig 26 See Table II for Tankless Heater Ratings FOLLOWING GUIDELINES SHOULD LOWED WHEN PIPING THE TANKLESS A Flow Regulation 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 waterline to the heater Refer to Figure 26 for piping recommendations The flow reg ulator should preferably be located below the inlet to the heater and a minimum of 12 away from the inlet so that the regulator is not subjected to excess tem peratures that may occur during off periods when it is possible for heat to be conducted back through the supply line The flow
29. M BOILERS Fill boiler to normal water line As shown in Figure 1 the normal water line is 46 from the floor At the start of each heating season and once or twice during the season try SAFETY VALVE to be sure it is in working condition To do this fast en wire or cord to lever of valve and pull lever standing safe distance away from valve B HOT WATER BOILERS In a hot water heating system the boiler and entire system other than the expansion tank must be full of water for satisfactory operation Water should be added to the system until the boiler pressure gauge registers normal system design operating pressure To insure that the system is full water should come out of all air vents when opened WARNING ON A HOT WATER SYSTEM THE PRESSURE MUST NOT EXCEED 50 POUNDS UNLESS THE BOILER IS EQUIPPED ESPECIALLY FOR 70 LBS MAXIMUM WORKING PRESSURE IF BOILER PRES SURE EXCEEDS PRESSURE SETTING OF SAFETY RELIEF VALVE IT MUST BE RELIEVED IMMEDI ATELY AND THE CAUSE OF RELIEF VALVE FAIL URE INVESTIGATED AND CORRECTED EXCESS PRESSURE IS DANGEROUS IN ADDITION COULD CAUSE DAMAGE TO HEATING SYSTEM DO NOT draw water from boiler while in use When adding water while boiler is in operation do not open supply valve fully but add water slowly 3 SET CONTROLS with burner service switch turned OFF 9 ADJUST BURNER according to the burner manu facturer s specifications and for Carlin Burners accord ing to Burnham
30. N SLOWLY AND EVENLY tightening each draw up rod a little at a time so that sections are equally spaced starting with lower draw up rods KEEP NIPPLES ALIGNED WITH NIPPLE PORTS If necessary tap nipples lightly with a blunt tool or rod to keep nipples from cocking while sections are being drawn up DO NOT DRAW UP SECTION WHEN NIPPLES ARE COCKED Con tinue tightening draw up rods equally periodically bumping the section with the heavy block of wood to relieve tension on the draw up rods until sec tions meet iron to iron on the ground surfaces CONTINUE ASSEMBLING SECTIONS IN THEIR RESPECTIVE ORDER Be certain that all sections are drawn up iron to iron at all three nipple ports 10 CAUTION Be sure to apply the sealant to the groove in the ground joints between adjacent sections as the boil er operates with a positive pressure in the firebox and products of combustion will escape between sections unless the sections are properly sealed The sealant should be applied before each section is plac ed on the assemblage APPLICATION OF SEALANT Fig 7 On long boiler assemblies it may be necessary to draw up a partial block if the entire boiler is not ready to be drawn up tight within four hours of the first application of Silastic If the block as sembly time extends overnight the partial block completed must be drawn up tight before leaving the boiler overnight If a joint springs out i
31. NING A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation KEF ARE CLOSED IN WINTER ANO OPEN IN SUMMER CRU ARE IN WINTER AND CLOSED IN SUMMER SHUT OFF VALVE RECOMMENDED PIPING FOR COMBINATION HEATING amp COOLING REFRIGERATION SYSTEMS WATER BOILERS Fig 18 18 OXYGEN CORROSION Oxygen contamination of the boiler water will cause corrosion of the iron and steel boiler components which can lead to failure As such any system must be designed to prevent oxygen absorption in the first place or prevent it from reaching the boiler Problems caused by oxygen contamination of boiler water are not covered by Burn ham s standard warranty 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 sys tem In order to insure long product life oxygen sources should be eliminated This can be accomplished by taking the following measures 1 Repairing system leaks to eliminate the need for addition of make up water 2 Eliminating open tanks from the system 3 Eliminating and or repairing fittings which allow oxygen absorption 4 Use of non permeable materials in the distribution System 5 Isolating the boiler from the system water by install
