Burnham V11 Series Service manual

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8142604R14-1/10 Price $5.00
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Commercial Boilers
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2

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IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be installed in accordance with National, State and Local Plumbing, Heating
and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations
may differ from this instruction manual. Authorities having jurisdiction should be consulted
before installations are made.
In all cases, reference should be made to the following Standards:
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls
and safety devices.
E. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
B. The equipment shall be installed in accordance with the current Installation Code for Gas
Burning Appliances and Equipment, CSA B149, and applicable Provincial Regulations for
the class; which should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating
properly when the installation is complete. The warranty for this boiler is valid only if the boiler has been
installed, maintained and operated in accordance with these instructions.

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DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other
appliance.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or
death. Read and understand all instructions, including all those contained in component manufacturers
manuals which are provided with the appliance before installing, starting-up, operating, maintaining or
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance
for reference by owner and service technician.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual. Installation, maintenance, and service must be performed only by an experienced, skilled
and knowledgeable installer or service agency. All heating systems should be designed by competent
contractors and only persons knowledgeable in the layout and installation of hydronic heating systems
should attempt installation of any boiler. It is the responsibility of the installing contractor to see that all
controls are correctly installed and are operating properly when the installation is completed. Installation
is not complete unless a pressure relief valve is installed into the specied tapping located at the rear of
appliance - See Section III of this manual for details.
This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting. Do not
operate on oors where heat affected material is below.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to
assure that the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale.
The inside of combustion chamber should also be cleaned and inspected at the same time.
Have Burner and Controls must be checked at least once a year or as may be necessitated.
Do not operate unit with jumpered or absent controls or safety devices.
Do not operate unit if any control, switch, component, or device has been subject to water.
Return water cannot be lower than 135°F for prolonged periods of time. Operation under these conditions will
result in sustained condensing within the combustion chamber and potentially reduce boiler longevity.
In addition, the return water cannot be introduced into the boiler if it is more than 40°F less than the idle
boiler temperature. Continued operation under these conditions may result in premature boiler failure
through thermal shock.
Example: A boiler that has been idle for some time since the last heat demand cycle may have it’s boiler
water temperature reduced to 150°F. The return temperature from the next zone activation cannot be
less than 110°F.
If the above conditions exist, an RTC (or similar type of control system) system must be installed to
protect the boiler from sustained condensing operation and thermal shock. See separate RTC Manual,
P/N 8146382.

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WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which
can cause death or serious injury and which are known to the state of California to cause cancer, birth
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when
servicing or working nearby the appliance.
This boiler contains very hot water under high pressures. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
This appliance must be properly vented and connected to an approved vent system in good condition.
Do not operate boiler with the absence of an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of the
heating season and should be inspected periodically throughout the heating season for any obstructions.
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's efciency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start 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.
This boiler is designed to burn No. 2 fuel oil, natural and/or LP gas only. Do not use gasoline, crankcase
drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to
any solid fuel (i.e. wood, coal). All ammable debris, rags, paper, wood scraps, etc., should be kept clear
of the boiler at all times. Keep the boiler area clean and free of re hazards.
Always keep the oil supply valve shut off if the burner is shut down for an extended period of time.
Probe and oat type low water cutoff devices require annual inspection and maintenance. Refer to
instructions in Section V, Paragraph C for inspection and cleaning instructions.
NOTICE
All V11 Series cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler
and Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each V11
jacket, which indicates the boiler Maximum Allowable Working Pressure (MAWP). Each cast iron section is
permanently marked with the MAWP listed on the boiler’s ASME Data Label. Those values for the V11 are as
follows:
MAWP, Steam - 15 psi
MAWP, Water (USA) - 80 psi
MAWP, Water (Canada) - 50 psi
It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler
MAWP. Therefore, Burnham offers safety relief valves set at or below the MAWP of the boiler. See Table 1 for
available safety relief valve set pressures.

