Burnham V7 SERIES User Manual

Price - $3.00

INSTALLATION,

OPERATING AND SERVICE

INSTRUCTIONS FOR

V7 SERIES OIL FIRED BOILER

KNOCKDOWN & PACKAGED

HEATING UNITS

Theseinstructionshavebeen

reviewedbyULCandfound

suitable for use in the

installationofULClabeled

V-7SeriesBoilers.

As an

ENERGY

STAR^®Partner,

Burnham Corporation

has determined that the

V73WR (0.60 GPH),

V74WR (0.80 GPH),

V75WR (0.90 GPH),

and V76WR (1.15 GPH)

meet the ENERGY STAR^®

guidelines for Energy

efficiency established by the

United States Environmental

Protection Agency (EPA).

The ULC label or listed

marking on a product is the

onlyevidenceprovidedby

Underwriters'Laboratoriesof

Canadatoidentifyproducts

whichhavebeenproduced

underthelistingandfollow-up

service.

For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide

Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

Boiler Serial Number

Installation Date

_V7 ____-____

6_ _ _ _ _ _ _

Heating Contractor

Phone Number

Address

8142711R24-7/99

IMPORTANT

Before starting to install this oil boiler, read these instructions carefully. Keep instructions in legible condition and

posted near oil boiler for reference by owner and service technician.

TABLE OF CONTENTS

I. General Information ............................. 3

II. Knockdown Boiler Assembly ............... 7

III. Installation Instructions...................... 12

IV. Operating Instructions........................ 21

V. Boiler Cleaning .................................. 29

VI. Repair Parts ........................................ 31

Burner Specifications ......................... 46

SECTION I: GENERAL INFORMATION

Figure 1A: V72 thru V79 Water Boiler Without Tankless Heater (WB)

TABLE 1: DIMENSIONAL DATA (SEE FIGURES 1A THRU 1E)

Heat Transfer

Dimensions

Water Content -

Gallons

Surface Area -

Sq. Ft.

Boiler

Model

No.

Approximate

Shipping Weight

(LB.)

Minimum

Chimney Size

Steam Water

Boiler Boiler

"A"

"B"

"C"

Steam Boiler

V72

V713

V73

V714

V74

V75

V76

V77

V78

V79

11-3/8" 6-3/8"

16" 8-3/4"

15-3/8" 8-3/8"

20" 10-3/4"

8" x 8" x 15'

8" x 12" x 15'

----

10.6

13.5

13.2

15.9

18.5

----

381

524

478

580

575

674

773

872

971

1070

10.8

----

13.8

----

19-3/8" 10-3/8"

23-3/8" 12-3/8"

27-3/8" 14-3/8"

31-3/8" 16-3/8"

35-3/8" 18-3/8"

39-3/8" 20-3/8"

13.5

16.1

18.6

21.2

23.8

26.4

19.7

25.6

31.4

37.3

43.1

49.0

23.6

26.2

28.8

NOTE: 1. Maximum Working Pressure 15 PSI (Steam) and 30 PSI (Water)

2. The V72, V713 and V714 Boilers are available as packaged water boilers only

3. The V713 and V714 are not ULC listed Models

Figure 1B: V73 thru V79 Water Boiler with Tankless Heater (WBT)

Figure 1C: V73 thru V79 Steam Boiler with or without Tankless Heater ("SBT" or "SB")

Β υρνηαµ

Figure 1D: V713 and V714 Packaged Water Boiler Less Tankless Heater (WB)

Burnham

Figure 1E: V713 and V714 Packaged Water Boiler with Tankless Heater (WBT)

A. INSPECT SHIPMENT carefully for any signs of

2. FOR BASEMENT INSTALLATION, provide a

solid base, such as concrete, if floor is not level, or

if water may be encountered on floor around boiler.

damage.

1. ALL EQUIPMENT is carefully manufactured,

inspected and packed. Our responsibility ceases

upon delivery of crated boiler to the carrier in good

condition.

3. PROVIDE SERVICE CLEARANCE of at least 24”

on right side of boiler for removal of rear tankless

heater. Provide at least 24” clearance from front

jacket panel for servicing and removal of front

tankless heater (increase to 30" for #A54 heater).

Provide at least 24" clearance from right side of

boiler or top of boiler for cleaning flueways. Boiler

flueways may be cleaned either from the top or

from the side.

2. 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.

4. For minimum clearances to combustible materials.

See Table 2.

B. LOCATE BOILER in front of final position before

removing crate. See Figures 1A thru 1E.

C. PROVIDE AIR SUPPLY AND VENTILATION to

accommodate proper combustion. If natural ventilation

is inadequate, provide a screened opening or duct from

the boiler room to the outside. The opening or duct

must be sized so the boiler input will not exceed 4,000

BTUH/Sq. In. of free area. If other air consuming

appliances are near the boiler, the air inlet should be

larger. Consult respective manufacturers.

1. LOCATE so that smoke pipe connection to

chimney will be short and direct. BOILER IS

SUITABLE FOR INSTALLATION ON

COMBUSTIBLE FLOOR. Boiler cannot be

installed on carpeting.

NOTE 1: Listed clearances comply with American

National Standard ANSI/NFPA 31, Installation of Oil

Burning Equipment.

TABLE 2: Minimum Installation Clearances To

Combustible Materials (Inches)

NOTE 2: V7 Series boilers can be installed in rooms

with clearances from combustible material as listed

above. Listed clearances cannot be reduced for

alcove or closet installations.

Chimney

Boiler Above Front

Connector

Rear Sides

NOTE 3: For reduced clearances to combustible

material, protection must be provided as described in

the above ANSI/NFPA 31 standard.

V7 24

SECTION II: KNOCKDOWN BOILER ASSEMBLY

Note: If Boiler is Packaged Go To Section III

section as shown in Fig. 3. Place gaskets so as not

to allow any flueway blockage.

A. REMOVAL OF BARE BOILER FROM SKID

1. Boiler is secured to base with 4 bolts, 2 on front and

2 on rear, see Figure 2. Remove all bolts.

2. Cut the remainder of the roll into two (2) equal

pieces. Place each piece along the sides, allowing

the ends to overlap the front and rear pieces.

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.

Do not allow any flueway blockage.

3. Position canopy body within the retaining bar

which borders the flueway openings on top of the

bare boiler block assembly.

Figure 2

B. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

C. TEST BOILER FOR LEAKS before installing

controls, trim, and jacket, and before connecting to

heating system.

1. Loosen nuts on tie rods until only finger tight.

2. Install pressure gauge (at least 30 P.S.I. capacity), a

hose to the city water and a valve in the supply

tapping. Plug remainder of tappings.

Figure 3

3. Fill boiler with water and apply a pressure of at

least 10 pounds but no more than 30 pounds gauge

pressure.

IMPORTANT: Jacket support bracket must be

facing left side of boiler — see Figure 3.

4. Secure canopy to boiler with two (2) 1/4" - 20 x 3"

lg. carriage bolts, 1/4" flat washers and 1/4" - 20

wing nuts provided.

4. Examine Boiler carefully inside and outside for

leaks or damage due to shipment or handling.

D. DRAIN WATER FROM BOILER. Remove gauge,

valve and plugs from those tappings to be used. Leave

other tappings plugged or bushed according to Figure

H. INSTALL the following steam or water trim that

would be concealed or inaccessible after flush jacket is

installed, see Figure 4 for boiler tapping locations and

usage.

E. INSPECT JOINTS BETWEEN SECTIONS. All joints

are factory sealed. If there are any spaces due to

shipment or handling, seal them with boiler putty.

1. STEAM BOILER — Top tappings:

a. Tapping "L" — Install 2" plug in rear section

top supply tapping on boiler sizes V73 thru

V75.

F. INSPECT FLUE COVER PLATES for tightness. If

loose, retighten mounting hardware. If flue plate or

sealing insulation is damaged repair or replace as

needed.

b. Tapping “M” — Install ¾” coupling and ¾” x

8” long nipple into ¾” tapping located next to

front section top supply tapping — all boiler

sizes.

G. INSTALL AND SECURE CANOPY with cerafelt

gasket and hardware provided to ensure gas tight seal

— see Figure 3.

2. WATER BOILER — Top tappings:

a. Tapping “L” — Install 2” plug in rear section

top supply tapping on boiler sizes V73 thru

V79.

1. Cut two (2) strips 13 ¾” lg. from the roll of cerafelt

gasket insulation. Place one (1) strip across the top

of the front section and the other across the rear

Figure 4: Boiler Tapping Locations and Usage (Knockdown Boilers Only)

PU RP OSE OF TA PP INGS

Tapping

Location

S team B oiler

Water B oiler

S ize

Non-Heater

w/Heater

Non-Heater

L81 48A

Front Heater

L81 24C

R ear Heater

Flush Plug

PA4 04A Pressuretrol (P robe LW CO )

Plugg ed (Flo at LW CO )

¾"

¼"

¾ "

¾"

½ "

Op erating C on trol Op erating C on trol

Pressure/Va cuum G auge

Temp era ture/Pre ssure G auge

Flush Plug

Pro be LWC O Std.

Plugged (Flo at LW CO )

C-C

Flush Plug

Water Gau ge Glass (Probe LW CO )

Flush Plug

Water G auge G lass, Pre ssuretrol, a nd LW CO (Flo at)

L4006A Op era tin g

L81 24C

Op erating C on trol

¾"

-----

Disre gard

C on trol

1½"

Bushe d to ¾ " for Draincock (O ptiona l Re tu rn )

R eturn

Bushe d to ¾ " for Draincock (O ptiona l Re tu rn )

Flush Plug

Su rface Blow off - Plugged

Front Su pply (3 thru 9 Section)

Plugged , Optional Se co nd Su pply (3 thru 5 Section)

R equire d S eco nd Supply (6 thru 9 Se ction )

Plu gge d (3 thru 9 Section)

Re lief Valve

¾"

Safety Valve

Aux. Ta pping -

Plu gged

Aux. Ta pping -

Plu gged

Au xiliary Tapp ing - Plugge d

Disre gard

Au xiliary Tapp ing - Plugge d

Figure 5: Knockdown Boiler Jacket Assembly

b. Tapping “M” —Install ¾” x 8” long nipple into

side panel mounting holes with the front and rear

panel holes. Secure with #8 x ½” long sheet metal

screws.