32. ON NO 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 1 Jacket Right Side Panel Sub Assembly 504 521 504 60425042 1 1 1 1 1 1 1 60425052 1 506 60425062 1 1 1 1 507 60425072 1 508 60425082 1 1 1 1 1 2 Jacket R S Integral Panel Assembly 509 521 509 60425044 1 1 1 1 510 60425054 1 1 1 1 511 60425064 1 1 1 512 60425074 1 1 1 1 1 1 1 3 Jacket L S Panel Sub Assembly 504 521 504 60425043 1 1 1 1 1 1 1 505 60425053 1 506 60425068 1 1 1 1 507 60425078 1 508 60425088 1 1 1 1 1 4 Jacket L S Integral Panel Assembly 509 521 509 60425045 1 1 1 1 510 r 60425055 1 1 1 1 511 60425065 1 1 1 512 60425075 1 1 1 1 1 1 1 5 Jacket L S Panel Filler Piece Assembly 6042501 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 Jacket Rear Panel Assembly 6042502 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7 Jacket Upper Front Panel Assembly 6042508 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8 Jacket Lower Front Panel Assembly 60425221 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9 Jacket Top Panel Assembly 504 604250461 1 505 604250561 1 506 604250661 vcl 507 604250761 1 508 604250861 1 509 604250961 1 510 604251061 1 511 604251161 1 512 604251261 1 513 604251361 1 514 604251461 1 515 604261561 1 516 604251661 1 517 604251761 1 518 604251861 1 519 604251961 1 520 604252061 1 521 604252161 1 10 Jacket Top Integral Panel Assembly 512 521 512 515 60425231 1 1 1 1 516 521 60425241 1 1 1 1 1 1 11 Jacket Top Panel Filler Piece Assembly 6042525 1 1
33. PRICE 3 00 INSTALLATION OPERATING AND SERVICE INSTRUCTIONS PF 5 SERIES CAST IRON HYDRONIC HEATING UNIT FORCED DRAFT FOR LIGHT OIL GAS LIGHT OIL OR GAS HOT WATER OR STEAM 18 SIZES GROSS OUTPUT 620 000 to 3 430 000 BTU HR H For service amp repairs to the heating plant call your heating contractor When seeking information on the boiler provide series and size designation shown on the rating plate Boiler Number Firing Type System Heating Contractor Address Phone No OBurnnam AMERICA S BOILER COMPANY Burnham Corporation Form No 52009N 8 94 1725f 8142501 Lancaster PA 17604 3079 SORT OUT ALL CARTONS BUNDLES AND SECTIONS and check against Shipping Schedule Chart Viet to be certain that you have all the material required to assemble the Boiler you ordered SHIPPING SCHEDULE CHART 5 Y a S gt Z lt o ow BOILER lt 28 3 S ZE m L o gt 2 gt z x lt lt Me 288258 56126 ls wl L uo ice w OF 2 jut lt x O l lt J x lt 5 lt alaa lt lt lt lt 5F GC x x S0 00 m woe u a nok c v t LL gt lt LL wem T 1 ELLEN ri mer el pr IMMIDD DEM b s e e Ce fo P L ti UU Dr je
34. TION SAFETY VALVE PIPED IN CONNECTION WITH BLOW OFF ON STEAM BOILERS SEE FIG 29 TAPPING USED FOR CONNECTING SAFETY RELIEF VALVE ON WATER BOILERS SEE FIG 32 27 13 WATER BOILERS INSTALL WATER TRIM BURNER INSTALLATION Items for water trim are located in the water trim carton except for the separately ordered low water cutoff Fig Refer to burner manufacturer s installation manual and ure 80 shows the proper tappings for each item Figure for Carlin burners Burnham Form 52003 for proper 91 shows front view of an assembled water boiler installation fuel piping wiring burner adjustment and service instructions If necessary use a hacksaw blade or knife to cut hole to the proper size in the burner plate in A Install the temperature pressure gauge sulation for receipt of burner air tube B Install the low water cutoff C Install the immersion well and mount the aquastat onto the well D Install the drain cock using the 3 NPT x hex bushing E Install the pressure relief valve as shown in Figure 82 F Plug extra tappings VALVE OUTLET PIPED TO DRAIN PRESSURE RELIEF VALVE l _ BACK OF BOILER WATER BOILER FRONT VIEW WATER BOILER T PRESSURE SAFETY RELIEF VALVE HOOK UP ig Fig 32 28 SECTION iV OPERATING INSTRUCTIONS 1 ALWAXS INSPECT INSTALLATION BEFORE STARTING BURNER 2 FILL HEATING SYSTEM WITH WATER A STEA
35. ancaster PA 17604 717 293 5861 Fax 293 5855 New Mexico New York Albany Fulton Montgomery Rensselear Saratoga Schenectady Schoharie Warren Washington Counties Sullivan County All other Counties North Carolina North Dakota Ohio Athens Belmont Gallia Jefferson Lawrence Meigs Monroe Washington Counties All other Counties Oklahoma Oregon Pennsylvania Rhode Island South Carolina South Dakota Tennessee Texas Utah Vermont Virginia Arlington Accomack Clarke Fairfax Frederick Fauquier Loudoun Northampton Prince William Counties All other Counties Washington Washington D C West Virginia Wisconsin Wyoming Canada gt gt aut WU K K gt gt gt gt G gt gt gt D gt gt gt gt gt G 9 CANOPY INSULATION SECUREO WITH CANOPY WIRE FLUE DAMPER CAUTION TAG FLUE DAMPER ASSEMBLY 4 20 FINISHED HEX NUT W Z PLATEO FLAT WASHER AS 20X5 LG J BOLT 18 XI LG HEX HEAD CAP SCREW 9 W FLAT WASHER CLEANOUT COVER ASSEMBLY W INSULATION FLAT WASHERS REAR SECTION F 20 X 7 LG J BOLT t DIA ROPE PRESSURE RELIEF GASKET DOOR ASSEMBLY 20X2 LG 18 HEAVY HEX NUT W amp PLATED FLAT WASHER CANOPY MOUNTING BRACKET 10X4 SLOTTED PAN HEAD b SHEET METAL SCREW GE we Pd _ CANOPY d ASSEMBLY CANOPY CHANNEL 5 I 18XI LG CARRIAGE BOLT 5
