Page 2 - SecTiON i – eQUiPMeNT cHecK LiST
2 BOILER SIZE 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B (1) LEH 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (1) REH 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (1) C 4 5 6 7 8 8 9 10 11 12 13 14 15 16 16 17 18 19 21 (2) CX --- --- --- --- -...
Page 3 - Carton 9; IMPORTANT INFORMATION; MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION
3 BOILER SIZE 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B CARTONS, PACKAGES OR BUNDLES 7 S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler 1 1 1 1 --- --- --- --- --- --- ---...
Page 4 - cANADiAN
4 BOILER SIZE 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B (1) LEH 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (1) REH 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 (1) C 4 5 6 7 8 8 9 10 11 12 13 14 15 16 16 17 18 19 21 (2) CX --- --- --- --- -...
Page 5 - CANADIAN; SECTION I - EQUIPMENT CHECK LIST - Page 2
5 BOILER SIZE 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B CARTONS, PACKAGES OR BUNDLES 7 S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler 1 1 1 1 --- --- --- --- --- --- ---...
Page 7 - Boiler must not be installed directly on combustible; WARNiNG; Adequate combustion and ventilation air must; unconfined space
7 SecTiON ii – GeNeRAL iNFORMATiON 1. BOILER INSTALLATION must conform to the requirements of the authority having jurisdiction, or in the absence of such requirements, to: USA – “National Fuel Gas Code, ANSI Z223.1”. When required by the authority having jurisdiction, the installation must conform ...
Page 8 - SecTiON iii – iNSTALLATiON iNSTRUcTiONS; Alternate method for boiler located within
8 SecTiON iii – iNSTALLATiON iNSTRUcTiONS equipment in space. Duct cross-sectional area shall be same as opening free area. 3. Horizontal ducts. Minimum free area of 1 square inch per 2,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. Al...
Page 11 - Open Steam or Water Trim Carton; in End Sections that will not be utilized on final
e. DRAW UP CENTER SECTION SLOWLY AND EVENLY, tightening each DRAW-UP ROD a little at a time so that sections are equally spaced. KEEP NIPPLES ALIGNED WITH NIPPLE PORTS. If necessary, tap Nipples lightly with a blunt tool or rod to keep Nipples from cocking while Sections are being drawn up. DO NOT D...
Page 12 - Open Heater Opening Cover Plate Carton(s); cAUTiON; DO NOT install gauge until after hydrostatic; Failure to properly hydrotest all boilers at the
2 FIG. 8 INSTALLATION OF BUILT-IN HEATER FIG. 9 TESTING BOILER ASSEMBLY FOR LEAKS Open Tankless Heater Carton(s) If Supplied. Open Heater Opening Cover Plate Carton(s) . 9. INSTALL BUILT-IN WATER HEATER(S) OR HEATER OPENING COVER PLATE(S), See Fig. 8. Heater may be installed in either End Section or...
Page 13 - NOTice; SEALING OF BASE, INSTALLATION OF
3 a. With Steam Heating System, refer to Fig. 12, 13A, 13B. NOTice Before using copper for steam piping, consider the following characteristics of copper piping:1) high coefficient of thermal expansion can induce mechanical stresses and cause expansion/ contraction noises if not accounted for in the...
Page 19 - Open Jacket Parts Carton; RECOMMENDED BOILER PIPING FOR
9 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. 4. Use of non-permeable materials in the distribution system. 5. Isolating the boiler from the system wa...
Page 22 - SECURING OF CANOPY/DRAFTHOOD
Page 28 - STEAM TRIM AND CONTROLS
28 FIG. 25 STEAM TRIM AND CONTROLS 32. TIGHTEN ALL SHEET METAL SCREWS. a. Install the following plates or labels which are found in the Instruction Envelope. See Fig. 23 or 24 for location. (1) Rating Label (2) Operating Instruction Plate (#8 SMS required to fasten) (3) Combustible Clearance Floorin...
Page 30 - WATER TRIM AND CONTROLS; Install automatic mixing valve at tankless heater
30 g. If boiler has been ordered with 3/8” try-valve tapping, install try-cock. h. Install “Lowest Permissible Water Level Plate” and “Frequent Water Addition – Caution Label” on upper left end jacket panel. i. Proceed directly to Paragraph 36. 34. INSTALL WATER TRIM AND CONTROLS, see Fig. 7 and 26....