¾” tapping located next to front section top

supply tapping — all boiler sizes.

I. INSTALL FLUSH JACKET (See Figure 5).

5. Install jacket top panel. Place jacket top panel on

boiler and secure to front, rear and left side panels

with #8 x ½” long sheet metal screws.

1. Remove burner swing door mounting plate. Loosen

the bottom bolt three full turns. Remove (5)

remaining 5/16” bolts securing mounting plate to

boiler sections.

6. Install jacket lower right side panel. Align right

side panel mounting holes with front and rear panel

holes. Secure with #8 x ½” long sheet metal screws.

Lift up and remove plate.

7. Install jacket upper right side access panel. Using

the thumb holes, hold access panel 1” above lower

right side panel. Engage flanges on access panel

with surrounding panels and lower into position

until access panel is resting flush with top panel

and bottom flange is properly locked into position

with lower right side panel.

2. Install rear jacket panel. Align two dimpled holes

on jacket panel with the cast iron lugs. Secure with

two #10 x 3/8” long self tapping screws.

3. JACKET FRONT PANEL

a. Install black plastic collar extension to jacket

front panels with 7-13/16" dia. heater opening.

Engage two (2) retaining tabs over raw edge of

opening. Provide support behind the panel with

one hand while applying pressure on collar to

snap each tab over edge of opening until all

eight (8) tabs are securing collar.

8. Attach the data labels shipped in the instruction

envelope as follows: (see Figure 5).

a. Place the Rating Label (serialized)

approximately 1/4" below the top edge and

3-1/2" from the right edge of the jacket front

panel as shown. Mark outline of label on jacket

with a pencil. Remove paper backing from

label, realign label with pencil marks and apply

label to jacket by using backing paper to rub

across face of label.

b. Install front jacket panel. Locate two 3/16”

diameter holes on front panel approximately 16”

up from the bottom of the panel and 4½” in

from each side. Align these holes with the

similarly located cast iron lugs on the front

section. Secure with two #10 x 3/8” long self-

tapping screws.

b. Locate the Combination Label (P/N 8142756)

on the front right corner of top panel,

4. Install jacket left side panel. Fold panel at

perforation keeping insulation inward. Align left

approximately 3/8" from each edge as shown.

Mark the location and apply label in the same

Figure 6

manner as rating label.

burner to the left. Install two remaining 5/16” x ½”

long bolts in horizontal sets of holes. Level burner

and fully tighten all bolts.

c. On steam boilers, install the Lowest Permissible

Water Level Plate, Form No. 1204 (shipped in

Steam Trim Carton), on the jacket right side

panel. Align the two holes in the plate with the

two 1/8” dia. holes located near the front edge,

in line with the lower sight glass tapping, and

secure with #8 x ½” lg. sheet metal screws.

K. INSTALL STEAM BOILER TRIM AND CONTROLS

(See Figures 1C & 4).

1. Thread the combination pressure/vacuum gauge

into the ¼” tapping. Tighten with wrench applied

to the square shank of the gauge. Do not apply

pressure to the gauge case — this might destroy the

calibration of the gauge.

J. INSTALL OIL BURNER (See Figure 6).

1. Check target wall and cerafelt blanket in

combustion chamber. If any damage or movement

occurred during shipment, repair or replace as

needed.

2. Thread 1½” x ¾” bushing and a ¾” drain cock into

the 1½” tapping located in the lower right corner of

the front casting. Tighten with wrench.

2. Check the burner mounting plate and swing door

insulation pieces for damage and adhesion. If

damaged, replace insulation. If loose, re-attach with

RTV 732 or 736 silicone caulk.

NOTE: Lower rear section tapping “H” is used for

standard condensate return on steam boilers.

3. Thread safety relief valve, as shown in Figure 1C,

into 3/4" coupling and 3/4” x 8” nipple previously

installed in step H. Tighten with wrench.

3. Engage bottom slot on burner mounting plate with

matching bolt in bottom tapping of front section.

Align mounting holes and fasten the mounting

plate to the boiler sections with (5) five 5/16” bolts

and washers removed in step 8a. Fully tighten all

bolts.

NOTE: Pipe discharge as shown in Figure 8.

4. Install probe type LWCO if so equipped. Thread

probe into ¾” tapping located on the front section

directly above the protectorelay on the oil burner.

Read the manufacturer’s instructions packed with

the probe LWCO for proper pipe dope application.

DO NOT use Teflon tape on probe threads. Use of

teflon can render the probe LWCO inoperational.

Slip the LWCO control over the probe and clamp in

place. Connect the wire(s) between the probe and

control per the manufacturer’s instructions. Install

4. Place burner flange gasket on burner swing door

and thread two 5/16” x ½” long bolts into vertical

set of holes approximately three full turns.

5. Insert oil burner air tube into the opening of the

burner swing door. Align keyhole slot with vertical

set of bolts, engage hex head of bolts and rotate

the sight glass using the two ½” tappings to the

right of the probe LWCO.

4. Screw drain valve into 1½” tapping in lower rear

section using 1½” x ¾” bushing (note - lower front

section tapping “G” (see Figure 4) is used for

standard return on water boilers).

5. Install float-type Low Water Cutoff, if so equipped.

See Figure below.

5. If CIRCULATOR (not supplied with boiler) is to be

mounted directly to 1½" boiler return tapping "G",

use the piping arrangements outlined in steps a. thru

e. as follows:

a. Install nipples and unions in Tappings D.

b. Mount hardware to low water cutoff body. Install

assembly.

c. Install water gage glass on low water cutoff

assembly's tee fittings.

a. Thread 1½” x 3” long nipple and 1½” x 90°

elbow into the return tapping and tighten with a

pipe wrench.

6. Install Limit Control.

a. Probe LWCO: Install Limit in Tapping A using

¾ NPT x 2" nipple, ¾ NPT elbow, ¾ NPT x ¼

NPT bushing, and syphon. See Figure below

right.

b. Float LWCO: Remove ¼ NPT plug from top of

Low Water Cutoff. Install Syphon and Limit into

this tapping. See Figure below.

b. Thread 1½” NPT x 15” long pipe nipple into the

90° elbow and tighten with a pipe wrench.

c. Thread one of the circulator flange onto the pipe

nipple and tighten with a pipe wrench. Position

flange so that the bolt slots are perpendicular to

the boiler front.

7. On units equipped with a tankless heater, install the

aquastat controller well in the ¾” tapping in tankless

heater plate. Slip the bulb of the aquastat into the well

and secure the control in place with the set screw.

d. Place a flange gasket in the flange groove on the

circulator and mount the circulator on the flange

installed in step 3. Note that this is the return

piping and the flow arrow on the circulator should

point down ê. Fasten circulator with 7/16” nuts

and bolts.

8. Connect the field wiring to the pressure limit, the

LWCO, the burner J-box, and from the aquastat

control (if equipped with tankless heater) to the oil

burner primary control's "T-T" terminals. Make the

wiring connections as shown in Figures 17 thru 20.

e. Bolt second circulator flange and gasket to the

circulator with 7/16” nuts and bolts.

6. Install pressure relief valve, as shown in Figure 1B,

onto ¾” x 8” nipple previously installed in Step H.

Tighten with wrench.

L. INSTALL WATER TRIM AND CONTROLS

(See Figures 1B and 4).

1. Thread ½” pipe plugs into gauge glass tappings in

the upper right side of front section.

NOTE: Pipe discharge as shown in Figure 9.

7. On units without a tankless heater, install the control

well into the ¾” tapping located on the front of the

boiler in the upper left corner. Tighten the well and

insert the control’s bulb into the well. Secure the

control with set screw on the control.

2. Thread ¾” pipe plug in probe low water cut off

tapping (just left of gauge glass tappings).

3. Thread combination pressure/temperature gauge into

¼” tapping. Tighten with wrench applied to the

square shank of the gauge. Do not apply pressure to

the gauge case - this might destroy the calibration of

the gauge.

8. On units with a tankless heater, install the control

well in the ¾” tapping on the tankless heater plate.

Tighten the well and insert the control’s bulb into the

well. Secure the control with set screw on the control.

9. Connect the field wiring from the circulator to the

control and from the control to the burner J-Box.

Make the wiring connections as shown on Figures 21

and 22.

NOTE: Proceed to Installation Instructions Section

III, step E, to continue.

Limit Installation for Probe LWCO Equipped

Boilers

Float-type Low Water Cutoff Installation

SECTION III: INSTALLATION INSTRUCTIONS

4. Packaged boilers with Probe style LWCO. Install

A. REMOVE CRATE — (Packaged Boilers)

Limit in Tapping A using ¾ NPT x 2" nipple, ¾

NPT elbow, ¾ NPT x ¼ NPT bushing, and syphon

included in trim bag. See Figure on previous page.

Connect wiring harness from Low Water Cutoff.

See Figure below.

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/relief valve, and pipe fittings.

B. REMOVAL OF BOILER FROM SKID

TS-39-126-A

5. If this boiler is used in connection with

refrigeration 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 10. Also consult I = B = R Installation and

Piping Guides.

TS-39-26-A

Fig. 7

6. 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

circulation of boiler water during the operation of

the cooling system.

1. Boiler is secured to base with 4 bolts, 2 on left side

and 2 on right side, see Figure 7. Remove all bolts.

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.

7. Use a boiler bypass if the boiler is to be operated in

a system which has a large volume or excessive

radiation where low boiler water temperatures may

be encountered (i.e. converted gravity circulation

system, etc.).

C. MOVE BOILER TO PERMANENT POSITION by

sliding or walking.

D. INSPECT COMBUSTION TARGET WALL AND

COMBUSTION CHAMBER LINER

Remove the circulator and install a pipe tee

between the circulator and boiler return along with

a second tee in the supply piping as shown in

Figure 11. The bypass should be the same size as

the supply and return lines with valves located in

the bypass and supply outlet as illustrated in Figure

11 in order to regulate water flow for maintenance

of higher boiler water temperature.