36. atures select boiler on basis of I B R Ratings shown above apply at altitudes up to 1000 feet on oil and i 2000 feet on gas For altitudes above those indicated the ratings NEE MBH should be reduced at the rate of 4 for each 1000 feet above The i B R burner capacity in GPH is based on oil having a heat sea level value of 140 000 BTU per galion SECTION GENERAL INFORMATION CONTINUED 1 INSPECT SHIPMENT carefully for any signs of damage A ALL EQUIPMENT is carefully manufactured inspect ed and packed Our responsibility ceases upon delivery of crated Boiler to the carrier in good condition B 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 2 BOILER INSTALLATION Must conform to the authority having jurisdiction or in the absence of such requirements to USA Installation of oil burning equipment ANSI NFPA 31 CANADA Oil Fired Steam and Hot Water Boilers for Commercial and Industrial use CSA Standard B140 7 2 1967 Re affirmed 1991 MINIMUM INSTALLATION CLEARANCES TO COM BUSTIBLE MATERIAL Front 24 Inches Above or Top 6 Inches Sides 6 Inches Vent Connector Pipe 18 Inches Rear 6 Inches NOTE 1 Listed clearances comply with American National Stan da
37. east from all combustible construction a TU With STEAM HEATING see Figure 20 consult I B W R Installation and Piping Guide No 200 H Place canopy insulation over canopy foil side up fold down sides and secure with wire NOTICE PARTICULAR ATTENTION SHOULD BE GIVEN TO THE CONSTRUCTION OF THE HARTFORD LOOP ON STEAM BOILERS FIGURE 22 ILLUSTRATES THE RIGHT AND WRONG WAY TO CONSTRUCT THE STEAM HEADER Inspect Seal A After the platework is in place a visual inspection C With forced circulation HOT WATER HEATING should be made of all sealed joints and repairs made if necessary A darkened boiler room with a light source in the combustion space and canopy will aid this inspection 16 see Figure 21 consult Installation and Piping Guide No 200 1 If this boiler is used in connection with refrigera tion systems the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler see Figure 18 Also consult I B R Installation and Piping Guides aa en n Z ZZ Hy ZZ GROOVES AT TOP OF SECTION FOR CANOPY SEALANT Fig 16 i A gt Ep TA ET quit i Py 7 h LZ k Vaks 7 vite osi L 2 4 THIMBLE
38. ed in paragraphs be low While service or maintenance is being done electri cal power to the boiler must be off 3 CLEAN THE BOILER HEATING SURFACES AND FLUE at least once each year preferably at the end of the heating season A CLEAN THE VENT SYSTEM Vent system should be checked annually for 1 Obstructions 2 Accumulations of soot 8 Deterioration of vent pipe or vent accessories due to condensation or other reasons 4 Proper support no sags particularly in horizontal runs 5 Tightness of joints Remove all accumulations of soot with wire brush and vacuum Remove all obstructions Replace all deterior ated parts and support properly Seal all joints B CLEAN THE BOILER FLUEWAYS 1 Remove the smokepipe 2 Remove the jacket top and left side panels 3 Remove the canopy being careful not to damage the cerafelt gasket 4 Loosen nuts securing the flue cleanout plates and remove the plates The insulation should be remov ed with the plates taking care not to damage the insulation 5 Using a 1 diameter wire or fibre bristle brush 36 handle clean the flueways Brush from the top and side using horizontal and diagonal strokes for best results C CLEAN TOP OF BOILER SECTIONS Brush and vacuum the tops of the boiler sections D CLEAN THE FIREBOX 1 Disconnect fuel line s and remove burner and burner mounting plate 2 Using wire or fibre bristle brush clean crown of boiler and inside o
39. es should be maintained with a chromate concentration of 2 lb 100 gal see Table 3 of boiler water 2200 ppm This concentration will be effective where all or practically all of the condensate is returned to the boilers B Hot Water Boilers The use of chromate boiler water treatment compound in a water boiler involves considerations Too high a concentration must be avoided as it may damage pump seals Therefore with a lower level of protection it is necessary to take even greater precautions to Keep free oxygen out of the system Free oxygen can enter from system leaks faulty vents or vents improperly located with regard to pumps and from makeup water Hot water heating boilers should be maintained with a chromate concentration of 1 lb 1400 gal of boiler water See Table 3 9 Make pH or Alkalinity Test After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except it gives specific readings A small color chart on the side of the small hydrion dispenser gives the reading in pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add some of the washout chemical caustic soda if necessary to bring the pH