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SECTION I - GENERAL INFORMATION
Dimensional Information ............................................................................................................................................... 8
Ratings/Data .................................................................................................................................................................. 9
Locating the Unit ......................................................................................................................................................... 10
Air Supply/Venting....................................................................................................................................................... 11
SECTION II - CAST IRON BLOCK ASSEMBLY (Knockdown Only)
Assembly of Sections, Manual Draw-up ..................................................................................................................... 14
Assembly of Sections, Hydraulic Draw-up ................................................................................................................. 19
Hydrostatic Test ........................................................................................................................................................... 20
SECTION III - INSTALLATION INSTRUCTIONS
Knockdown
Canopy ......................................................................................................................................................................... 23
Flue Cover Plates ......................................................................................................................................................... 25
Rear Observation Port Cover........................................................................................................................................ 25
Inspect All Boiler Seals ................................................................................................................................................ 25
Ceramic Fiber Firewall Plates ...................................................................................................................................... 25
Jacket Assembly .......................................................................................................................................................... 26
Burner Mounting Plate / Burner Adapter Plate ........................................................................................................... 30
Steam Trim .................................................................................................................................................................. 31
Water Trim ................................................................................................................................................................... 33
Burner Installation ....................................................................................................................................................... 33
Package Boilers
Preparation for Installation ........................................................................................................................................... 33
Common Installation Requirements
Boiler Piping - Heating Applications .......................................................................................................................... 34
Boiler Piping - Steam Applications .............................................................................................................................. 42
Boiler Piping - Domestic Hot Water (DHW) Applications .......................................................................................... 44
Tankless Heater Piping ................................................................................................................................................ 45
Electric Wiring.............................................................................................................................................................. 46
SECTION IV - OPERATING INSTRUCTIONS
Filling System............................................................................................................................................................... 50
Adjusting Controls ....................................................................................................................................................... 50
Adjusting Burner ......................................................................................................................................................... 51
Test Controls ................................................................................................................................................................ 51
Initial Cleaning, Steam Boilers .................................................................................................................................... 51
Initial Cleaning, Water Boilers .................................................................................................................................... 52
Frequent Water Addition .............................................................................................................................................. 53
Oxygen Corrosion ........................................................................................................................................................ 53
SECTION V - SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces ............................................................................................................................... 54
Maintenance of Low Water Cutoff Devices ................................................................................................................ 55
Checking Burner & Controls........................................................................................................................................ 56
Lubrication ................................................................................................................................................................... 56
General Maintenance Considerations........................................................................................................................... 56
Attention to Boiler While Not in Operation ................................................................................................................. 56
TABLE OF CONTENTS

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SECTION VI - BURNER SPECIFICATIONS
Beckett Burners (Table VI)...........................................................................................................................................57
Power Flame Burners (Table VII) ................................................................................................................................58
Webster Burners (Table VIII) .......................................................................................................................................61
Carlin Burners (Table IX).............................................................................................................................................64
SECTION VII - REPAIR PART
Regional Ofce Directory ............................................................................................................................................ 65
Jacket Assembly .......................................................................................................................................................... 66
Bare Boiler Assembly................................................................................................................................................... 70
Steam/Water Trim......................................................................................................................................................... 74
WARRANTY .......................................................................................................................................................REAR COVER
TABLE OF CONTENTS - Continued

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SECTION I - GENERAL INFORMATION
Figure 1: Dimensional Information