1. OPEN FLAME OBSERVATION DOOR AND/OR

BURNER SWING DOOR on front of boiler. Use

flashlight to inspect target wall secured to rear

section with silastic sealant. Inspect ceramic fiber

blanket secured to floor of boiler with water glass

adhesive. If either is damaged they must be

replaced.

E. CONNECT SUPPLY AND RETURN PIPING TO

Set the by-pass and boiler supply valves to a half

throttle position to start. Operate boiler until the

system water temperature reaches its normal

operating range.

Adjust the valves to maintain 180°F boiler water

temperature. Adjust both valves simultaneously.

Closing the boiler supply valve and opening the by-

pass valve will raise the boiler water temperature

and lower the supply temperature. Opening the

boiler supply valve while closing the by-pass valve

will lower the boiler water temperature and raise

the supply temperature.

HEATING SYSTEM.

CLEARANCES — Steam and hot water pipes shall

have clearances of at least ½” from all combustible

construction.

1. With STEAM HEATING, see Figure 8. Consult I =

B = R Installation and Piping Guide No. 200.

2. With Forced Circulation HOT WATER HEATING,

see Figure 9. Consult I = B = R Installation and

Piping Guide No. 200.

3. Packaged boilers. Install Safety Valve in Tapping

M. Use ¾ NPT x 8" nipple and ¾ NPT coupling

included in trim bag. Safety Valve must be

installed with spindle in vertical position.

8. A hot water boiler installed above radiation level

must be provided with a low water cutoff device as

part of the installation.

TS-39-17-D

Fig 8: V73 Thru V79 Recommended Boiler Piping For Gravity Return Steam Boiler

TS-39-4-C

Fig. 9: V72 thru V79, V713 and V714 Recommended Boiler Piping for Series Loop Forced Hot Water System

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.

TS-O-62-B

4. Use of non-permeable materials in the distribution

system.

5. Isolating the boiler from the system water by installing

a heat exchanger.

F. CONNECT TANKLESS HEATER PIPING AS

SHOWN IN Figure 12. See Tables 3 and 3A for

Tankless Heater Ratings.

Fig. 10: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

Water Boilers

TS-0-63-B

TS-39-7-A

Fig. 12: Schematic Tankless Heater Piping

Fig. 11: Recommended Bypass Piping

Water Boilers

THE FOLLOWING GUIDELINES SHOULD BE FOL-

LOWED WHEN PIPING THE TANKLESS HEATER:

1. 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 water line to the heater. The flow regulator

should preferably be located below the inlet to the

heater and a minimum of 3’ away from the inlet so

that the regulator is not subjected to excess

CAUTION

Oxygen contamination of boiler water will cause

corrosion of iron and steel boiler components,

and can lead to boiler failure. Burnham's

standard warranty does not cover problems

caused by oxygen contamination of boiler water.

temperatures that may occur during “off” periods

when it is possible for heat to be conducted back

through the supply line. The flow regulator also

limits the flow of supply water regardless of inlet

pressure variations in the range of 20 to 125 psi.

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.

2. TEMPERING OF HOT WATER — Installation of

an automatic mixing valve will lengthen the

3. Oxygen permeable materials in the distribution

system.

delivery of the available hot water by mixing some

TABLE 3: TANKLESS HEATER DATA: Rear

Mounted Heater on Steam and Water

Boilers

WARNING

Install an automatic mixing valve at the tankless

heater outlet to avoid risk of burns or scalding

due to excessively hot water at the fixtures.

Adjust and maintain the mixing valve in

Pressure Drop

thru Heater

(PSI)

Heater Rating

(GPM)

Boiler Heater

Model

No.

accordance with the manufacturer's instructions.

Steam Water Steam Water

3. FLUSHING OF HEATER — All water contains

some sediment which settles on the inside of the

coil. Consequently, the heater should be

V713

V73

V1-2

V1-1

V1-2

---

2.75

---

3.25

---

3.9

---

4.7

5.6

7.2

5.6

4.7

4.4

periodically backwashed. This is accomplished by

installing hose bibs as illustrated and allowing

water at city pressure to run into hose bib A,

through the heater, and out hose bib B until the

discharge is clear. The tees in which the hose bibs

are located should be the same size as heater

connections to minimize pressure drop.

3.5

V714

---

V74

V75

V76

V77

V78

V79

3.25

3.5

3.75

5.6

6.4

7.2

3.25

3.75

4. HARD WATER — A water analysis is necessary

to determine the hardness of your potable water.

This is applicable to some city water and

particularly to well water. An appropriate water

softener should be installed based on the analysis

and dealer’s recommendation. This is not only

beneficial to the tankless heater but to piping and

fixtures plus the many other benefits derived from

soft water.

4.5

9.8

TABLE 3A: TANKLESS HEATER DATA: Front

Mounted Heater on Water Boilers

Boiler

Model

Heater Heater Rating

Pressure Drop

Thru Heater (PSI)

NOTE: STEAM BOILERS

No.

222

A54

222

A54

222

A54

(GPM)

a. During summertime operation, the normal water

line should be raised 1”, from 22-5/8” to

23-5/8” (see Figure 1C) for improved tankless

heater performance.

V73

V74

V75

V76

3.5

30.5

G. INSTALL SMOKEPIPE — The V7 should be vented

into a fireclay tile-lined masonry chimney or chimney

constructed from type L vent or a factory built chimney

that complies with the type HT requirements of

UL103. The chimney and vent pipe shall have a

sufficient draft at all times, to assure safe proper

operation of the boiler. See Figure 13 for recommended

installation.

4.5

4.6

5.5

4.75

V77

V78

V79

39.5

4.75

1. Install a draft regulator (supplied with boiler)

following the instructions furnished with the

regulator. See Figure 14 for alternate draft regulator

locations.

39.5

cold water with the hot. This prevents excessive

and possibly scalding hot water at the fixtures. In

addition, savings of hot water will be achieved

since the user will not waste as much hot water

while seeking water temperature to his liking.

Higher temperature hot water required by

dishwashers and automatic washers is possible 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.

2. Consider the chimney overall. Chimneys that have

a high heat loss may become less suitable as the

heat loss of the home goes down and the efficiency

of the boiler installed goes up. Most homes have a

chimney appropriate for the fuel and the era in

which the home was built. That may have been a

coal fired or an inefficient oil fired boiler built into

a home without insulation or storm windows. With

increasing fuel prices that home probably has been

insulated and fitted with storm windows so that the

heat loss of the home has been reduced. This

Fig. 14: Proper and Improper Locations

of Draft Regulator

Fig. 13: Recommended Smokepipe Arrangement

and Chimney Requirements

3. For the same reasons as in (2.) above, heat

extractors mounted into the breeching are not

recommended.

requires less fuel to be burned and sends less heat

up the chimney.

H. INSTALL ELECTRIC WIRING in accordance with

National Electrical Code and local regulations. A

separate ELECTRICAL CIRCUIT should be run from

meter with a Fused Disconnect Switch in the Circuit.

Wiring should conform to Figures 17 thru 23.

A new boiler probably has a higher efficiency than

the boiler being replaced. That probably means that

the stack temperature from the new boiler will be

lower than that from the old boiler and with less

room air being drawn up the chimney to dilute the

stack gases. The combination of a large uninsulated

chimney, reduced firing rate, reduced firing time,

lower stack temperature and less dilution air can, in

some cases, contribute to the condensing of small

amounts of water vapor in the chimney. Such

condensation, when it occurs, can cause chimney

deterioration. In extreme cases, condensed water

may be visible on the outside of the breeching or

chimney. In those extreme cases, the chimney may

have to be lined to insulate the chimney and thus

prevent the condensation. The addition of dilution

air into the chimney may assist in drying the

chimney interior surfaces.

CANADA- Refer to CSA standard C22.2 Part 1, 1990,

Electrical Features of Fuel Burning Equipment (Gas

and Oil).

I. FUEL UNITS AND OIL LINES

SINGLE-PIPE OIL LINES - Standard burners are

provided with single-stage 3450 rpm fuel units with

the by-pass plug removed for single-pipe installations.

The single-stage fuel unit may be installed single-pipe

with gravity feed or lift. Maximum allowable lift is 8

feet. See Figure 15.

TWO-PIPE OIL LINES - For two-pipe systems where

more lift is required, the two-stage fuel unit is

recommended. Table 4 (single-stage) and Table 5

(two-stage) show allowable lift and lengths of 3/8-inch

and 1/2-inch OD tubing for both suction and return

lines. Refer to Figure 16.

A massive chimney on a cold, or exposed outside

wall may have produced adequate draft when it was

fired with a higher input and greater volumes of

heated gases. With reduced input and volume, the

draft may be severely affected. In one instance our

research showed a new chimney of adequate sizing

produced only -.035" W.C. after 30 minutes of

continuous firing at 13.0% CO₂. Outside wall

chimneys take longer to heat up and can have .00"

W.C. draft at burner startup. You may have to

consider a special alloy chimney flue liner with

insulation around it and a stabilizing draft cap or

even a draft inducing fan in severe cases.

Be sure that all oil line connections are absolutely

airtight. Check all connections and joints. Flared

fittings are recommended. Do not use compression

fittings or PTFE ("Teflon®") tape.

Open the air-bleed valve and start the burner. For

clean bleed, slip a 3/16" ID hose over the end of the

bleed valve and bleed into a container. Continue to

bleed for 15 seconds after oil is free of air bubbles.

Stop burner and close valve.

TABLE 4: SINGLE-STAGE UNITS (3450 RPM) -

TWO-PIPE SYSTEMS

Manimum Length of Tubing

"H" + "R" (See Figure 16)

Lift "H"

(See Fig. 16)

3/8" OD

1/2" OD

Tubing (3 GPH) Tubing (3 GPH)

84'

78'

73'

68'

63'

57'

52'

47'

42'

36'

31'

26'

21'

---

100'

83'

Figure 15

10'

11'

12'

13'

14'

IMPORTANT

Single-pipe installations must be absolutely

airtight or leaks or loss of prime may result.

