Page 4 - for reference by owner and service technician.
4 DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in t...
Page 5 - WARNING; servicing or working nearby the appliance.; NOTICE; available safety relief valve set pressures.
5 WARNING Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cau...
Page 6 - TABLE OF CONTENTS
6 SECTION I - GENERAL INFORMATION Dimensional Information ............................................................................................................................................... 8 Ratings/Data ......................................................................................
Page 7 - TABLE OF CONTENTS - CONTINUED; SECTION VI - BURNER SPECIFICATIONS
TABLE OF CONTENTS - CONTINUED SECTION VI - BURNER SPECIFICATIONS Beckett Burners (Table V) ............................................................................................................................................ 52 Power Flame Burners (Table VI) .....................................
Page 8 - Figure
8 SECTION I - G ENERAL INFORMA TION Figure : Dimensional Information
Page 10 - INSPECT SHIPMENT; must be filed immediately against the carrier by the; LOCATE THE UNIT; boiler jacket for access to flame observation port,; maintenance difficulty will result.; floor is weak or uneven or if a water condi; Above
0 SECTION I - GENERAL INFORMATION (Continued) A. INSPECT SHIPMENT carefully for any signs of damage.1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition. 2. ANY CLAIMS for damage or shortage in shi...
Page 11 - Failure to supply adequate air to the boiler will; In the absence of local requirements, the confined; CHIMNEY OR VENT; When a V9A gas fired boiler is connected to
WARNING Failure to supply adequate air to the boiler will result in unsafe boiler operation. C. PROVIDE AIR SUPPLY AND VENTILATION to accommodate proper combustion. For commercial and industrial equipment, permanent facilities for supplying an ample amount of outside air shall be provided in accorda...
Page 12 - When a V9A gas fired boiler is connected
2 WARNING When a V9A gas fired boiler is connected to a venting system that is designed so that it will operate under a positive pressure, manufactured vent systems, designed and approved for positive pressure application per UL8, must be used (for example, Van-Packer model CS, Protech Model FasNSea...
Page 13 - RAIN CAP; “A” CAP; RIGHT; TEE TYPE; RIGHT; WRONG; ELBOW; installations with a high draft condition.; FAULTY BOILER BURNER OPERATION; The tee is frequently used as shown in C.; Figure b: Vents — Faults & Suggestions
D C A B E RAIN CAP RIGHT “A” CAP RIGHT TEE TYPE RIGHT WRONG WRONG 90° ELBOW UP or DOWN VENT SIZING - Area must be the same as or greater than the boiler breeching (Smoke Outlet). A barometric damper may be required on installations with a high draft condition. FAULTY BOILER BURNER OPERATION 1. If im...
Page 14 - SECTION II - CAST IRON BLOCK ASSEMBLY; FACTORY ASSEMBLED SECTIONS; FIELD ASSEMBLED SECTIONS; was ordered to be field assembled, follow the assembly; CAUTION; draw-up equipment, never assemble more than; a. Place the rear section in its approximate final
4 SECTION II - CAST IRON BLOCK ASSEMBLY A. FACTORY ASSEMBLED SECTIONS — If the boiler was ordered with factory assembled sections, the assembly should be set in the proper location as outlined in Section I. Lifting arrangement and weights are given in Figure 4.1. Proceed to Paragraph C of this Secti...
Page 15 - Figure 7: Affixing the Fiberglass Rope
5 WARNING Nipples must be driven in evenly and to the proper depth to assure tight joints. Most nipple leaks are caused by tilted or cocked nipples.DO NOT use steel/iron head hammer to drive nipples without using a wood block. Nipple damage may result. g. A special nipple setting gauge is provided f...
Page 16 - Figure 8: V9A Section Arrangement; it is advisable to enter the upper nipple first in; To avoid damage to the draw-up rod threads while; and finishing with upper left lug. When you
6 Figure 8: V9A Section Arrangement j. Clean and lubricate nipple ports on next section to be assembled and place on nipples previously installed in rear section. To facilitate assembly, it is advisable to enter the upper nipple first in its port. Then enter the lower nipples in their respective por...
