Burnham 8H - Manuals - manualsarea.com

Page 2 - IMPORTANT INFORMATION - READ CAREFULLY; shall be consulted before installations are made.; stalled combustible floor shield.

2 IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment must be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted b...

Page 3 - WARNING; system to prevent damage if the boiler is inoperative.; NOTICE

3 WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual b...

Page 4 - Table of Contents

4 Table of Contents I. Pre-Installation .............................................................6 II. Boiler Assembly ...........................................................8 III. Gas Control System Assembly ..................................15 (Knockdown Boilers) IV. Water Trim and Piping ...

Page 6 - for damage or shortage in shipment must be filed; Install boiler on level floor; such as concrete or masonry construction if floor is not; unconfined

6 I. Pre-Installation WARNING Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. A . Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our re...

Page 7 - flammable vapors or liquids, or sources of

b. If result is less than 50 ft 3 per 1,000 Btuh, space is considered a confined space . 4. Determine building type. A building of unusually tight construction has the following characteristics: a. Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with a rating o...

Page 8 - Tapping; Table 3: Purpose of Tappings

8 II. Boiler Assembly A. Remove Crate 1. Remove all fasteners at crate skid.2. Lift outside container and remove with all other inside protective spacers and bracing. B. Remove boiler from skid. See Figure 2. Exercise care to avoid dropping boiler.1. Place boiler in approximate location. Refer to Se...

Page 9 - Connect fill valve and piping to Drain Tapping G.; Do not use air to leak test boiler.; flooring. See Figure 4. Floor shield adds 43⁄4” to boiler

6. Lift boiler with pry bar. Remove wood blocks. Lower boiler. C. For Packaged Boiler only, proceed to Paragraph E. D. Test Section Assembly for leaks before connecting to system and installing controls, trim and jacket. Refer to Figure 3 and Table 3.1. Plug Tappings C & E (¾ NPT) and Return Tap...

Page 10 - Confirm that one (1) Flue Baffle is properly; of each Flue Baffle should be resting on top row of Flue

0 F. Move boiler to permanent location by sliding or walking. Do not drop. For Packaged Boiler, proceed to Paragraph L. G. Confirm that one (1) Flue Baffle is properly positioned in each Boiler Flueway. Tabs at the top of each Flue Baffle should be resting on top row of Flue Pins on each adjoining s...

Page 12 - Attach Flame Roll-out Switch; Affix Lighting/Operating Instructions Label and; Install Junction Box.; Install Honeywell R7847 Flame Amplifier.

2 M. Attach Flame Roll-out Switch to Burner Access Panel. See Figure 6. Flame Roll-out Switch and hardware are located in Combination Boiler Parts and Control Carton. Flame Roll-out Switch is a single use device - do not test with heat - switch cannot be reset.1. Cut insulation from semicircular not...

Page 13 - Assembly

Page 16 - Install Gas Control System

6 F. EP-CSD-1 Control System Install Gas Control System . All components are located in Combination Boiler Parts and Control Carton.1. Install Gas Control Assembly on Manifold. See Figure 17. 2. Install pilot burner piping and controls. See Figure 17. 3. Install Ignition Transformer. a. Attach Ignit...

Page 17 - Figure

Figure 0: Schematic Gas Piping, 24V Standing Pilot, 806H & 80 H

Page 25 - IV. Water Trim and Piping; Design and install boiler and system piping; b. Absorption through open tanks and fittings.; Design boiler piping and flow rate; Install Safety Relief Valve.

25 IV. Water Trim and Piping A . Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions.1. There are many possible causes of oxygen contamination such as:a. Addition of excessive make-up water as a result of system leaks. b. Absorptio...

Page 27 - Detail “A”: Blend Pump Piping

2 2. If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during cooling system operation. 3. The piping diagrams shown (Figure 23, D...

Page 28 - temperature protection by reducing flow through; Alliance SLTM Water Heater

28 a. A boiler by-pass is recommended for any installation for improved system temperature balance, while serving to protect the boiler from sustained condensing operation. The by-pass also provides some measure of low return water temperature protection by reducing flow through the boiler. See Figu...