Bleed line and fuel unit completely.

62'

---

41'

TABLE 5: TWO-STAGE UNITS (3450 RPM) -

TWO-PIPE SYSTEMS

Maximum Length of Tubing

"H" + "R" (See Figure 16)

Lift "H"

(See Fig. 16)

3/8" OD

1/2" OD

Tubing (3 GPH) Tubing (3 GPH)

93'

85'

77'

69'

60'

52'

44'

36'

27'

---

100'

76'

10'

12'

14'

16'

18'

Figure 16

Fig. 17: Wiring Diagram for Steam Boilers with Standard Hydrolevel CG-450 Probe LWCO,

Beckett AFG Burner and Controls, with or without Tankless Heater

Fig. 18: Wiring Diagram for Steam Boilers with Optional McDonnell & Miller PS-801 Probe LWCO,

Beckett AFG Burner and Controls, with or without Tankless Heater

BOILER SEQUENCE OF OPERATION WITH PROBE LWCO

When the thermostat calls for heat, it energizes the cad cell primary control, bringing on the burner. The burner will operate until the

thermostat is satisfied or the limit setting on the high limit is reached. When the high limit control restores the circuit on a drop in

pressure, the burner will start if the thermostat is still calling for heat.

Any of the probe low water cutoffs will shut down the burner after a 10-15 second delay, if the water level in the boiler drops too low.

The Hydrolevel CG-450 and the McDonnell & Miller PS-804-120 low water cutoffs will shut down the burner for 90 seconds every 10

minutes of firing time to allow water level to stabilize. If the water level is too low the burner will not be allowed to restart.

Any of the probe low water cutoffs reset and restart the burner with a call for heat a few seconds after the water is returned to its

normallevel.

On burner start, if the cad cell does not see flame within approximately 45 seconds, primary control will lock out on safety and must be

reset before burner can be restarted.

When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected setting for proper

operation of the domestic water heater, if equipped with optional tankless heater.

TS-39- -C Rev. O

Fig. 19: Wiring Diagram for Steam Boilers with Optional McDonnell & Miller PS-804-120 Probe LWCO,

Beckett AFG Burner and Controls, with or without Tankless Heater

NOTE: The McDonnell Miller low water cut off incorporates a 10 second delay to prevent nuisance burner cut-off due to rapid

water level fluctuations. The LWCO also has a time delay of 15 seconds which allows additional fill time after water touches the

probe. Red LED indicates a low water condition.

Fig. 20: Wiring Diagram for Steam Boilers with McDonnell & Miller #67 LWCO,

Beckett AFG Burner and Controls, with or without Tankless Heater

BOILER SEQUENCE OF OPERATION WITH FLOAT LWCO

When the thermostat calls for heat, it energizes the cad cell primary control, bringing on the burner. The burner will operate until

the thermostat is satisfied or the limit setting on the high limit is reached. When the high limit control restores the circuit on a

drop in pressure, the burner will start if the thermostat is still calling for heat. The low water cut off will shut down the burner if the

water level in the boiler drops too low. The control resets and restarts the burner with a call for heat a few seconds after the water

is returned to its normal level.

On burner start, if the cad cell does not see flame within approximately 45 seconds, primary control will lock out on safety and

must be reset before burner can be restarted.

When there is no demand for heat, the operating control will maintain the boiler water temperature at the selected setting for

proper operation of the domestic water heater, if equipped with optional tankless heater.

Fig. 21: Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls, without Tankless Heater

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L8148A control which in turn energizes the R4184D primary control to turn on the

burner. If burner ignites within approximately 45 seconds and the cad cell sees flame, the burner will continue to operate until the call

for heat is satisfied or the setting of the high limit is reached. The circulator will operate as long as the thermostat is calling for heat. If

the thermostat is not satisfied and the high limit is reached, the circulator will continue to operate, and the burner will stop until the high

limit is closed by a drop in boiler water temperature.

Fig. 22: Wiring Diagram for Water Boilers with Beckett AFG Burner and Controls, with Tankless Heater

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the L8124C control which in turn energizes the R4184D primary control to turn on the

burner. If burner ignites within approximately 45 seconds and the cad cell sees flame the burner will continue to operate until the call

for heat is satisfied. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting

of the low limit in the L8124C control. If boiler water temperature is below the low limit setting the burner will operate but the circulator

will not, giving preference to the domestic hot water demand.

On call for heat by the thermostat the burner will continue to operate until the thermostat is satisfied or the setting of the high limit is

reached. If the thermostat is not satisfied when the high limit is reached the burner will stop but the circulator will continue to operate

until the thermostat is satisfied. Any time the boiler water temperature drops below the setting of the low limit the burner will be

energized in order to maintain domestic water temperature.

SECTION IV: OPERATING AND SERVICE INSTRUCTIONS

WARNING

All boilers equipped with burner swing door have a potential hazard which can cause severe property

damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to

boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door

fastener completely when service is completed.

A. ALWAYS INSPECT INSTALLATION BEFORE

(Note - If make-up water line is equipped with

pressure reducing valve, system will

automatically fill to 12 psi. Leave globe valve

open).

STARTING BURNER.

B. FILL HEATING SYSTEM WITH WATER.

NOTE: It is important, especially in a steam system,

to properly remove the oil and dirt from the system.

Failure to clean the system can result in erratic water

lines and surging.

j. Open isolation valve in boiler supply piping.

k. Remove hose from bib cock.

C. CHECK CONTROLS, WIRING AND BURNER to be

sure that all connections are tight and burner is rigid,

that all electrical connections have been completed and

fuses installed, and that oil tank is filled and oil lines

have been tested.

CLEAN HEATING SYSTEM IF boiler water or

condensate return water is dirty or if erratic water lines

or surging exist after a few days of boiler operation.

Refer to step "N" for proper cleaning instructions for

steam and water boilers.

D. LUBRICATION — Follow instruction on burner and

circulator label to lubricate, if oil lubricated. Most

motors currently used on residential type burners

employ permanently lubricated bearings and thus do

not require any field lubrication. Water lubricated

circulators do not need field lubrication.

1. STEAM BOILERS — Fill boiler to normal water

line. Refer to Figure No. 1C.

2. HOT WATER BOILERS. Fill entire heating system

with water and vent air from system. Use the

following procedure on a series loop or multi-zoned

system installed as per Figure 9, to remove air from

system when filling:

Do not over-lubricate. This can cause as much trouble

as no lubrication at all.

E. SET CONTROLS with burner service switch turned

a. Close isolation valve in boiler supply piping.

“OFF”.

b. Isolate all circuits by closing zone valves or

balancing valves.

1. SET ROOM THERMOSTAT about 10° above

room temperature.

c. Attach a hose to bib cock located just below

isolation valve in boiler supply piping.

2. PRESS RED RESET BUTTON on primary control

(R4184D/R8184G) and release.

(Note - Terminate hose in five gallon bucket at a

suitable floor drain or outdoor area).

3. On STEAM BOILERS, set cut-in pressure on

PA404 pressuretrol for three (3) pounds and

differential pressure for two (2) pounds. These

pressures may be varied to suit individual

requirements of installation.

d. Starting with one circuit, open zone valve.

e. Open bib cock.

f. Open fill valve (make-up water line should be

located directly above isolation valve in boiler

supply piping).

4. On STEAM BOILERS WITH TANKLESS

DOMESTIC WATER HEATERS, set boiler water

temperature dial on L4006 operating control at

190°F (max.). Set differential at 10°.

g. Allow water to overflow from bucket until

discharge from hose is bubble free for 30

seconds.

5. On WATER BOILERS WITHOUT TANKLESS

HEATERS, set high limit dial on L8148 at 210°F.

This temperature may be varied to suit

requirements of installation.

h. Open zone valve to the second zone to be

purged, then close the first. Repeat this step

until all zones have been purged, but always

have one zone open. At completion, open all

zone valves.

6. On WATER BOILERS WITH TANKLESS

HEATERS, set operating control dial (low limit) on

L8124 at 190°F and high limit dial at 210°F.

Operating control (low limit) must be a minimum

of 20° below high limit setting. Set differential at

25°.

i. Close bib cock, continue filling the system until

the pressure gauge reads 12 psi. Close fill valve.

NOTICE

Burner-specific references in the following instructions pertain to the Beckett AFG, supplied as

standard equipment. For optional burners, Riello R40 and Carlin EZ-1HP and 102CRD-3, consult

Table 6 at the rear of this manual for specifications, the instruction booklet shipped with the

burner, and the appropriate Supplemental Instructions shipped with the boiler:

Burnham Part Number

Supplemental Instructions for:

Riello R40

8142761

8142759

8142760

Carlin EZ-1HP

Carlin 102CRD-3

V72 thru V77; V713 and V714:

F. REMOVE GUN ASSEMBLY

"L1" and "F" head burners have a fixed head which

is non-adjustable. To check combustion head

location refer to Figure 24.

1. Items to be checked are nozzle size, type, and

angle; head size (and setting on MD(V1)head); gun

setting; and positioning of electrodes. This

informations is shown in Figures 23 and 24 and

Table 6 (at rear of manual).

V78 & V79:

“V1” (variable) head burners have the ability to

control air by moving the head either forward or

back.

2. Reinstall gun assembly.

G. ADJUST OIL BURNER BEFORE STARTING.

Loosen the adjusting plate assembly hold down

screw. Slide the head and plate to the required

firing rate setting as shown in Figure 24. Tighten

the screw and knurled nut.

1. SET BURNER AIR BAND AND AIR SHUTTER,

see Table 6 at rear of manual..

2. OPEN ALL OIL LINE VALVES.

3. Attach a plastic hose to fuel pump vent fitting and

provide a pan to catch the oil.

It might be necessary to move the head forward or

back one position at a time to optimize the smoke

and CO₂readings. See Figure 24.

4. REMOVE GAUGE PORT PLUG from fuel pump

and install pressure gauge capable of reading at

least 150 PSI.