40. et side panels If the boiler has more than eight sections the jacket side panels will consist of two pieces which should be assembled before application in addition a small filler piece attaches to the left side panel If the boil er has more than sixteen sections the jacket side panels will consist of three pieces which should be as sembled before application See Figure 24 for proper arrangement of right side panels Install jacket side panels In case of steam boilers remove knockouts from the left side panel filler piece for gauge glass fittings When tankless heaters are used remove the appropri ate knockouts from the right hand side panel Install the back panel and then the top panel s If the boiler has more than 11 sections the jacket top panels will consist of two pieces which should be as sembled before application Knockouts in the top panel are provided for supply piping clearance Filler pieces are to be assembled to panel where knockouts are removed Tighten all jacket screws uniformly tight 22 FRONT JACKET PANEL IN POSITION Fig 23 H Locate the Rating Plate Water Treatment Caution 1 Plate Burnham Logo Plate in the Miscellaneous Parts Carton Install the Rating Plate and Water Treatment Caution Plate on the jacket front panel using sheet meta screws Attach the Burnham Logo Plate to the front panel by peeling off the paper back ing and lining up the tabs with the jacket slots
41. f water legs E REASSEMBLE BOILER 1 Install the canopv taking care to align the cerafelt strips If strips are damaged replace as needed 2 Reinstall burner mounting plate to front section making sure Flextex rope gasket is in place and forms gas tight seal If gasket is damaged replace 3 Bolt burner to burner mounting plate Inspect gas ket to assure adequate seal Replace if damaged Connect oil line s and or gas line s 4 Reinstall flue plates making sure gasket on each plate is in place and forms gas tight seal If dam aged all edges of the cleanout plates should be seal ed with Silastic sealant when reinstalled until in sulation can be replaced 33 5 Reinstall jacket top and left side panels 6 Reinstall smokepipe 0 MAINTENANCE OF LOW WATER CUTOFF DE VICES IMPORTANT PROBE AND FLOAT TYPE LOW WATER CUTOFF DEVICES REQUIRE ANNUAL INSPECTION AND MAINTENANCE A PROBE TYPE LOW WATER CUTOFF Athough these devices are solid state in the operation the probe is exposed to possible contamination in the boiler water and subject to fouling It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scale or sediment Follow these steps to inspect clean and or replace the probe 1 Turn off electric service to the boiler 2 Drain boiler water to a level below the tapping for the probe 3 Disconnect wiring connections between the low
42. g lugs in the mounting plate carton Attach the lugs to the weld studs on the burner mounting plate with the hex nuts amp washers When the burner is in stalled orient the lugs towards the center of the open ing such that they hold the burner flange in place 5 Assembly Attach the canopy brackets to the ends of the canopy with sheet metal screws Two piece canopies should be joined together using the 10 x sheet metal screws provided B Along the groove provided on top of the sections and across the top of the end sections apply 2 wide strips of cerafelt and lap joint at corners See Fig 16 C Place the canopy on the sections with the word 1 BOILER PIPING FRONT positioned over the front section zs CONNECT SUPPLY AND RETURN PIPING TOL D Secure the canopy to the end sections by extending the HEATING SYSTEM amp x 1 carriage bolts from the end sections to the canopy brackets Attach the canopy channels to the canopy and intermediate sections with the appropriate NOTICE IT IS IMPORTANT THAT THE MINI J bolts MUM PIPING REQUIREMENTS AND ARRANGE MENTS BE COMPLIED WITH IN ORDER TO INSURE E Check the seal between the canopy and the sections MAXIMUM RELIABILITY PERFORMANCE F Assemble the flue thimble to the top of the canopy with the bracket toward the front of the boiler using 10 x screws A CLEARANCES steam and hot water pipes shall have clearances of at l
43. ic to one side of each joint to be mated Touch up any missed spots before draw up Touch up after draw up has no value See Figure 7 CAUTION SECTIONS MUST BE DRAWN UP TIGHT WITHIN FOUR HOURS OF THE TIME WHEN SILASTIC IS FIRST APPLIED SILASTIC CURES IN FOUR HOURS AND WILL NOT FLOW INTO SEAL GROOVES AFTER FOUR HOURS FROM APPLICATION REGARDLESS OF THE PRESSURE APPLIED From arrangement of sections chart see Figure 8 select next section according to code letters on section NOTICE SECTIONS MUST BE ASSEMBLED IN PROPER ORDER Clean nipple ports and place section on nipples in rear section To facilitate assembly it is advisable to enter the upper nipple first in its port then enter the lower nipples in their respective ports Drive section in place with a heavy block of wood striking blows as squarely as possible over nipples Insert the three draw up rods through the nipple ports in the intermediate section extending them through the tapped holes in the rear section Place a 12 lg steel channel on each end of the upper draw up rod and an 812 steel channel on each end of the lower draw up rods along with nuts and washers These items are all located in the Draw Up Kit See Figures 9 and 10 NOTICE AVOID DAMAGE TO THE DRAW ROD THREADS WHILE DRAWING UP SECTIONS APPLY OIL OR GREASE FREELY TO TIE ROD THREADS WHILE ASSEMBLING SECTIONS TO PREVENT STRIPPING OF THREADS ON ROD DRAW UP SECTIO