Page 29 - National Fuel Gas Code; gas connectors may result in leaks of flammable; Connect boiler gas valve; National

2 V. Gas Piping WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An additional gas pressure regulator may be needed. C...

Page 30 - Table 7: Equivalent Lengths of Standard Pipe Fittings & Valves; Specific; Table 8: Specific Gravity Correction Factors; other ignition source.; detector, soap and water, or similar nonflammable

30 Length (Feet) 0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 4...

Page 31 - Install vent system; clay flue lining or listed chimney lining system; Inspect chimney; or liquid fuel-burning appliances or fireplaces.; DANGER; Install Draft Hood; Install Blocked Vent Switch.

3 A. Install vent system in accordance with local building codes; or local authority having jurisdiction; or National Fuel Gas Code , ANSI Z223.1/NFPA 54, Part 7, Venting of Equipment and/or CAN/CSA B149.1, Venting Systems and Air Supply for Appliances. Install any of the following for this Series 8...

Page 32 - Boiler Equipped With Vent Damper.; CAUTION; Do not use one vent damper to control two or; modification to either (Refer to instructions packed; Provide adequate clearance for servicing -; chimney - keep vent connector flush with inside of

32 E. Boiler Equipped With Vent Damper. See Figure 26. 1. Open Vent Damper Carton and remove Installation Instructions. Read Installation Instructions thoroughly before proceeding. CAUTION Do not use one vent damper to control two or more heating appliances. 2. Vent damper must be same size as draft...

Page 33 - Figure 2: Typical Vent System; When an existing boiler is removed from a; deficiencies which could cause an unsafe condition.

33 Figure 2: Typical Vent System 9. Design vent system for sea level input. 10. Provide adequate ventilation of Boiler Room. See Section I: Pre-Installation. 11. Never pass any portion of vent system through a circulating air duct or plenum. WARNING When an existing boiler is removed from a common v...

Page 34 - once power is turned off.; National Electrical Code; Wire Vent Damper; flexible conduit and attach to Jacket Top Panel.; Install thermostat.; approximately 4 feet above floor. Do not install on; Figure 28: Vent Damper Schematic Wiring Diagram

34 VII. Electrical WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm.Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.Each boiler must be protected with a properly sized fused d...

Page 35 - Alliance SLTM Installation, Operating; Vent Damper Sequence of Operation.; the damper are satisfied.; Sequence of Operation and Wiring.

35 E. Alliance SL™ Water Heater (if used). May be used with Intermittent Circulation only. Refer to Alliance SL™ Installation, Operating and Service Instructions for wiring, piping and additional information. F. Vent Damper Sequence of Operation. See Figure 28 for schematic wiring diagram.1. The Ven...

Page 36 - Table 10: Sequence of Operation and Wiring Diagrams

36 1. Standing Pilot (24) Sequence of Operation a. Normal Operation i. Thermostat or operating control calls for heat. Vent Damper (if used) opens. ii. Gas valves are energized allowing main gas flow and ignition of main burners. iii. Call or heat ends. Gas valves are de- energized, extinguishing ma...

Page 52 - American National Standard for Gas-Fired Low-; Confirm all electrical, water and gas supplies; Confirm that the boiler and system have no water; Do not use matches, candles, open flames or; Honeywell EI

52 WARNING Completely read, understand and follow all instructions in this manual before attempting start-up. A. Safe operation and other performance criteria were met with the gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard fo...

Page 57 - BOILER OPERATING INSTRUCTIONS; a. Intermittent electric ignition rectification pilot(s)

5 BOILER OPERATING INSTRUCTIONS TO SHUT DOWN: 1. Close manual main shut-off valve(s) and pilot valve(s). 2. Turn off main electric switch. TO START UP: 1. Make sure that both the main manual and the pilot valve(s) have been off for at least five minutes. 2. Turn room thermostat and all operating con...

Page 58 - Check pilot burner flame and main burner flames; Check pilot flame. Refer to Table 11 for appropriate; Figure 4: Honeywell Q348 Pilot Flame

58 I. Check pilot burner flame and main burner flames through observation port. 1. Check pilot flame. Refer to Table 11 for appropriate pilot detail. 2. Adjust thermostat to highest setting. 3. Check main burner flames. See Figure 52. Flame should have clearly defined inner cones with no yellow tipp...