3. ADJUST DRAFT REGULATOR for a draft

of — .02” (water gauge) over the fire after chimney

has reached operating temperature and while

burner is running.

5. OPEN FLAME OBSERVATION DOOR on front

of boiler.

4. READJUST AIR BANDS on burner for a light

orange colored flame while the draft over the fire is

—.02”. Use a smoke tester and adjust air for

minimum smoke (not to exceed #1) with a

minimum of excess air. Make final check using

suitable instrumentation to obtain a CO₂of 11.5 to

12.5% with draft of —.02” (water gauge) in fire

box. These settings will assure a safe and efficient

operating condition. If the flame appears stringy

instead of a solid fire, try another nozzle of the

same type. Flame should be solid and compact.

After all adjustments are made recheck for a draft

of —.02” over the fire.

H. START OIL BURNER.

1. Open vent fitting on fuel pump.

2. TURN ‘ON’ BURNER service switch and allow

burner to run until oil flows from vent fitting in a

SOLID stream without air bubbles for

approximately 10 seconds.

3. Close vent fitting and burner flame should start

immediately.

I. ADJUST OIL PRESSURE.

1. Locate oil pressure adjusting screw and turn screw

to obtain 140 PSI pressure (100 PSI for V74R

only).

2. DO NOT REMOVE PRESSURE GAUGE until

later.

J. OTHER ADJUSTMENTS

1. ADJUST THE AIR BAND AND/OR AIR

SHUTTER.

(Non-Burnham Drawing

Copy from other Manual)

Adjust air supply by loosening lock screws and

moving the air shutter and if necessary the air band.

Refer to Table 6 for preliminary settings.

2. ADJUST THE COMBUSTION HEAD.

Fig. 23: "F" Head Electrode Positioning and Gun

Setting (Beckett AFG)

(Non-Burnham Drawing,

Copy from LE Manual, 81433010R4, Page 13, without

"Figure 12A, 12B, 12C and 12D"; sample enclosed)

Fig. 24: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)

5. TURN “OFF” BURNER and remove pressure

gauge. Install gauge port plug and tighten. Start

burner again.

6. CAD CELL LOCATION AND SERVICE

The burner is supplied with a cadmium sulfide

flame detector mounted at the factory, mounted on

the bottom of the ignitor. See Figure 25. To service

cad cell or to replace the plug in portion, swing

open the ignitor. After service is complete, be sure

to fasten down the ignitor.

7. FLAME FAILURE

The V7 boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to fire and the reset button on the primary

control has tripped, the burner has experienced

ignition failure. Before pressing the reset button

call your serviceman immediately.

Figure 25: Cad Cell Location

CAD CELL TEST

g. Open line switch. Clean cell face and see that

cell is securely in socket. Reconnect leads. Reset

safety switch.

h. Close line switch. If burner starts and runs

beyond safety switch cut-out time, cell is good.

If not, install new cell.

K. CHECK FOR CLEAN CUT OFF OF BURNER.

3. WARNING — Check High Limit Control —

Jumper Thermostat Terminals. Allow burner to

operate until shut-down by limit. Installation is not

considered complete until this check has been

made.

1. AIR IN THE OIL LINE between fuel unit and

nozzle will compress when burner is on and will

expand when burner stops, causing oil to squirt

from nozzle at low pressure as burner slows down

and causing nozzle to drip after burner stops.

Usually cycling the burner operation about 5 to 10

times will rid oil line of this air.

REMOVE JUMPER.

4. Check low water cut off control with water level at

normal water line (see Figure 1C). Raise thermostat

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.

2. IF NOZZLE CONTINUES TO DRIP, repeat step

K.1.. If this does not stop the dripping, remove

cutoff valve and seat, and wipe both with a clean

cloth until clean, then replace and readjust oil

pressure. If dripping or after burn persist replace

fuel pump.

Close boiler drain and refill to normal water line.

Burner should automatically restart during fill.

Lower thermostat setting.

L. TEST CONTROLS.

5. 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 shut-down.

WARNING

Before installation of the boiler is considered

complete, the operation of the boiler controls

should be checked, particularly the primary

control and high limit control.

IF CONTROLS DO NOT MEET REQUIREMENTS

OUTLINED IN PARAGRAPH L., REPLACE

CONTROL AND REPEAT CHECK-OUT

PROCEDURES.

1. Check thermostat operation. Raise and lower

thermostat setting as required to start and stop

burner.

M. MAINTENANCE OF LOW WATER CUTOFF

DEVICES

2. VERIFY PRIMARY CONTROL SAFETY

FEATURES using procedures outlined in

Instructions furnished with control (See back of

control cover) or instructions as follows:

IMPORTANT

Probe and float type low water cut-off devices

require annual inspection and maintenance.

CHECKOUT PROCEDURE

1. PROBE TYPE LOW WATER CUT-OFF

FOR SERVICEMAN ONLY

Although these devices are solid state in their

operation, the probe is exposed to possible

contamination in the boiler water and subject to

fouling.

a. Check wiring connections. Close line switch.

Check power at control.

PRIMARY RELAY TEST

It is important to physically remove the probe from

the boiler tapping annually and inspect that probe

for accumulation of scale or sediment.

b. Disconnect cad cell leads (f-f). Reset safety

switch.

c. Set controller to call for heat. Burner should

start.

Follow these steps to inspect, clean and/or replace

the probe:

d. Jumper F-F terminal within 15 to 30 seconds.

Burner should run.

a. Turn off electric service to the boiler.

b. Drain boiler water to a level below the tapping

for the probe.

e. Remove F-F Jumper. Burner shuts down in

approximately 15 to 60 seconds.

c. Disconnect wiring connections between the low

water cutoff control and the probe.

f. If burner operates as described, relay is good. If

not, install new relay.

d. Dismount the low water cutoff control from the

probe.

required. Examine all visible wiring for brittle or

worn insulation and make sure electrical contacts

are clean and that they function properly. Give

special attention to solder joints on bellows and

float when this type of control is used. Check float

for evidence of collapse and check mercury bulb

(where applicable) for mercury separation or

discoloration. Do not attempt to repair mechanisms

in the field. Complete replacement mechanisms,

including necessary gaskets and installation

instructions are available from the manufacturer.

e. Unscrew the probe from the boiler tapping.

f. Inspect that portion of the probe that is exposed

to the boiler water for a scale or sediment

buildup.

g. 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 removed from the probe by

using a diluted amount, 3 parts of water to 1

part of phosphoric acid (H₂PO₄).

N. BOILER AND SYSTEM CLEANING

INSTRUCTIONS FOR TROUBLE FREE

OPERATION.

1. STEAM BOILERS

CAUTION

a. Oil, greases & sediments which accumulate in a

new boiler and piping must be removed from the

system in order to prevent an unsteady water

line and carry over of the water into the supply

main above boiler.

Exercise caution when handling phosphoric acid

and follow the instruction label on its container.

h. Clean the pipe threads of the probe to remove

old, hardened pipe dope and other foreign

matter.

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 returned to the boiler, boil out the

boiler using the SURFACE BLOWOFF

connection, see Figure 4.

i. 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.

j. Screw the probe into the boiler tapping.

k. Mount the low water cutoff control on the probe.

l. Reconnect the control to probe wiring.

m. Fill the boiler to its normal waterline.

i. Drain boiler until 1” of water is visible in

gauge glass. Run temporary 1½” pipe line

from the surface blowoff connection to an

open drain or some other location where hot

water may be discharged safely. Do not

install valve in this line.

n. Add boiler water treatment compound as needed

(refer to paragraph N.).

o. Restore electric service to the boiler.

p. Fire burner to bring the water in the boiler to a

boil to drive off free oxygen.

ii. Drain about 5 gallons of hot water from

boiler into a container and dissolve into it

an appropriate amount of recommended

boil out compound. Remove safety valve &

add solution to boiler water thru exposed

tapping using a funnel.

q. WARNING — BEFORE RETURNING

BOILER TO SERVICE: Follow the low water

cutoff check out procedure in step L.4..

2. FLOAT TYPE LOW WATER CUT-OFF

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.

NOTICE

Check with local authorities or consult local

water treatment services for acceptable chemical

cleaning compounds.

Low-water cutoffs and water feeders should be

dismantled 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

iii. Start burner and operate sufficiently to boil

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 overflow is clear.

v. 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 oil 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 return main and

refilling the boiler until sample is clear.

iv. Stop burner and drain boiler in a manner

and to a location that hot water can be

discharged with safety.

v. Refill boiler to normal water line. If water

in gauge glass does not appear to be clear,

repeat steps (i. thru iii.) and boil out the

boiler for a longer time.

b. Low pressure steam boilers such as the V7

Series should be maintained with appropriate

water treatment compounds. Add suitable water

treatment compounds as recommended by your

qualified water treatment company.

vi. 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 oil burner and allow

c. Remove temporary surface blowoff piping, plug

tapping 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.

Condensate to flow to drain until it has run

clear for at least 30 minutes while feeding

water to boiler so as to maintain normal

water level. Turn off oil burner, drain

boiler, open gate valve in Hartford Loop,

then repeat step 1 above.

d. If unsteady water line, foaming or priming

persist, install gate valve in Hartford Loop and

drain valves in return main and at boiler as

shown in Figure 8 and proceed as follows:

e. Make pH or Alkalinity Test.

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.

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 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

Close all radiator valves. Remove all supply

main air valves and plug the openings in

supply main.

ii. Draw about 5 gallons of hot water from

boiler into a container and dissolve into it

the appropriate amount of a recommended

boilout compound. Remove safety valve

from boiler and pour this solution into

boiler, then reinstall safety valve.

necessary, to bring the pH within the specified

range.

f. Boiler is now ready to be put into service.

2. WATER BOILERS

iii. Turn on oil 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.

a. Filling of Boiler and System — General —-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 12 psi. To insure that

the system is full, water should come out of all

air vents when opened.

iv. Stop feeding water to boiler but continue

operating oil burner until excess water in

boiler flows out through supply main and

water lowers (by steaming) until it reaches

normal level in boiler. Turn off oil burner.