44. ing while sections are being drawn up DO NOT DRAW UP SECTION WHEN NIPPLES ARE COCKED Con tinue tightening draw up rods equally periodically bumping the section with the heavy block of wood to relieve tension on the draw up rods until sec tions meet iron to iron on the ground surfaces 6 Continue to draw up until all sections make contact at the ground joints 7 Repeat steps 13 and 14 under Assembly of Sec tions Manual Draw Up 2 N O 85 STEEL CHANNEL BLOCK HEX NUT 7 6 REOD 84 STEEL CHANNEL BLOCK STEEL CHANNEL BLOCK FLAT WASHER E 6 REQD SB gt NA DRAW ROD CLAMP GW 3 REQD Pet S i 3 PUMP AND RAM SET 3REQD HYDRAULIC DRAW UP OF SECTIONS 3 HYDROSTATIC TEST After the boiler sections have been assembled it is essential that the boiler be hy drostatically tested before platework jacket or piping is installed A Tankless Heater Installation If boiler is ordered with tankless heaters install heat ers with the gaskets provided Table II on page 25 gives the maximum number of heater permissible per assemblage and the heater ratings B Plug all boiler tappings and fill entirely with cold water To protect and safeguard the accuracy of steam or water gauge supplied DO NOT INSTALL GAUGE UNTIL AFTER TESTING OF BOILER Fig 12 14 C Testing pressure should be at least 10 pounds but D should not exceed 5
45. ler water at the rate of 1 lb of either chemical per 50 gallons of total water in the system Table 3 Reinstall safety relief valve Fill the entire system with water Start firing the boiler Cireulate the water through the entire system Vent the system including the radiation H m UO O Allow boiler water to reach operating temperature if possible p Continue to circulate the water for a few hours c Stop firing the boiler 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 us ing a high pressure water stream M Refill the system with fresh water BOILER WATER TREATMENT NOTICE Certain state and local codes may restrict the use of some of the chemicals listed for cleaning and maintaining the boiler Check with local authorities before proceeding to use these chemicals Add boiler water treatment compound as needed A chromate boiler water treatment compound consisting of 95 sodium chromate and 5 sodium borate has been tested and found reliable These tests have shown that the material when used and maintained at the concen trations listed below is effective in controlling and arrest ing corrosion These chemicals may be purchased from any reliable chemical company A Low pressure steam boilers such as the PF 5 Seri
46. odate proper combustion A permanent opening or duct should be provided so that the boiler input will not exceed 4 000 Btuh in of free area 4 CHIMNEY OR VENT The PF 5 is designed for forced draft firing and may be used with a conventional natural draft staek or a stub vent see Figure 3 See Table I for the proper vent size Draft controls are not normally required although they may be used on installations where a natural draft stack is used or on multiple boiler installations with a common stack The boiler is provided with a breeching damper which should be adjusted to maintain a slightly positiv pressure in the vent connector box up to 0 1 W C dur ing burner operation SECTION il CAST IRON BLOCK ASSEMBLY LIFTING INSTRUCTIONS Fig 4 NO OF LIFTING MIN SLIN SECTS WEIGHT LENGTH FOUR LEG SLING REQUIRED MIN 15 DIA CABLE 1 FACTORY ASSEMBLED SECTIONS The assem blage should be set in the proper location as outlined in Section I Lifting arrangement and weights are given in Figure 4 The tie rod nuts should then be loosened until finger tight Now proceed to part 3 of this section HY DRO STATIC TEST 2 FIELD ASSEMBLED SECTIONS Follow the as sembly procedure outlined on the following pages A Assembly of Sections Manual Draw Up NOTICE WHEN ASSEMBLING SECTIONS WITHOUT HY DRAULIC DRAW UP EQUIPMENT NEVER ASSEM BLE MORE THAN ONE SECTION AT A TIME 1 Place
47. 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 flush out boiler and refill with clean water to prescribed water level SECTION VI REPAIR PARTS All Repair Parts can be ordered through the nearest Burnham Regional Sales Office or Manufacturer s Representative for delivery from Lancaster These offices can advise as to the availability of their products and repair parts from a more local source BURNHAM CORPORATION REGIONAL OFFICES A Burnham Corporation Western Region P O Box 3079 Lancaster PA 17604 717 293 5836 Fax 293 5832 B Burnham Sales Corporation Northeast Region 19 27 Mystic Avenue Somerville MA 02145 617 625 9735 Fax 625 9736 Contact Regional Office Indicated for your State Alabama Alaska Arizona Arkansas California Colorado Connecticut Delaware Florida Georgia Hawaii Idaho Illinois Indiana Iowa Kansas Kentucky Louisiana Maine Maryland Massachusetts Michigan Minnesota Mississippi Missouri Montana Nebraska Nevada New Hampshire New Jersey Mercer County All other Counties Orr Pr 5 QW PrP K P P P gt P gt gt gt gt U U P gt P P gt gt atv 35 C Burnham Corporation Metropolitan Region 100 Davidson Avenue Somerset NJ 08873 908 560 9800 Fax 560 9814 Burnham Corporation Mid Atlantic Region P O Box 3079 L
