Burnham V8 Series Section III Packaged Boiler Assembly, Remove Crate, Remove Boiler from Skid

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SECTION III: PACKAGED BOILER ASSEMBLY

A.REMOVE CRATE.

1.Remove all fasteners at crate skid.

2.Lift outside container and remove all other inside protective spacers and bracing. Remove draft regulator box and miscellaneous trim bag containing safety or relief valve, and pipe ﬁttings.

B.REMOVE BOILER FROM SKID.

1.Boiler is secured to base with 4 bolts, 2 in front and 2 in rear of shipping skid, see Figure 11. Remove all bolts.

Figure 11: Packaged Boiler Removal from Skid

2.Tilt boiler to right and to rear. Using right rear leg as pivot, rotate boiler 90° in a clockwise direction, and lower left side of boiler to ﬂoor. Tilt boiler and remove crate skid. Care should be exercised to prevent damage to jacket or burner.

CAUTION

Do not drop boiler. Do not bump boiler jacket against floor.

C.MOVE BOILER TO PERMANENT POSITION by sliding or walking.

D.PROCEDURE TO OPEN, CLOSE AND SECURE BURNER SWING DOOR with articulated hinge. Throughout this manual you will be instructed to open and close the burner swing door for various reasons. There is a proper and improper method to closing and securing the burner swing door after it has been removed and re-installed for Field Assembly (Knockdown Boiler) or opened for inspection, cleaning or ﬁeld service.

1.TO OPEN BURNER SWING DOOR (see Figures 11A and 11B).

Step 1. Loosen and remove right side latching hardware (5/16" ﬂange nut and washer).

Step 2. Loosen and remove left side hinge hardware (5/16" x 3-1/2" lg. hex head ﬂange bolt).

Step 3. The duel pivot articulated hinge allows right side of door to be pulled outward and rotated to the left all in one motion. To do so, place your right hand under burner air tube and lift up slightly to help carry the weight of the door and burner. Use your left hand to grasp the door's left side hinge ﬂange, pull outward to rotate the hinge, this motion will move the door outward and to the left approximately 3" (see Figure 11B, Position 2).

Figure 11A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured

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Contents V8 Series Important Information Read Carefully USA BoilersPage Table of Contents Dimensional Data see Figures 1A Thru 1D V82 thru V89 Water Boiler without Tankless Heater V83 thru V89 Water Boiler with Front Tankless Heater V83 thru V89 Water Boiler with Rear Tankless Heater V83 thru V89 Steam Boiler with or without Tankless Heater Section I PRE-INSTALLATION Page Do not allow any flueway blockage by gasket Section II Knockdown Boiler AssemblyRemoval of Bare Boiler from Skid Boiler Tapping Locations and Usage Knockdown Boilers Only Knockdown Boiler Jacket Assembly Install Boiler JACKET. See FigureOil Burner Installation Beckett Burner Shown Install Beckett OIL BURNER. See FigureSteam Boilers Only Do not install burner without gasketInstall Carlin 102CRD OIL BURNER. See Figure Combustion Head Adjustment Water Boilers OnlyInstall Carlin Elite EZ OIL BURNER. See Figure Installation/Removal of Drawer Assembly Nozzle Replacement Install probe type Low Water Cut-Off Lwco if so equipped Float-Type Low Water Cut-Off Pressure Limit Installation Aquastat bulb must be fully inserted into the well Install Trim and Controls with Carlin 102CRD Burner Burners Supplied by Burnham utilize Install Trim and Controls with Carlin Elite EZ BurnerInstall Trim and Controls with Riello Burner Page Remove Boiler from Skid Section III Packaged Boiler AssemblyRemove Crate Do not drop boiler. Do not bump boiler jacket against floorPage Page Steam or Water Boilers Install Safety or Relief Valve in Tapping M Inspect Nozzle and ElectrodesSection IV Water Boiler Piping and Trim Evaluate the Existing Water SystemPage Recommended Water Piping for Circulator Zoned Heating System Page Page Section V Steam Boiler Piping and Trim Evaluate the Existing Steam SystemPage Section VI Tankless and Indirect Water Heater Piping GPM Alliance Water Heater Piping with V8 Boiler Connect Alliance Indirect Water Heater Piping as shown in BDo not exceed maximum allowable air intake length Section VII Venting and AIR Intake PipingGeneral Venting Guidelines Recommended Vent Pipe Arrangement and Chimney Requirements Seal all external joints with weatherproof caulk Section Viii Electrical GeneralBoiler Sequence of Operation with Probe Lwco Page Page Jumper Page Page Boiler Sequence of Operation with Float Lwco Page Page Boiler Sequence of Operation Page Page Boiler Sequence of Operation Page Page Boiler Sequence of Operation Page Page Section IX OIL Piping Single Pipe OIL LinesTWO Pipe OIL Lines SINGLE-STAGE Units 3450 RPM TWO Pipe SystemsFill Heating System with Water Always Inspect Installation Before Starting BurnerSection X System START-UP Carlin 102CRD Burners Adjust OIL Burner Before StartingBeckett Burners Carlin Elite EZ BurnersStart OIL Burner Adjust OIL Burner While OPERATING. ﬂame presentRiello Burners L1 and V1 Head Electrode Check for Clean CUT OFF of Burner Test ControlsCAD Cell Resistance When Sensing Flame Aquastat Switching Action Within L8124C Control Jumper must be removed after this checkAquastat Switching Action Within L8148A Controls Avoid Breathing Fiber Particulates and Dust Section XI Maintenance and Service Instructions Maintenance of LOW Water CUT- OFF DevicesPage Frequent Water Addition Gal/Month V83 V85 V87 V89 V84 V86 V88 14½Page Clean TOP of Boiler Sections if cleaning from the top Section XII Boiler CleaningClean the Flueways See Figure Clean the Combustion ChamberCleaning of Boiler Flueways OIL Primary Control Section Xiii Trouble ShootingCombustion Section XIV Repair Parts Bare Boiler Assembly Bare Boiler Assembly Bare Boiler Assembly Bare Boiler Assembly 1BBJacket Assembly Page V83 Thru V89 Steam Boilers Trim and Controls V83 Thru V89 Steam Boilers Trim and Controls V82 Thru V89 Water Boilers Trim and Controls V82 Thru V89 Water Boilers Trim and Controls Beckett AFG Burner Beckett OIL Burner Part NOS. for V8 Series Boilers Beckett OIL Burner Part NOS. for V8 Series Boilers Carlin OIL Burner Part Numbers for V8 Series Boilers Burner Specifications XV. LOW Water CUT OFF Lwco WhenService Record Limited Warranty For Residential Cast Iron Steam Boilers