Drain boiler. Open all radiator valves.

Reinstall all supply main air valves. Open

gate valve in Hartford Loop.

b. Boiling Out of Boiler and System. The oil and

grease which accumulate in a new hot water

boiler can be washed out in the following

manner.

i. Remove safety relief valve using extreme

care to avoid damaging it.

ii. Add an appropriate amount of

recommended boil out compound.

iii. Replace safety relief valve.

iv. Fill the entire system with water.

v. Start firing the boiler.

and can vary from sample to sample. For all of

those reasons a spare nozzle is a desirable item for

a serviceman to have.

2. FLAME SHAPE — Looking into the combustion

chamber through the observation door, the flame

should appear straight with no sparklers rolling up

toward the crown of the chamber. If the flame drags

to the right or left, sends sparklers upward or makes

wet spots on the target wall, the nozzle should be

replaced. If the condition persists look for fuel

leaks, air leaks, water or dirt in the fuel as

described above.

vi. Circulate the water through the entire

system.

vii. Vent the system, including the radiation.

viii. Allow boiler water to reach operating

temperature, if possible.

ix. Continue to circulate the water for a few

hours.

3. FUEL LEAKS — Any fuel leak between the pump

and the nozzle will be detrimental to good

combustion results. Look for wet surfaces in the air

tube, under the ignitor, and around the air inlet.

Any such leaks should be repaired as they may

cause erratic burning of the fuel and in the extreme

case may become a fire hazard.

x. Stop firing the boiler.

xi. Drain the system in a manner and to a

location that hot water can be discharged

with safety.

xii. Remove plugs from all available returns and

wash the water side of the boiler as

thoroughly as possible, using a high-

pressure water stream.

4. AIR LEAKS — Any such leaks should be repaired,

as they may cause erratic burning of the fuel and in

extreme cases may become a fire hazard.

xiii. Refill the system with fresh water.

c. Add appropriate boiler water treatment

compounds as recommended by your qualified

water treatment company.

5. GASKET LEAKS — If 11.5 to 12.5% CO₂with a

#1 smoke cannot be obtained in the breeching, look

for air leaks around the burner mounting gasket,

observation door, and canopy gasket. Such air leaks

will cause a lower CO₂reading in the breeching.

The smaller the firing rate the greater effect an air

leak can have on CO₂readings.

d. 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 color chart on the side of

the small hydrion dispenser gives the reading

pH. Hydrion paper is inexpensive and

obtainable from any chemical supply house or

thru your local druggist. The pH should be

higher than 7 but lower than 11. Add

appropriate water treatment chemicals, if

necessary, to bring the pH within the specified

range. With this lower level of protection, care

must be exercised to eliminate all of the free

oxygen in the system.

6. DIRT — A fuel filter is a good investment.

Accidental accumulation of dirt in the fuel system

can clog the nozzle or nozzle strainer and produce a

poor spray pattern from the nozzle. The smaller the

firing rate, the smaller the slots become in the

nozzle and the more prone to plugging it becomes

with the same amount of dirt.

7. WATER — Water in the fuel in large amounts will

stall the fuel pump. Water in the fuel in smaller

amounts will cause excessive wear on the pump, but

more importantly water doesn’t burn. It chills the

flame and causes smoke and unburned fuel to pass

out of the combustion chamber and clog the

flueways of the boiler.

e. Boiler is now ready to be put into service.

8. COLD OIL — If the oil temperature approaching

the fuel pump is 40°F or lower poor combustion or

delayed ignition may result. Cold oil is harder to

atomize at the nozzle. Thus, the spray droplets get

larger and the flame shape gets longer. An outside

fuel tank that is above grade or has fuel lines in a

shallow bury is a good candidate for cold oil. The

best solution is to bury the tank and lines deep

enough to keep the oil above 40°F.

O. HINTS ON COMBUSTION

1. NOZZLES — Although the nozzle is a relatively

inexpensive device, its function is critical to the

successful operation of the oil burner. The selection

of the nozzle supplied with the V7 boiler is the

result of extensive testing to obtain the best flame

shape and efficient combustion. Other brands of the

same spray angle and spray pattern may be used but

may not perform at the expected level of CO₂and

smoke. Nozzles are delicate and should be protected

from dirt and abuse. Nozzles are mass-produced

9. HIGH ALTITUDE INSTALLATIONS

Air openings must be increased at higher altitudes.

Use instruments and set for 11.5 to 12.5% CO₂.

clean water to prescribed water level.

IMPORTANT

4. Always keep the manual fuel supply valve shut off

if the burner is shut down for an extended period of

time.

SUCTION LINE LEAKS - THE OIL MUST BE

FREE OF AIR. Try bleeding the pump

through a clear tube. There must be no froth

visible. There are various test kits available

to enable you to look at the oil through clear

tubing adapted to the supply line at the

pump fitting. Air eliminators are on the

market that have potential. Also, electronic

sight glasses are being used with good

success. At times, new tubing must be run

to the tank or new fittings put on. Just make

sure you get the air out.

5. To recondition the heating system in the fall season

after a prolonged shut down, follow the instructions

outlined in Section IV, Items A through M.

CAUTION

This boiler contains controls which may

cause the boiler to shut down and not

restart without service. If damage due to

frozen pipes is a possibility, the heating

system should not be left unattended in

cold weather; or appropriate safeguards

and alarms should be installed on the

heating system to prevent damage if the

boiler is inoperative.

Any air leaks in the fuel line will cause an

unstable flame and may cause delayed

ignition noises. Use only flare fittings in the

fuel lines.

10. START-UP NOISE — Late ignition is the cause of

start-up noises. If it occurs recheck for electrode

settings, flame shape, air or water in the fuel lines.

11. SHUT DOWN NOISE — If the flame runs out of

air before it runs out of fuel, an after burn with

noise may occur. That may be the result of a faulty

cut-off valve in the fuel pump, or it may be air

trapped in the nozzle line. It may take several firing

cycles for that air to be fully vented through the

nozzle. Water in the fuel or poor flame shape can

also cause shut down noises.

Q. FREQUENT WATER ADDITION

IMPORTANT

CHECK TEST PROCEDURE. A very good test for

isolating fuel side problems is to disconnect the

fuel system and with a 24" length of tubing, fire

out of an auxiliary five gallon pail of clean, fresh,

warm #2 oil from another source. If the burner

runs successfully when drawing out of the

auxiliary pail then the problem is isolated to the

fuel or fuel lines being used on the jobsite.

A leaky system will increase the volume of make-up

water supplied to the boiler which can significantly

shorten 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

P. ATTENTION TO BOILER WHILE NOT IN

OPERATION.

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 presence

of free oxygen in the boiler creates a corrosive

atmosphere 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.

1. IMPORTANT

IF BOILER IS NOT USED DURING WINTER

TIME, IT MUST BE FULLY DRAINED TO

PREVENT FREEZE DAMAGE.

2. Spray inside surfaces with light lubricating or

crankcase oil using gun with extended stem so as to

reach all corners.

3. With steam boilers, at end of season add sufficient

water to fill boiler to top of water column and leave

it that way until fall when water should be drained

again to proper level. If at this time boiler water is

dirty, drain water, flush out boiler, and refill with

(Non-Burnham Drawing

Copy from other Manual)

AQUASTAT SWITCHING ACTION WITHIN L8124C

CONTROL

The switching action within the L8124C control has

EXAMPLE: Set point of 140°F; differential set at 25°F.

On a temperature rise, R-B will break and R-W will make

at 155°F. On a temperature fall, R-B will make and R-W

will break at 130°F.

three settings:

1. high limit

2. low limit

3. adjustable differential

Set low limit indicator at the minimum temperature

recommended for domestic hot water supply. This setting

must be at least 20°F below high limit setting to prevent

one switch from locking out the other.

HIGH LIMIT OPERATION —-

The high limit opens and turns off the burner when the

water temperature reaches the set point. The high limit

automatically resets after the water temperature drops past

the set point and through the 10°F differential.

Set the indicator at desired shutoff temperature.

Set the differential the desired number of degrees.

25°F differential gives longest burner cycles.

AQUASTAT SWITCHING ACTION WITHIN L8148A

CONTROLS

LOW LIMIT OPERATION —-

On a temperature rise, with the adjustable differential

at the minimum setting of 10°F, the burner circuit (R-B)

breaks and the circulator circuit (R-W) makes at the low

limit set point. On a temperature drop of 10°F below the set

point, the R-B circuit makes and the R-W circuit breaks.

The switching action in the L8148A control has one

setting, the high limit. The switching relay is controlled by

the low voltage room thermostat. On a call for heat, the

relay contacts make to complete the line voltage circulator

circuit and also the burner circuit if the boiler water

temperature is below the high limit setting. The high limit

switch shuts off the burner if boiler water temperature

exceeds the high limit setting.

ADJUSTABLE DIFFERENTIAL —-

At any differential setting greater than 10°F, the R-B

make temperature and R-W break temperature will remain

the same-control setting minus 10°F. The R-B break and R-

W make temperature will be the set point temperature plus

the difference between the differential setting and 10°F.

Set the indicator at the desired shutoff temperature.

SECTION V: BOILER CLEANING

WARNING

All boiler cleaning must be completed with burner service switch turned off. Boilers

equipped with burner swing door have a potential hazard which can cause severe property

damage, personal injury or loss of life if ignored. Before opening swing door, turn off

service switch to boiler to prevent accidental firing of burner outside the combustion

chamber. Be sure to tighten swing door fastener completely when service is completed.

smokepipe, burner mounting plate, burner swing door

and all flue plates are secured in place.

A. CLEAN THE FLUEWAYS (See Figure 26).

1. Prior to cleaning boiler, lay a protective cloth or

plastic over combustion chamber blanket to collect

debris falling from flueways.

1. Install the canopy taking care to align the gaskets

without blocking the flueways. If gasket is

damaged, replace as needed.

2. For access to firebox

2. Reinstall flue plates, making sure gasket on each

plate is in place and forms gas tight seal. If

damaged replace as needed.