48. onnections to minimize pressure drop D Hard Water This is applicable to some city water and particularly to well water This should not be a deterent but pre 24 cautions are necessary A water analysis is necessary and an appropriate water softener installed This is not only beneficial to the heater but to piping and fix tures plus the many other benefits derived from soft water 12 STEAM BOILERS INSTALL STEAM TRIM Items for steam trim are located in the steam trim carton except for the separately ordered low cutoff and tankless heater control Figure 30 shows the proper tappings for each item Figure 28 shows front view of an assembled steam boiler A Install the gauge glass set into the extension fittings that were installed before the jacket was assembled B Install the low water cutoff C Install the Pressuretrol to the boiler using the 4 x 90 2 syphon and the 4 NPT x hex bushing D Install the drain cock using the 3 NPT x FPT hex bushing E Install the steam gauge using the NPT x 4 hex bushing F Install the safety valve to the back section as shown in Figure 29 The safety valve 15 installed in the tee provided for blow off piping G For boilers with tankless heaters install the operating control in an unused tapping through one of the heater plates H Plug extra tappings TANKLESS HEATER SCHEMATIC TANKLESS HEATER PIPING
49. or losses such as loss of the use of the products inconvenience loss of time or labor expense involved in repairing or replacing alleged defective pro duct Burnham Corporation shall have no responsibility for the performance of any product sold by it under conditions varying materially from those under which such product is usually tested under existing industry standards nor for any damage to the product from abrasion erosion corrosion deterioration or the like due to abnormal temperatures or the influence of foreign matter or energy nor for the design or operation of any system of which any such product may be made a part or for the suitability of any such product for any particular application For products or parts not manufactured by Burnham Corporation the warranty obligations of Burnham Corporation shall in all respects conform and be limited to the warranty actually extended to Burnham Corporation by its vendors Warranty service can be obtained by contacting the original installer of the product and providing him with a detailed description of any apparent defect If this procedure fails to result in satisfactory warranty service the owner should notify Burnham Corporation Burnham America s Boiler Company P O Box 3079 Lancaster PA 17604 Transportation to a factory or other designated facility for repairs of any products or items alleged defective shall in all events be the responsibility and at the cost of the owner Notwi
50. r See Figure 14 IMPORTANT THIS BOILER REQUIRES NO COM BUSTION CHAMBER 4 MOUNT BURNER MOUNTING PLATE A Cast iron burner mounting plate Install 10 x 2 long studs with the short length of threads into the boiler front section Apply a bead of sealant around the periphery of the cast iron burner plate and secure to front section with nuts and washers B Cast iron burner mounting plate with adapter plate R 6 Burner Only The adapter plate is furnished by Gordon Piatt and is shipped with the burner Mount the cast iron burner mounting plate as stated in above Mount the adapter plate to the mounting plate with 8 36 x 174 cap screws 16 hex nuts washers and gasket provided The R6 burner can now be secur ed to 4 studs on adapter plate using 4 16 hex nuts and washers FIREWALL PLATES Fig 14 15 C Steel burner mounting plate see item D below for R 8 amp R 10 mounting plate instructions With the use of silastic secure the rope gasket to the front section just inside the rib to which the burner plate seats Using the 10 18 x 1 long hex head machine screws mount burner plate to front section With bolts pro vided mount burner to steel burner plate see Figure 15 for view showing stee burner plate installed Stee burner mounting plate with mounting lugs R 8 and R 10 Burner Only Mount the burner mounting plate as stated in c above Locate the 6 mount in
51. r eee oe hn where JI 5 6 2 hT w heater 18 9019990 a RI T wo heoter 11 14 13 1 fis Bl 1 ie ET mer he NOTES Not furnished with Gordon amp Piatt R8 and R10 gas or gas oil burners since these burners are furnished with steel mounting plates WNot required when sections are factory assembled SE pa r Tess a i b NR a held MEE OPTIONAL EQUIPMENT 548 Quantity as ordered Heater opening cover plate Quantity as ardered Additional Controls Type and quantity as ordered 10 IMPORTANT INFORMATION PLEASE READ THIS PAGE CAREFULLY READ THIS MANUAL AND BURNER INSTALLATION MANUAL CAREFULLY BEFORE INSTALL ING OPERATING OR SERVICING THIS UNIT IF YOU DO NOT HAVE A BURNER MANUAL WRITE TO BURNHAM AND ASK FOR FORM NO 52008 Part 814502 ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL STATE AND LOCAL PLUMBING HEATING AND ELECTRICAL CODES AND THE REGULATIONS OF THE SERVING UTILITIES 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 THE BOILER MUST BE PROPERLY VENTED IN ACCORDANCE WITH NATIONAL FUEL GAS