Page 31 - TABLe i - NATURAL GAS; TABLe ii; gage pressure for a period of not less than 10 minutes
3 FIG. 27 RECOMMENDED PIPING TO BUILT-IN TANKLESS HEATERS TABLe i - NATURAL GAS Maximum Capacity of Piping in Cubic Feet of Gas Per Hour (Based on a Pressure Drop of 0.3” Water and 0.6 Specific Gravity) Pipe Length in Feet NOMINAL IRON PIPE SIZE IPS INCHES ¾ 1 1¼ 1½ 2 2½ 3 4 10 278 520 1050 1600 305...
Page 33 - INSTALLATION OF S8610M MODULE; EI Control System; INSTALLATION OF GAS VALVE TRANSFORMER
33 FIG. 28 INSTALLATION OF S8610M MODULE EI Control System 1. INSTALLATION OF GAS VALVE TRANSFORMER AND PILOT PIPING (for Robertshaw Pilot Piping, see Fig. 29) – Attach the bracket for mounting of the junction box to the lower front corner of the Jacket Upper End Panel using two #10-32 x ½” MS and n...
Page 35 - EO Control System; INSTALLATION OF PILOT SAFETY SWITCH AND
35 EO Control System 1. INSTALLATION OF PILOT SAFETY SWITCH AND PILOT PIPING – Using two #10-32 x 2” MS and nuts, install the L62GB-3C pilot safety switch bracket on the manifold just to the right of the main burner with pilot. Install L62GB-3C pilot safety switch on bracket using three #8 x ½” SMS....
Page 36 - EE Control System; Use two #10-32 x 1⁄2” MS and nuts in the front holes
36 MS and nuts in the front holes and two #8 SMS in the rear holes. Connect the two wires from the Q179D pilot to the RA890F Protectorelay Sub base as follows:a. Ground Wire (200ºC) to the “G” terminalb. Flame detector wire (Honeywell 1298020) to “F” terminal c. Thermocouple Lead to L62 Pilotstat. W...
Page 37 - EOP Control System; Attach the bracket for mounting of the junction box to
37 3. INSTALLATION OF BLEED PIPING – Using ¼” OD aluminum tubing, install a bleed line on both diaphragm valves, connect together, see Fig. 25 or 26, and, on USA boilers, run tubing to bleed line protruding from inside base, see Fig. 34. On boilers installed in Canada, run bleed line to outdoors. 4....
Page 39 - EEP Control System; knockout of the J-box using conduit fittings furnished,; Thermocouple Control System; . INSTALLATION OF PILOT SAFETY SWITCH; NOTE: PILOT PIPING DUPLICATED ON 15 SECTION AND LARGER BOILERS.
39 made. All wiring must be adequately supported and strain relief provided. All wiring including ground connections must comply with the requirements of the authority having jurisdiction and, in the absence of such to the National Electrical Code, ANSI NFPA No. 70-2005. 4. INSTALLATION OF BLEED PIP...
Page 40 - INSTALLATION OF PILOT SAFETY SWITCH; safety switch on bracket using two #10-32 x 1⁄2”; Using 1⁄4” OD aluminum tubing, connect the outlet of; Connect Q309 thermocouple to pilot safety switch.
40 “THERMOCOUPLE CONTROL SYSTEM” CANADA ONLY FIG. 38 PILOT PIPING THERMOCOUPLE CONTROL SYSTEM CANADA ONLY FIG. 39 NOTE - TWO PILOT SAFETY SWITCHES REQUIRED ON 15 SECT. AND LARGER BOILERS. INSTALLATION OF PILOT SAFETY SWITCH THERMOCOUPLE CONTROL SYSTEM safety switch on bracket using two #10-32 x ½” M...
Page 41 - Venting; Upper End Panel using two #10-32 x 1⁄2” MS and
4 FIG. 40 SINGLE VENT SYSTEM FIG. 41 MANIFOLD VENT SYSTEM Venting 1. INSTALL VENT CONNECTOR from canopy Drafthood or damper to chimney maintaining 6” clearances from combustible materials. 2. INSTALL VENT SYSTEM – Typical vent systems are shown in Fig. 40 and 41. Some of the factors affecting vent s...
Page 42 - SEAL ANY UNUSED OPENINGS IN THE COMMON VENTING SYSTEM.
42 WARNiNG WHEN AN EXISTING BOILER IS REMOVED FROM A COMMON VENTING SYSTEM, THE COMMON VENTING SYSTEM IS LIKELY TO BE TOO LARGE FOR PROPER VENTING OF THE APPLIANCES REMAINING CONNECTED TO IT. AT THE TIME OF REMOVAL OF AN EXISTING BOILER, THE FOLLOWING STEPS SHALL BE FOLLOWED WITH EACH APPLIANCE REMA...