Page 17 - torque limit has been reached and a gap greater; positive pressure in the firebox and products of; After all sections have been drawn up, the; of the first application of Silastic. If the block
WARNING When tightening the draw-up nuts, DO NOT EXCEED 50 FT-LB OF TORQUE. If the maximum torque limit has been reached and a gap greater than .025” still exists between the sections, consult the regional office. KEEP NIPPLES ALIGNED WITH NIPPLE PORTS. If necessary, tap edge of nipples lightly with...
Page 18 - beyond front and rear section to ensure proper fit; Tighten all tie rod; hydrostatically tested before the canopy, flue cover
8 draw-up rod clamps on the other. These items are all located in the Draw-Up Kit. See Figure 12. CAUTION Do not apply pressure directly on threaded tappings on front and rear sections with draw-up channels during assembly procedures. Rods should be approximately centered in openings so that rods an...
Page 19 - Figure : Boiler Section Assembly; Failure to properly hydrotest all boilers at the
9 Figure 2: Hydraulic Draw-Up Sections Figure : Boiler Section Assembly a. STEAM BOILERS: The assembled boiler must be subjected to a hydrostatic test of 45 psig to 55 psig. b. HOT WATER BOILERS: The assembled boiler must be subjected to a hydrostatic test of not less than 1½ times the maximum allow...
Page 20 - SECTION III - INSTALLATION INSTRUCTIONS; INSTALL CANOPY/FLUE OUTLET ASSEMBLY
20 SECTION III - INSTALLATION INSTRUCTIONS A. INSTALL CANOPY/FLUE OUTLET ASSEMBLY , Refer to Figures 14, 15 and 16. 1. Open canopy carton.2. Attach the two (2) canopy brackets to the front end cap of canopy with four (4) #10 x 1/2” sheet metal screws each. 3. Across the top of the front section and ...
Page 22 - Warning; AVOID Breathing Fiber Particulates and Dust; Precautionary Measures
22 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame conta...
Page 24 - MOUNT REAR OBSERVATION PORT COVER; flat washers provided.; INSPECT ALL BOILER SEALS; On boilers with rear flue outlet damper assembly,; To install multiple side panels, start at the rear; JACKET LEFT SIDE PANEL USAGE CHART; JACKET RIGHT SIDE PANEL USAGE CHART
24 C. MOUNT REAR OBSERVATION PORT COVER Refer to Figure 16. 1. With the silastic sealant, secure the 3/16” diameter rope gasket into the groove around the perimeter of the rear observation port cover. 2. Mount the rear observation port cover onto the rear section (with the word “Top” in the upright ...
Page 26 - specified burner will be provided by Burnham.; Figure 2: Burner Mounting Plate/Burner Adapter Plate Options
26 8. Combination Label and Burnham Logo Plate were attached to jacket front panel at time of manufacture. If loose or peeling, apply pressure to reset adhesive. 9. On steam boilers, attach lowest permissible water level plate (from steam trim carton) to the front panel using sheet metal screws. 10....
Page 27 - Failure to properly fill all gaps between the; If you have questions, call Honeywell Inc. at; WATER BOILERS - INSTALL WATER TRIM
2 insulation and blast tube. If additional rope gasket is not provided with the burner, use 3/8” fiberglass rope rated for 2300°F (provided by others). Reinstall burner mounting plate when finished. CAUTION Failure to properly fill all gaps between the insulation and burner blast tube may result in ...
Page 29 - BOILER PIPING - HEATING APPLICATIONS; may result in premature boiler failure due to flue; be equipped with flow control valves to prevent
29 Boiler Model Number of Sections Length A Width B* Height C** Approx. Center of Gravity D*** Approx. Shipping Weight LBS*** V903A 3 63-5/8 34-1/2 61 17-1/2 1478 V904A 4 69-5/8 34-1/2 61 20-1/2 1790 V905A 5 75-5/8 34-1/2 61 23-1/2 2102 V906A 6 81-5/8 34-1/2 61 27-1/2 2418 V907A 7 87-5/8 34-1/2 61 3...