Page 59 - Avoid operating this boiler in an environment; c. Slowly open air adjustment until clearly defined; Check thermostat or operating control operation; 2 to determine gas flow rate in Cubic Feet per; Warning; Failure to properly adjust gas input rate will result; a. Boiler must not be overfired. Reduce input rate

5 CAUTION Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation. a. Loosen lock screw.b. Close ...

Page 61 - originally supplied by Burnham Commercial.; Label all wires prior to disconnection when

6 IX. Service WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. Keep boiler area clear and free of combustible mater...

Page 62 - AVOID Breathing Fiber Particulates and Dust; Precautionary Measures

62 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame conta...

Page 63 - on Main Burner Orifices, and secured with hitch pin; Boiler Model; Table 3: Pilot Burner Location

63 F. Clean Combustion Chamber by vacuuming. Exercise care to avoid damaging Base Insulation. G. Install Burners by reversing procedures used to remove burners. Verify Main Burners are properly located on support bracket in Base Rear Panel, seated on Main Burner Orifices, and secured with hitch pin ...

Page 64 - Note; : This indication may flash temporarily during or; Honeywell EI Ignition Module Yellow LED Flame Codes

64 Yellow LED Flash Code a Indicates Recommended Service Action Heartbeat Normal Flame Signal N/A 2 Weak Flame Signal - System will operate reliably but flame signal is less than desired. Note: This indication may flash temporarily during or shortly after lightoff on some applications. Perform routi...

Page 65 - Honeywell EI Ignition Module Green LED Status Codes

65 Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None 2 5 minute Retry Delay- Pilot flame not detected during trial for ignition Initiate new ...

Page 66 - Honeywell EI Trouble Shooting Guide

Page 68 - . Heat Exchanger Assembly

68 Item No. Description Part No. Quantity 805H 806H 807H 808H 809H 810H . Heat Exchanger Assembly 1 Complete (Less Flue Baffles) 6171605 1 --- --- --- --- --- 6171606 --- 1 --- --- --- --- 6171607 --- --- 1 --- --- --- 6171608 --- --- --- 1 --- --- 6171609 --- --- --- --- 1 --- 6171610 --- --- --- -...

Page 71 - Manifold and Main Burners

Item No. Description Part No. Quantity 805H 806H 807H 808H 809H 810H 4. Manifold and Main Burners 4A Main Burner 8231602 8 10 12 15 17 19 4B Main Burner with Pilot Bracket, Standing Pilot (24V) 8231601 --- 1 1 1 1 1 Main burner with Pilot Bracket, Honeywell EI 8231604 1 1 1 1 1 1 Main Burner with Pi...

Page 72 - Canada Only

2 Item No. Description Part No. Size Quantity 5- Gas Train -- Standing Pilot (24V, OP) 24V: USA & Canada, 6 & Section, Natural & LP Gas OP: USA & Canada, 6 - 0 Section, Natural & LP Gas A Gas Valve, Robertshaw 7000ERHC-S7C, Natural Gas, 1” NPT 81660156 806H - 810H 1 Gas Valve, Ro...

Page 73 - Street Elbow, 90° x 1”

3 Item No. Description Part No. Quantity 5-2 Gas Train -- Standing Pilot (OP-CSD-) OP-CSD-: USA Only, 8-0 Section, LP Gas Only A Gas Valve, Robertshaw 7000GVERHC-S7C, LP Gas, 1” NPT 81660271 1 B Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 1 C Lubricated Manual Shut-Off Valve, Conbraco ...

Page 74 - USA: 5 - 0 Section, Natural and LP Gas

4 Item No. Description Part No. Size Quantity 5-3 Gas Train -- Intermittent Ignition (EI) USA: 5 - 0 Section, Natural and LP Gas Canada: 5 - 0 Section, Natural Gas 5 - Section, LP Gas A Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT 81660151 805H-810H 1 Gas Valve, Robertshaw 7000DERHC-LP, LP G...