52. rd ANSI NFPA 31 Installation of oil burning equipment 2 Listed clearances can not be reduced for alcove or closet installations 3 For reduced clearances to combustible material pro tection must be provided as described in the above ANSI NFPA 31 standard A SERVICE CLEARANCE Locate the unit in the boil er room so as to provide ease of venting and adequate clearance for maintenance serviceability and installa tion of piping Allow a minimum clearance of 3 feet at front and back of boiler for burner service and ac cess to pressure relief door flame observation port and on each side of the unit for cleaning of flues and for tankless water heater installation Refer to Figure 1 for boiler dimensional data B PROVIDE ADEQUATE FOUNDATION for the unit 1 AA DO NOT INSTALL BOILER ON CARPETING Boiler is suitable for installation on combustible floors 2 Floor construction should have adequate load bear ing characteristics to bear the weight of the boiler filled with water see Table 1 A boiler foundation similar to the one shown in Figure 2 is recommend ed if the boiler room floor is weak or uneven or if a water condition exists IF THE BOILER ROOM FIOOR IS WEAK OR UNEVEN OR IF SIMILAR TO THE ONE SHOWN BELOW IS RECOMMENDED a aN A WATER CONDITION EXISTS A BOILER FOUNDATION 4U 5 4 1 4 OR STEEL TYPICAL ARRANGEMENT FOR STUB VENT Fig 3 3 PROVIDE AIR SUPPLY AND VENTILATION to accom
53. spect to the limitations on implied warranties set forth above Burnham Corporation hereby notifies each person to whom such warranty is made as follows Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state AMERICA S BOILER COMPANY Burnham Corporation NAQA ADN PATNA PATA ALI ADAYA AK YAQA TA aig alie C alg SS ASS ASS AEN RS LOS GOSSAGE GES GES GES IGS IGN IG ON IG GON GC IGN GON ITN TNS IGN TN Ss SD 10 93 Lancaster PA 17604 i aZ A Say aZ IN GEN GRR GRR CAS CS GARS G AN GARS G GEN GRY CSS UNA
54. t must be re drawn tight within four hours of first appli cation of Silastic to the joint 13 Tie rods must be installed in lugs immediately after draw up is complete a Insert tie rods through the lugs on the front amp back sections Place regular steel nuts amp flat washers on both ends of rods and tighten finger tight CAUTION Do not overtighten tie rods Steel nuts should be finger tight only to prevent section damage due to thermal expansion b Remove draw rod assembly from the sections and remove the draw rod couplings from the tie rods NOTICE If a joint springs apart it must be re drawn tight PULL UP ASSEMBLY within four hours of the time of application of the Fig 9 silastic to that joint A ARRANGEMENT OF SECTION sections must be according arrongement listed in figure below to insure proper operation and proper alignment of piping with jacket knockouts SECTION ARRANGEMENT CODE LETTERS FX FRONT SECTION WITH 4 TOP TAPPING C CENTER SECTION CX CENTER SECTION 4 TOP TAPPING CT CENTER SECTION W T W H OPENING BX BACK SECTION WITH 4 TOP TAPP ING NOTE For boilers less tankless water heaters replace the CT sections with C sections 4 c 5 ex 6 Ic 7 FX cT c cr JBx e rx cr c 9 jer je
55. the boiler 17 Fire burner to bring the water in the boiler to a boil to drive off free oxygen 19 WARNING BEFORE RETURNING BOILER TO SERVICE Follow the low water cutoff check out procedure on page 29 FLOAT TYPE LOW WATER CUTOFF During the heating season if an external low water cutoff is on the boiler the blow off valve should be opened once a month use greater frequency where conditions warrant to flush out the sediment chamber so the device will be free to function properly Low water cutoffs and water feeders should be dis mantled annually by qualified personnel to the extent necessary to insure freedom from obstructions 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 atten tion 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 sep aration or discoloration DO NOT ATTEMPT TO RE PAIR MECHANISMS IN THE FIELD Complete re placement mechanisms including necessary gaskets and installation instructions are available from the manu facturer 5 Check burner and controls at least once year See Item under Operating Instructions for control checks See Burner Manual