On boilers with burner swing door and flexible fuel

line(s), remove fastener securing door and swing

door open. For full access to firebox, remove burner

and swing door from mounting plate by pulling

hairpin cotter from bottom of hinge pin and

removing pin from hinge. Set burner aside. Remove

swing door mounting plate, see Figure 6.

3. Reinstall jacket top panel and secure with sheet

metal screws. Replace jacket upper right side access

panel.

4. Reinstall smokepipe on canopy and secure to collar

with sheet metal screws.

5. Install swing door mounting plate to front section

with fasteners, see Figure 6.

6. Reinstall burner in reverse order of disassembly

outlined in paragraph A.2 above. For details, see

Figure 6.

3. For cleaning from the side:

a. Lift the jacket's upper right side access panel off

to expose the flue cleanout plates.

b. Loosen nuts securing the flue cleanout plates

and remove the plates. The insulation should be

removed with the plates taking care not to

damage the insulation.

4. For cleaning from the top:

a. Lift the jacket's upper right side access panel off

to allow removal of the jacket top panel.

b. Remove as much smokepipe as necessary to

allow removal of the jacket top panel and

canopy (smokebox).

c. Remove the jacket top panel.

d. Remove the canopy, being careful not to damage

the ceramic fiber gasket.

5. Using a 1¼” diameter wire or fibre bristle brush

(30” handle) clean the flueways. Brush from the top

and/or side using horizontal and diagonal strokes

for best results. DO NOT allow brush to strike the

target wall or liner in the chamber.

B. CLEAN TOP OF BOILER SECTIONS (if cleaning

from the top).

Figure 26: Cleaning of Boiler Flueways

Brush and vacuum the tops of the boiler sections.

C. CLEAN THE FIREBOX.

WARNING

Using wire or fibre bristle brush, clean crown of boiler

and inside of water legs. DO NOT allow brush to strike

target wall or blanket in the combustion chamber.

The boiler must be connected to an approved

chimney in good condition. Serious property damage

could result if the boiler is connected to a dirty or

inadequate chimney. The interior of the chimney flue

must be inspected and cleaned before the start of the

heating season and should be inspected periodically

throughout the heating season for any obstructions.

A clean and unobstructed chimney flue is necessary

to allow noxious fumes that could cause injury or loss

of life to vent safely and will contribute toward

maintaining the boiler's efficiency.

D. AFTER CLEANING, remove protective cloth with

debris and vacuum as necessary, but be careful not to

damage blanket. Inspect target wall, combustion

chamber blanket, burner mounting plate insulation and

burner swing door insulation for signs of damage. If

damaged, replace as needed.

E. REASSEMBLE BOILER.

CAUTION: Do not start the burner unless canopy,

SECTION VI: REPAIR PARTS

All V7 Series Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance

in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair

parts, please contact your Burnham Regional Sales Office as listed below.

Burnham Corporation Regional Offices

A. Burnham Corporation - Central & Western Regions

P.O. Box 3079

C. Burnham Corporation - Metropolitan Region

P.O. Box 3079

Lancaster, PA 17604-3079

Phone: (717) 481-8400

Lancaster, PA 17604-3079

Phone: (717) 481-8400

FAX: (717) 481-8408

FAX: (717) 481-8409

B. Burnham Sales Corporation - Northeast Region

19-27 Mystic Avenue

D. Burnham Corporation - Mid-Atlantic Region

P.O. Box 3079

Somerville, MA 02145

Lancaster, PA 17604-3079

Phone: (717) 481-8400

Phone: (617) 625-9735

FAX: (617) 625-9736

FAX: (717) 481-8409

Contact Regional Office Indicated for your State

Alabama

Alaska

Nebraska

Oregon

Nevada

Pennsylvania

Rhode Island

South Carolina

South Dakota

Tennessee

Texas

Arizona

New Hampshire

New Jersey

Arkansas

California

Colorado

Connecticut

Delaware

Florida

Atlantic, Burlington, Camden,

Cape May, Cumberland,

Gloucester, Mercer,

Monmouth, Ocean, Salem

Counties

Utah

Vermont

Georgia

Hawaii

All other Counties

Virginia

New Mexico

New York

Albany, Fulton, Montgomery,

Arlington,Accomack,Clarke,

Idaho

Fairfax,Frederick,Fauquier,

Loudoun,Northampton and

Prince William Counties

All other Counties

Illinois

Indiana

Rensselaer, Saratoga,

Schenectady, Schoharie,

Warren, Washington Counties

All Other Counties

Iowa

Kansas

Washington

Kentucky

Louisiana

Maine

Washington, D.C.

West Virginia

Wisconsin

North Carolina

North Dakota

Ohio

Maryland

Massachusetts

Michigan

Minnesota

Mississippi

Missouri

Montana

Wyoming

Athens, Belmont, Gallia,

Jefferson, Lawrence, Meigs,

Monroe, and Washington

Counties

All other Counties

Oklahoma

Canada

BARE BOILER ASSEMBLY

Item

No.

Description

Part No. V72 V713 V73 V714 V74 V75 V76 V77 V78 V79

BARE BOILER ASSEMBLY (See Page 32 for Illustration)

Front Section (Non-Htr.), Machined Water 71727019

Front Section (Non-Htr.), Machined Water 71727015

Front Section (Non-Htr.), Machined Steam 71727018

---

Front Section w/Htr. Opening, Machined

Water

71727016

---

Front Section w/Htr. Opening, Machined

Steam

71727017

Center Section

7172202

---

71727021

Narrow Back Section (Non-Htr.), Machined 7172204

---

Wide Back Section (Non-Htr.), Machined

Water

71727033

---

Wide Back Section (Non-Htr.), Machined

Steam

71727034

---

Rear Section w/Htr. Opening, Machined

5" Cast Iron Slip Nipple

7172203

71727036

7066003

7066001

8202701

82027023

82022033

82027031

82022043

---

2½" Cast Iron Slip Nipple

Rear Target Wall Insulation

Combustion Chamber Liner, ½" x 23" x 4"

Combustion Chamber Liner, ½" x 24" x 5"

Combustion Chamber Liner, ½" x 23" x 8"

Combustion Chamber Liner, ½" x 24" x 9"

---

Combustion Chamber Liner, ½" x 23" x 12" 82027041

Combustion Chamber Liner, ½" x 23" x 16" 82027051

Combustion Chamber Liner, ½" x 23" x 20" 82027061

Combustion Chamber Liner, ½" x 23" x 24" 82027071

Combustion Chamber Liner, ½" x 23" x 28" 82027081

Combustion Chamber Liner, ½" x 23" x 32" 82027091

---

Tie Rod, 3/8"-16 x 7¾" Lg.

Tie Rod, 3/8"-16 x 12½" Lg.

Tie Rod, 3/8"-16 x 17" Lg.

Tie Rod, 3/8"-16 x 20¾" Lg.

Tie Rod, 3/8"-16 x 25¼" Lg.

Tie Rod, 3/8"-16 x 27½" Lg.

Tie Rod, 3/8"-16 x 31½" Lg.

Tie Rod, 3/8"-16 x 36½" Lg.

80861072

80861010

80861011

80861012

80861013

80861014

80861015

80861036

---

----

---

CONTINUED ON PAGES 34 AND 35

BARE BOILER ASSEMBLY (CONTINUED)

CONTINUED FROM PAGE 33

Item

No.

Description

Part No. V72 V713 V73 V714 V74 V75 V76 V77 V78 V79

BARE BOILER ASSEMBLY (See Page 34 for Illustration)

Flue Cover Plate Assembly

6112214

8036068

8036058

7036002

---

Heater Cover Plate Gasket - Front Heater

---

11A Heater Cover Plate Gasket - Rear Heater

Blank Heater Cover Plate (WB) - Front Heater

---

Tapped Heater Cover Plate (WBTL) - Front

Heater

12A

7036001

7036020

---

Blank Heater Cover Plate (SB & WB) - Rear

Heater

12B

12C

Tapped Heater Cover Plate (WBTL) - Rear

Heater

7036021

6036036

6031204

6036031

---

222A Heater Carton Assy. - (WBT) Front Heater

---OR---

A54 Heater Carton Assy. - (WBT) Front Heater

---

V1-2 Heater Assy. - (SBT & WBT) - Rear

Heater

13A

13B V1-1 Heater Carton Assy. - (WBT) Rear Heater

14 Burner Swing Door Mounting Plate

14A Burner Swing Door Mounting Plate Insulation

6036030

7172705

82027021

72027014

7172706

82027022

72027015

7022701

80861614

80861667

7026001

8026015

7202710

611270211

---

Rope Gasket - Burner Mounting Plate - 53" Lg.

Burner Swing Door

16A Burner Swing Door Insulation

16B Rope Gasket (Burner Swing Door) - 28" Lg.

16C Hinge

16D Hinge Pin

16E Hairpin Cotter

Observation Port Cover

Spring 3/8" I.D. x ½" Lg.

Canopy Sealing Strip (½" x 1" x 98")

V72 Canopy Assembly, Type II

V713 Canopy Assembly

---

611270313 ---

611270311 ---

611270413 ---

611270411 ---

611270511 ---

611270611 ---

611270711 ---

611270811 ---

611270911 ---

V73 Canopy Assembly, Type II

V714 Canopy Assembly

---

V74 Canopy Assembly, Type II

V75 Canopy Assembly, Type II

V76 Canopy Assembly, Type II

V77 Canopy Assembly, Type II

V78 Canopy Assembly, Type II

V79 Canopy Assembly, Type II

---

TS-39-112-D

V713 and V714 FLUSH JACKET

Item No. Description

Part No.

V713

V714

V713 and V714 Flush Jacket Components - Items 1 thru 6 Include Insulation As Part of Assembly

Jacket Front Panel Assembly

Jacket Rear Panel Assembly

60427097

60427096

604270314

604270414

604270322

604270422

604270337

604270437

604270336

604270436

604270335

604270435

7042715

---

Jacket Left Side/Top Panel Assembly

Jacket Top Panel Assembly

---

Jacket Lower Right Side Panel Assembly

---

Jacket Upper Right Side Access Panel Assembly without Heater Opening (WB

Only)

---

Jacket Upper Right Side Access Panel Assembly with Heater Opening (WBT Only)

---

Jacket Bracket (WB Only)

Jacket Bracket (WBT Only)

7042714

TS-39-109-D

V72 Thru V79 FLUSH JACKET

Item

No.