Page 76 - USA Only: 8 - 0 Section, Natural Gas Only

6 Item No. Description Part No. Quantity 5-5 Gas Train -- Intermittent Ignition (EP-CSD-) USA Only: 8 - 0 Section, Natural Gas Only A Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 1 B Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 1 C Lubricated Manual Shut-Off Valve,...

Page 77 - USA & Canada: 6 & Section, Natural and LP Gas; All

Item No. Description Part No. Size Quantity 5-6 Pilot Assembly and Piping -- Standing Pilot (24V) USA & Canada: 6 & Section, Natural and LP Gas A Pilot Burner, Honeywell Q314A3687, Natural Gas 8236033 All 1 Pilot Burner, Honeywell Q314A3828, LP Gas 8236034 B Thermocouple, Honeywell Q309A1996...

Page 78 - - 0 Section, Natural and LP Gas; Ground Wire Assembly

8 Item No. Description Part No. Size Quantity 5- Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) USA 5 - 0 Section, Natural and LP Gas A Pilot Burner, Honeywell Q348A1002, Natural Gas 8236072U 805H-810H 1 Pilot Burner, Honeywell Q348A1010, LP Gas 8236081 B Igniter/Sensor Cable, 36”...

Page 79 - - 0 Section, Natural Gas

Item No. Description Part No. Size Quantity 5-8 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) Canada 5 - 0 Section, Natural Gas 5 - Section, LP Gas A Pilot Burner, Honeywell Q348A1002, Natural Gas 8236072U 805H-810H 1 Pilot Burner, Honeywell Q348A1010, LP Gas 8236081 805H-807H B ...

Page 80 - USA & Canada: 6 - 0 Section, Natural and LP Gas

80 Item No. Description Part No. Size Quantity 5- Pilot Assembly and Piping -- Standing Pilot (OP) USA & Canada: 6 - 0 Section, Natural and LP Gas A Pilot Burner, Honeywell Q179D1008, Natural Gas 8236025 806H-810H 1 Pilot Burner, Honeywell Q179D1008 w/388146KD Orifice, LP Gas 6236039 B Thermocou...

Page 81 - USA Only: 8 - 0 Section, LP Gas Only

8 Item No. Description Part No. Size Quantity 5-0 Pilot Assembly and Piping -- Standing Pilot (OP-CSD-) USA Only: 8 - 0 Section, LP Gas Only A Pilot Burner, Honeywell Q179D1008 w/388146KD Orifice, LP Gas 6236039 808H-810H 1 B Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead 8236004 1 C Flame Rod Lea...

Page 82 - USA & Canada: 6 - 0 Section, Natural Gas Only

82 Item No. Description Part No. Size Quantity 5- Pilot Assembly and Piping -- Intermittent Ignition (EP) USA & Canada: 6 - 0 Section, Natural Gas Only A Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017 806H-810H 1 B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1 C Rajah Connecto...

Page 83 - USA Only: 0 Section, Natural Gas Only

83 Item No. Description Part No. Size Quantity 5-2 Pilot Assembly and Piping -- Intermittent Ignition (EP-CSD-) USA Only: 0 Section, Natural Gas Only A Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017 808H-810H 1 B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1 C Rajah Connector, Hon...

Page 87 - . Trim and Miscellaneous Controls

8 Item No. Description Part No. Quantity 805H 806H 807H 808H 809H 810H . Trim and Miscellaneous Controls A Limit, 140-220°F, Honeywell L4080D1218 (EI & Standing Pilot); L4080B1212 (EP * OP) 80160251 80160474 1 1 1 1 1 1 Immersion Well, ¾” NPT x 1½” Insul. Depth 80160426 1 1 1 1 1 1 B Limit, Manu...

Page 88 - Draft Hood and Automatic Vent Damper

88 Item No. Description Part No. Quantity 805H 806H 807H 808H 809H 810H 8. Draft Hood and Automatic Vent Damper 8A Draft Hood 8111605 1 --- --- --- --- --- 8111604 --- 1* --- --- --- --- 8111607 --- 1** --- --- --- --- 8111603 --- --- 1* --- --- --- 8111608 --- --- 1** --- --- --- 8111602 --- --- --...

Page 89 - SERVICE RECORD; DATE