Page 30 - A properly constructed Hartford Loop must be
0 i. If minimum return water temperature can be maintained at 135°F and temperature differential across the system is at 40°F or less, refer to Figure 26 or 27 for recommended minimum boiler piping details. ii. If minimum return water temperature cannot be maintained at 135°F or the temperature diff...
Page 31 - ater Boiler
Figure 26: V9A Series Minimum Piping - Parallel - W ater Boiler
Page 39 - BOILER PIPING, DOMESTIC HOT WATER; DO NOT use the boiler circulator as an indirect; heating professional to design for the proper application.
9 M. BOILER PIPING, DOMESTIC HOT WATER (DHW) APPLICATION – The V9A boiler can be used in many different piping applications to produce Domestic Hot Water (DHW). In some applications, depending on the control strategy (outdoor reset, setpoint operation, etc.) and size of boiler, it is recommended to ...
Page 40 - CONNECT TANKLESS HEATER PIPING; If flow through the heater is greater than its rating,; excessively hot water at fixtures. Do not operate; This is not only beneficial to the tankless heater but
40 N. CONNECT TANKLESS HEATER PIPING as shown in Figure 37a. See Table IV for Tankless Heater Ratings. NOTICE The following guidelines should be followed when piping the tankless heater: 1. Install Flow Regulator If flow through the heater is greater than its rating, the supply of adequate hot water...
Page 41 - Figure a: Schematic Tankless Heater Piping; flow of water heated from 40°F to 140°F with 200°F; Boiler; Table IV: Tankless Heater Ratings
4 Figure 36: Minimum Piping Requirements for V9A Tankless Heater Manifolds Figure a: Schematic Tankless Heater Piping Notes: 1. Ratings are given in gallons per minute continuous flow of water heated from 40°F to 140°F with 200°F boiler water. 2. For tankless heater quantities less than maximum allo...
Page 44 - ELECTRIC WIRING; - Install all field wiring in; Figure 8b: Water Boiler - Pressure Relief
44 O. ELECTRIC WIRING - Install all field wiring in accordance with the National Electric Code and Local Regulations. Control voltage and/or 3-phase line voltage must be supplied to the burner panel box through a fused disconnect. Figure 8a: Steam Boiler - Safety Valve Hook-up Figure 8b: Water Boile...
Page 45 - exactly, a fire or explosion may result; SET CONTROLS
45 SECTION IV - OPERATING INSTRUCTIONS WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury.If any unusual or improper operation or site conditions are observed, turn the boiler off and contact an experienced and skilled s...
Page 46 - ADJUST BURNER; TEST CONTROLS; Probe and float type low water cutoff devices; A qualified water treatment chemical specialist; clothing and equipment when working with/
46 4. ON WATER BOILERS WITHOUT TANKLESS HEATERS, set high limit dial on L4006A at 210°F. This temperature may be varied to suit requirements of installation. 5. ON WATER BOILERS WITH TANKLESS HEATERS, set low limit operating control dial at 190°F and high limit dial 210°F. Operating control must be ...
Page 48 - IMPORTANT; FREQUENT WATER ADDITION; frequent addition of water.
48 k. Drain the system in a manner and to a location that hot water can be discharged with safety. l. Remove plugs from all available returns and wash the water side of the boiler as thoroughly as possible, using a high-pressure water stream. m. Refill the system with fresh water. 3. Add appropriate...
Page 49 - before attempting any disassembly or service.; boiler back in service.