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(1) SUFFIX "S" INDICATES STEAM BOILER, "W" INDICATES
WATER BOILER. SUFFIX "G" INDICATES GAS–FIRED, "O"
INDICATES OIL–FIRED, "GO" INDICATES COMBINATION
GAS–OIL FIRED.
(2) I=B=R NET RATINGS SHOWN ARE BASED ON PIPING AND
PICKUP ALLOWANCES WHICH VARY FROM 1.333 TO 1.288
FOR STEAM AND 1.15 FOR WATER.
CONSULT MANUFACTURER FOR INSTALLATIONS HAVING
UNUSUAL PIPING AND PICKUP REQUIREMENTS, SUCH
AS INTERMITTENT SYSTEM OPERATION, EXTENSIVE PIPING
SYSTEMS, ETC.
THE I=B=R BURNER CAPACITY IN GPH IS BASED ON OIL HAVING
A HEAT VALUE OF 140,000 BTU PER GALLON.
(3) BOILER RATINGS ARE BASED ON 13.0% CO2(OIL) AND
10.0% CO2(NATURAL GAS) AND + .10" WATER COLUMN
PRESSURE AT BOILER FLUE OUTLET.
RATINGS SHOWN ABOVE APPLY AT ALTITUDES UP
TO 1000 FEET ON OIL AND 2000 FEET ON GAS. FOR
ALTITUDES ABOVE THOSE INDICATED, THE RATINGS
SHOULD BE REDUCED AT THE RATE OF 4% FOR EACH
1000 FEET ABOVE SEA LEVEL.
SAFETY (RELIEF) VALVE SET PRESSURE:
USA BOILER CANADIAN BOILER
STEAM - 15 PSI STEAM - 15 PSI
WATER - 50 PSI WATER - 50 PSI
OPTIONAL WATER - 30 PSI OPTIONAL WATER - 30 PSI
- 80 PSI
BOILER MODEL
BOILER HORSEPOWER
I=B=R
GROSS OUTPUT MBH
NET I=B=R RATING
I=B=R
BURNER
INPUT
HEATING
SURFACE
(SQ. FT.)
NET FIREBOX VOLUME
(CU. FT.)
PRESSURE IN FIREBOX
(INCHES WTR. COLUMN)
WATER
CONTENT
(GALLONS)
BOILER
WEIGHT
W / WATER
(LBS.)
I=B=R VENT DIA. (INCHES)
SQ. FT. STEAM
MBH STEAM
MBH WATER
OIL (GPH)
GAS (MBH)
STEAM
WATER
STEAM
WATER
STEAM
WATER
V1104 19.9 667 2083 500 580 5.8 837 64.6 74.4 7.9 0.35 59 72 2596 2704 8
V1105 25.6 857 2679 643 745 7.4 1068 83.5 96.2 10.6 0.36 68 84 3076 3210 8
V1106 31.9 1069 3342 802 930 9.2 1328 102.4 118.0 13.2 0.37 77 96 3561 3720 8
V1107 38.3 1281 4013 963 1114 11.0 1588 121.3 198.8 15.9 0.42 87 108 4050 4225 10
V1108 45.3 1517 4829 1159 1319 13.0 1876 140.2 161.6 18.5 0.42 96 120 4533 4733 10
V1109 51.7 1729 5563 1335 1503 14.8 2136 159.1 183.4 21.1 0.39 105 132 5022 5247 10
V1110 58.0 1941 6279 1507 1688 16.6 2396 177.0 204.2 23.8 0.42 115 144 5515 5757 12
V1111 64.3 2154 6967 1672 1873 18.4 2656 195.9 226.0 26.5 0.40 124 156 5997 6263 12
V1112 69.7 2334 7550 1812 2030 20.0 2887 214.8 247.8 29.1 0.42 133 169 6482 6782 12
V1113 74.8 2503 8096 1943 2177 21.5 3103 233.7 296.6 31.8 0.40 143 181 6962 7279 12
V1114 81.6 2730 8833 2120 2374 23.5 3392 252.6 291.4 34.4 0.38 152 193 7450 7792 14
V1115 88.3 2957 9567 2296 2571 25.5 3680 271.5 313.2 37.1 0.36 161 205 7942 8309 14
V1116 93.4 3126 10113 2427 2718 27.0 3897 290.4 335.0 39.7 0.38 171 217 8432 8816 14
V1117 100.2 3353 10846 2603 2916 29.0 4186 309.3 356.8 42.4 0.41 180 229 8916 9325 14
V1118 106.9 3580 11583 27780 3113 31.0 4474 328.7 377.6 45.0 0.39 189 241 9397 9831 16
V1119 111.7 3739 12096 2903 3251 32.5 4691 346.1 399.4 47.7 0.38 199 253 9889 10338 16
V1120 118.2 3957 12800 3072 3441 34.5 4979 365.0 421.2 50.3 0.38 208 265 10371 10845 16
V1121 124.7 4174 13504 3241 3630 36.5 5268 383.9 443.0 53.0 0.40 217 277 10861 11360 16
V1122 129.5 4334 14021 3365 3769 38.0 5485 402.8 464.8 55.6 0.41 227 290 11347 11872 18
V1123 136.0 4551 14721 3533 3957 40.0 5733 421.7 486.6 58.3 0.43 236 302 11831 12381 18
(3)
(1) (2)
TABLE I – RATINGS/DATA

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SECTION I - GENERAL INFORMATION (continued)
Table II: Minimum Installation Clearances To
Combustible Materials (Inches)
A. INSPECT SHIPMENT carefully for any signs of
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated Boiler to the carrier in good
condition.
2. ANY CLAIMS for damage or shortage in shipment
must be led immediately against the carrier by the
consignee. No claims for variances from, or short-
age in orders, will be allowed by the manufacturer
unless presented within sixty (60) days after the
receipt of goods.
B. LOCATE THE UNIT
NOTICE
Recommended clearance for service may be
reduced to minimum clearance to combustible
material. However, increased service and
maintenance difculty will result.
1. RECOMMENDED SERVICE CLEARANCE
- Locate the unit in the boiler room so as to
provide ease of venting and adequate clearance
for maintenance, serviceability, and installation of
piping. Refer to Figure 1 for boiler dimensional
data.
FRONT --- Provide 54" service clearance for
removal, maintenance, and servicing of burner and
controls.
REAR --- Provide a minimum service clearance
from the boiler jacket for access to pressure relief
door, ame observation port, rear ue damper and
vent piping, relief valve, and boiler return piping.
See following chart.
LEFT SIDE --- Provide a minimum clearance from
the boiler jacket of 36" for cleaning of ueways.
RIGHT SIDE --- Less Tankless Heater - Provide a
minimum clearance from boiler jacket of 12".
With Tankless Heater - Provide a minimum
clearance from the boiler jacket of 35" for
installation and removal of tankless heater(s).
TOP --- Provide a minimum clearance from the
boiler jacket of 24".
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table II.
3. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
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Table III: Recommended Rear Service Clearance
* See Table III for recommended service clearance
to access rear of boiler.
A B C D E
Above Front Rear Sides Vent Connector
6 24 6 6 18
Boilers with Top Flue Outlet
Boilers with Rear Flue Outlet