Description

Part No.

V72

V73

V74 V75 V76 V77 V78 V79

V72 Thru V79 Flush Jacket Components - Items 1 thru 7 Include Insulation As Part of Ass'y

Jacket Front Panel Ass'y w/o Htr. Opg. (Wtr. Blr.)

Jacket Front Panel Ass'y w/o Htr. Opg. (Stm. Blr.)

Jacket Front Panel Ass'y w/Htr. Opg. (Wtr. Blr.)

Jacket Front Panel Ass'y w/Htr. Opg. (Stm. Blr.)

Plastic Collar Extension-Jkt. Frt. Panel w/Htr. Opg.

Jacket Rear Panel Assembly

60427090

60427091

---

60427092

60427094

8032704

60427093

604270241

604270341

604270441

604270541

604270641

604270741

604270841

604270941

604270221

604270321

604270421

604270521

604270621

604270721

604270821

604270921

604270234

604270334

604270434

604270534

604270634

604270734

604270834

604270934

604270233

604270333

604270433

604270533

604270633

604270733

604270833

604270933

604270332

604270432

604270532

604270632

604270732

604270832

604270932

---

Jacket Left Side/Top Panel Assembly

---

Jacket Top Panel Assembly

---

Jacket Lower Right Side Panel Assembly

---

Jacket Upper Right Side Access Panel Assembly

without Heater Opening

---

Jacket Upper Right Side Access Panel Assembly

with Heater Opening

---

V73 Thru V79 STEAM BOILERS - TRIM AND CONTROLS

Item

No.

Description

Part No.

V73 V74 V75 V76 V77 V78 V79

V73 Thru V79 STEAM BOILERS - TRIM AND CONTROLS (See Page 40 for Illustration)

1. Draft Regulator

DR-6 Draft Regulator

DR-7 Draft Regulator

8116029

8116001

---

2. Instruction Envelope Containing:

Installation and Operating Instructions

10 Year Limited Warranty Mailer (Steam Boilers)

I=B=R Pamphlet

8142711

81460121

81460061

3. Probe Low Water Cutoff

Low Water Cutoff, Hydrolevel CG450 (less probe)

80160628

80160624

Low Water Cutoff, McDonnell & Miller PS-801-120

Low Water Cutoff, McDonnell & Miller PS-804-120

Probe, Hydrolevel EL-1214 (Hydrolevel CG450)

Limit, Honeywell PA404A1009

80160662

80160629

80160300

806603030

806600508

806601520

806600003

8056091

Syphon, ¼ NPT x 4" x 180°

3D1 Bushing, ¾ NPT x ¼ NPT

3D2 Elbow, ¾ NPT

3D3 Nipple, ¾ NPT x 2"

Gage Glass Set, 6", ConBraCo 20-104-10

4. Float Low Water Cutoff

Low Water Cutoff, McDonnell & Miller 67

80160597

80160300

806603030

8056091

Limit, Honeywell PA404A1009

Syphon, ¼ NPT x 4" x 180°

Gage Glass Set, 6", ConBraCo 20-104-10

5. Miscellaneous Trim and Controls

Oil Primary Control, Honeywell R8184G1286

80160416

81660530

Safety Valve, ¾ NPT, 15 psi, ConBraCo 13-511-

5B1 Coupling, ¾ NPT

806602561

806600221

806603011

806600507

80160400

80160426

5B2 Nipple, ¾ NPT x 8"

Drain Valve, ¾ NPT, ConBraCo 31-606-02

5C1 Bushing, 1½ NPT x ¾ NPT

Limit, Honeywell L4006A2015 (SBPT & SBFT)

Well, ¾ NPT x 1½", Honeywell 123890A

V72 Thru V79, V713 and V714 WATER BOILERS - TRIM AND CONTROLS

ITEM

NO.

DESCRIPTION

Part No.

V72 V713 V73 V714 V74 V75 V76 V77 V78 V79

V72 Thru V79, V713 and V714 WATER BOILERS - TRIM AND CONTROLS (See Page 42 for Illustration)

1. DRAFT REGULATOR

DR-6 Draft Regulator

DR-7 Draft Regulator

8116029

8116001

---- ---- ----

---- ---- ---- ---- ---- ---- ----

2. INSTRUCTION ENVELOPE CONTAINING:

Installation and Operating Instructions

8142711

81460135

81460061

Limited Warranty Mailer (Water

Boilers)

2C I=B=R Pamphlet

3. CONTROLS

Honeywell L8148A1090 Hi Limit, Circ. 80160449U

Relay (WB)

--OR --

Honeywell L8124C1102 Hi & Lo Limit, 80160406U

Circ. Relay (WBT)

----

Honeywell #123870A Immersion Well,

80160426

¾NPT x 1½ Insulation (WB)

-- OR --

Honeywell #123872A Immersion Well,

80160497 ----

½NPT x 3" Insulation (WBT)

Honeywell R4184D (1027/1001)

Protectorelay

80160473

4. CIRCULATOR & PIPING (Packaged Boiler Only)

Circulator, Taco 007F (position 2)

Gasket, Taco "00" Series Circulator

8056007

806602006

806602014

4C Circulator Flange, 1½"NPT

Cap Screw, Hex Head, 7/16" -14 x

80861301

1½"

Hex Nut, 7/16" - 14

80860406

806600011

806601003

806600006

Nipple, 1½"NPT x18"

4G Tee, 1½" x ¾" x 1½"NPT, Black

4H Nipple, 1½"NPT x 3"

5. MISCELLANEOUS WATER TRIM

Relief Valve, ¾"NPT, F/F 30 LB,

81660319

806600221

8056169U

Conbraco 10-408-05

Nipple, ¾"NPT x 8"

Te m p/ Pr es su re Gau ge, 2½" Dia.,

ENFM #41042.5210

Drain Cock, ¾"NPT Short Shank

806603011

806603515

(WB and WBT), Conbraco #31-606-02

Plug, Square Head, 1½"NPT

(Packaged)

Reducing Bushing, 1½" x ¾"NPT

80660507

(Knockdown)

Beckett AFG Burner

BECKETT OIL BURNER PART NOS. FOR V7 SERIES BOILERS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also

provide the name of the part(s) and part number as listed below.

Boiler Model

V72

V713

V73

V714

V74

V75

V76

V77

V78

V79

Air Tube Combination

Beckett's Spec No.

Air Band

AFG70MB AF72YH

AF44XN

AF72YY

AF44WH

AF44RA

AF44XO AF72WK AFG50MD AFG50MD

BCB6111 BCB6119 BCB6112 BCB6120 BCB6113 BCB6114 BCB6115 BCB6116 BCB6117 BCB6118

3492

4150

4198

3709

4198

2999

2454

5880

3666

5636

149

3492

4150

4198

3709

4198

2999

2454

5880

3666

5636

149

3492

4150

4198

3709

4198

2999

2454

[1]

3492

4150

4198

3709

4198

2999

2454

---

3492

4150

4198

3709

4198

2999

2454

[1]

3492

4150

4198

3709

4198

2999

2454

---

3492

4150

4198

3709

4198

2999

2454

---

3492

4150

4198

3709

4198

2999

2454

---

3492

4150

4198

3709

4198

2999

2454

---

3492

4150

4198

3709

4198

2999

2454

---

Air Band Nut

Air Band Screw

Air Shutter

Air Shutter Screw

Blower

Coupling

Low Firing Rate Baffle

Bulkhead Knurled Locknut

Connector Tube Assembly

Electrode Clamp

Electrode Clamp Screw

Electrode Insulator Assembly

Spider Spacer Assembly

Escutcheon Plate

Adjusting Plate Assembly

Head

3666

5636

149

3666

5636

149

3666

5636

149

3666

5636

149

3666

5636

149

3666

5636

149

3666

5636

149

3666

5636

149

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

3493

---

4219

5780

5503

---

4219

5780

5503

---

5941

5913

4221

31498

5877

2456

213

5941

5913

4221

31498

5877

2456

213

5912

4221

31498

5877

2456

213

360003 [4] 360004 360006 [5] 360004 [6] 360006 [7] 360012 360016

Head Screws

4221

31498

5877

4221

31498

5877

4221

31498

5877

4221

31498

5877

4221

31498

5877

4221

31498

5877

2456

213

4221

31498

5877

2456

213

Flange Gasket

AFG Housing

Motor

2456

Nozzle Adapter

213

Nozzle Line Electrode Assembly NL72BN

NL72YH

2460

NL44YH

2460

NL72YY

2460

NL44WP

2460

NL44YB

2460

NL44X0 NL72WK NL50MD

NL50MD

2460

3383P

51771

4217

4292

51304

10251

5770

7006

21789

Pump

2460

3384

2460

3383P

51771

4217

2460

None

51771

4217

2460

3383P

51771

4217

Static Plate

3384

[2] 3384

51771

4217

3384

[3] 3383P

51771

4217

3384

Ignitor

51771

4217

51771

4217

51771

4217

51771

4217

Ignitor Hinge Screw

Ignitor Holding Screw

Ignitor Gasket Kit

Wire Guard

4292

51304

10251

5770

51304

10251

5770

51304

10251

5770

51304

10251

5770

51304

10251

5770

51304

10251

5770

51304

10251

5770

51304

10251

5770

51304

10251

5770

Junction Box

Flame Detector

Oil Solenoid Valve

7006

21789

[1] 5880 in V73R, V73M and V74R [2] 3912 in V73M and V73R [3] 3384 in V74M and V74R [4]360000 in V73R; 360003 in V73M

[5] 360003 in V74R and V74M [6] 360003 in V75R; 360006 in V75M [7] 360006 in V76R; 360012 in V76M

Print word document

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