49 SECTION V - SERVICE INSTRUCTIONS DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. More...
Page 50 - burner mounting plate and all flue plates are; d. Reinstall flue plates making sure gasket on each; MAINTENANCE OF LOW WATER CUTOFF; DANGER; Always use protective clothing and equipment; where conditions warrant), to flush out the sediment
50 5. REASSEMBLE BOILER CAUTION Do not start the burner unless canopy, smokepipe, burner mounting plate and all flue plates are secured in place. a. If removed, install the canopy taking care to align the cerafelt strips. If strips are damaged replace as needed. b. Reinstall burner mounting plate to...
Page 51 - CHECK BURNER AND CONTROLS; If boiler is not used during winter time, it must be; With steam boilers, at end of season add sufficient
5 and proper functioning of the working parts. Inspect connecting lines to boiler for accumulation of mud, scale, etc., and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly. Give special attention...
Page 52 - Table V: Beckett Burner Specifications
52 SECTION VI - BURNER SPECIFICATIONS NOTICE V9A boiler ratings and capacities are based upon the following burners, pump pressures, nozzle sizes and manifold pressures. Refer to instructions furnished with burner for additional information regarding proper installation, fuel piping, wiring details,...
Page 55 - SECTION VII - REPAIR PARTS
55 OIL BURNERS Table VIII: Carlin Burner Specifications Boiler Model Burner Input (GPH) Burner Mfr. Burner Model Air Tube Comb. Burner Settings Pump Pressure (PSI) Nozzle Make Nozzle Data Head Air Band Air Damper Low High Low Fire High Fire V903A 3.1 Carlin 301CRD 8” - Style ‘B’ 1/4” 60% N/A N/A ---...
Page 56 - ONTINUE
56 SECTION VII - REPAIR PARTS (C ONTINUE d) Figure 39: V9A Series Jacket Assembly (Boiler Models V903A thru V912A)
Page 57 - JACKET REPAIR PARTS (Models V90A Thru V92A)
5 JACKET REPAIR PARTS (Models V90A Thru V92A) ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY PART NO. V903A V904A V905A V906A V907A V908A V909A V910A V911A V912A 1 Jacket Front Panel Assembly 1 1 1 1 1 1 1 1 1 1 6042926 2 Jacket Rear Panel Assembly 1 1 1 1 1 1 1 1 1 1 6042927 3 Jacket Upper Tie Bar Pan...
Page 58 - Figure 40: Bare Boiler Assembly
Page 59 - REPAIR PARTS FOR BARE BOILER ASSEMBLY
59 REPAIR PARTS FOR BARE BOILER ASSEMBLY ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY PART NO. V903A V904A V905A V906A V907A V908A V909A V910A V911A V912A 1 Front Section 1 1 1 1 1 1 1 1 1 1 7172936 2 “C” Center Section - Steam Boiler 1 2 3 4 5 6 7 8 9 10 7172940 Water Boiler 1 2 3 4 5 6 7 8 9 10 717...
Page 60 - REPAIR PARTS FOR BARE BOILER ASSEMBLY (Continued)
60 ITEM NO. DESCRIPTION BOILER SIZE / QUANTITY PART NO. V903A V904A V905A V906A V907A V908A V909A V910A V911A V912A 21B Top Outlet Canopy Cover, 7 & 8” Dia. Opening 1 1 1 1 1 7112638 Top Outlet Canopy Cover, 10” Dia. Opening 1 1 1 7112639 Top Outlet Canopy Cover, 12” Dia. Opening 1 1 7112640 22 ...
Page 61 - STEAM TRIM / WATER TRIM; STEAM TRIM; BOILER SIZE / QUANTITY
6 STEAM TRIM / WATER TRIM STEAM TRIM BOILER SIZE / QUANTITY PART NO. V903A/ V904A V905A/V908A V909A/V912A Pressuretrol: Honeywell L404F1060 1 1 1 80160942 Honeywell L4079B1033 (Pkgd. Boiler) 1 1 1 80160943 Low Water Cutoff, M&M 63M (Pkgd. Boiler Only) 1 1 1 80160509 Steam Gauge, 3½” Dia. Ametek ...
Page 62 - SERVICE RECORD; DATE