56. the op eration is completed within four hours after 1 tion of the sealant Hydraulic Draw Up Equipment is available through Burnham by ordering part number 6196008 1 Repeat steps 1 through 9 under Assembly of Sec tions Manual Draw Up 2 Continue driving sections in place in their respect ive order until all sections are in the assemblage Ground surfaces between adjoining sections should be spaced to apart Spacing of more than 38 will limit number of sections that can be drawn up in one unit and could indicate cocked nipples CAUTION Be sure to apply the sealant to the groove in the ground joints between adjacent sections as the boil er operates with a positive pressure in the firebox and products of combustion will escape between sections unless the sections are properly sealed The sealant should be applied before each section is placed on the assemblage On long boiler assemblies it may be necessary to draw up a partial block if the entire boiler is not ready to be drawn up tight within four hours of the first application of Silastic If the block as sembly time extends overnight the partial block completed must be drawn up tight before leaving the boiler overnight If a joint springs out it must be re drawn tight within four hours of first appli cation of Silastic to the joint Insert the three draw up rods and couplings if appropriate through the tapped holes in
57. thstanding any of the above provisions 1 failures resulting from mis se improper installation or lack of maintenance are not covered by this warranty and 2 Burnham Corporation s liability under this warranty shall not exceed the selling price of the product found to be defective Equipment furnished by the Buyer either mounted or unmounted and when contracted for by the Buyer to be installed or handled is not covered by this warranty Burnham Corporation does not assume any responsibility in connection with such equipment operation warranty performance or any other liability connected thereto The foregoing provisions of this WARRANTY shall be effective to the maximum extent permitted by applicable law and to the extent that any such provision would otherwise have an unconscionable result or would otherwise be inconsistent with applicable law such provision shall be limited in effect to the minimum extent necessary to avoid such unconscionable result or inconsistency with applicable law Any implied warranties including implied warranties of merchantability and fitness for a particular purpose shall to the extent permitted by applicable law be limited in duration to a period of one year after the date of installation To the extent permitted by applicable law the remedies for breach of any such implied warranty shall be limited to the remedies set forth above with respect to a breach of the express limited warranty provided With re
58. within the specified range If during normal operation it is necessary to add water to this boiler more frequently than once a month consult a qualified service technician to check your system for N leaks leaky system will increase the volume of make up water supplied to the boiler which can significantly short en the life of the boiler Entrained in make up water are dissolved minerals and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas 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 The pre sence of free oxygen in the boiler creates a corrosive at mosphere which if the concentration becomes high enough can corrode the cast iron through from the inside Since neither of these failure types are the result of a casting defect the warranty does not apply Clearly it is in everyone s best interest to prevent this type of failure The maintenance of system integrity is the best method to achieve this 32 SECTION V SERVICE INSTRUCTIONS 1 IMPORTANT See Item under Operating Instructions if it be comes necessarv to add water to the boiler more frequentiv than once a month 2 GENERAL Inspection should be conducted annual ly Service as fre uently as specifi
59. y water line foaming or priming persist install gate valve in Hartford Loop and drain valves in return main and at boiler and proceed as follows 1 Connect hoses from drain cocks to floor drain Close gate valve in Hartford Loop and open drain cock in return main Fill boiler to normal water level turn on oil burner and operate boiler at this water level for at least 30 minutes after the condensate begins to run hot then turn off burner Close all radiator valves Remove all supply main air valves and plug the openings in supply main 2 Draw about 5 gallons of hot water from boiler into a container and dissolve into it the quantities of caustic soda and trisodium phosphate shown in Table 3 Remove safety valve from boiler and pour this solution into boiler then r install safety valve 3 Turn on burner and keep operating while feeding water to boiler slowly This will raise water level in boiler slowly so that water will be boiling hot and will rise slowly into supply main and back through return main flowing from drain hose at about 180 F Continue until water runs clear from drain hose for at least 30 minutes 4 Stop feeding water to boiler but continue operating burner until excess water in boiler flows out through supply main and water lowers by steam ing until it reaches normal level in boiler Turn off burner Drain boiler Open all radiator valves Reinstall all supply main air valves Open gate valve in Hartford Loop 5

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