Page 43 - SecTiON iV - OPeRATiON; Steam Boilers
43 SecTiON iV - OPeRATiON Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13. 1. GENERAL a. INITIAL FILL – Before putting water into a new boiler, make certain that the firin...
Page 44 - Water Boilers; TABle IV: WATer CONTeNT
44 b. 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. c. Turn on burner and keep operating while feeding wate...
Page 45 - cONTROL VARiATiONS; appears that the boiler is leaking. This condensation
45 3. CONDENSATION Following a cold start, condensation (sweating) may occur in a gas fired boiler to such an extent that it cONTROL VARiATiONS NATURAL GAS MODeL NO. cONTROL SYSTeM TYPe OF PiLOT GAS VALVeS OPTiONAL MAiN VALVeS ReFeReNce PAGe PiLOT MAiN 5006B-5009B (USA) EI Elec. Ign. (1) 7000DERHC-S...
Page 46 - Be sure power is off when checking high voltage
46 4. EI CONTROL SYSTEM – The EI control system utilizes a solid state ignition control which lights the pilot burner by spark. Pilot gas is ignited and burns during each running cycle (intermittent electric pilot). Main burner and pilot gas are extinguished during the “off” cycle. This system permi...
Page 48 - SEQUENCE OF OPERATION
48 FIG. 43 SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (V88 GAS TRAIN) U.S.A. 5010B THRU 5014B CANADA 5006B THRU 5014B SEQUENCE OF OPERATION WHEN OPERATING CONTROL CLOSES, THE ELECTRIC SPARK AND PILOT VALVE ARE AUTOMATICALLY ENERGIZED. THE SENSING PROBE PROVES THE PRESENCE OF THE PILOT FLAME. INTER...
Page 52 - Proceed to Paragraph 15
52 5. EO CONTROL SYSTEM – 5006B thru 5014B The EO Control System utilizes an RA890F Protectorelay and a Q179D Rectification Pilot (standing or continuous burning pilot) to which has been added a Q309 thermocouple. The RA890F Protectorelay Primary Control is a non-programming, amplifying relay which,...
Page 63 - Proceed To Paragraph 15
63 This thermocouple will cool in 45 to 90 seconds allowing the pilot line safety valve to close. This shuts off the flow of gas to the pilot. It is in this manner that 100% shut-off is achieved. If the operating control calls for heat during this period and the “Power On” switch is still in the “ON...
Page 72 - The following procedures should only be
72 cAUTiON The following procedures should only be performed by a qualified service technician. 15. MINIMUM INPUT ADJUSTMENTS This section covers Minimum Input Adjustments on Honeywell V8944B Diaphragm Type “Lo-Hi-Lo” Gas Valves, Honeywell V5055B Fluid Power Gas Valves equipped with either a V4062A ...
Page 74 - Avoid operating this boiler in an environment
74 Proceed with test as follows: a. Thermocouple Pilot System Using a 3/8” wrench loosen the thermocouple lead at the gas valve. Main gas and pilot gas must shut off. If not, replace gas valve. b. EI Pilot System Carefully remove ignitor sensor wire from ignition module Main gas and pilot gas must s...
Page 75 - label all wires prior to disconnection when; SECTION V – SERVICE; ATTACHMENT OF FLUE COVERS
75 1. GENERAL – “Inspection should be conducted annually. Service as frequently as specified in paragraphs below.” While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be “off”. cAUTiON label all wires prior to disconnection when servicing controls. Wiri...
Page 76 - Warning; AVOID Breathing Fiber Particulates and Dust; Precautionary Measures
76 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 80 - iMPORTANT; The EE and EEP Control Systems utilize a Honeywell
80 FIG. 66 PILOT FLAME HONEYWELL Q179C PILOT FIG. 67 PILOT FLAME HONEYWELL Q327A PILOT W/THERMOCOUPLE 7. LOW WATER CUT-OFF – a. Float Type Low Water Cut-off During the heating season, if an external low water cut-off is on the boiler, the blow off valve should be opened once a month (use greater fre...
Page 81 - Clean the pipe threads of the probe to remove; slowly; - Refill the boiler to the normal water level.
8 b. Probe Type Low Water Cut-off It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scale or sediment. Follow these steps to inspect, clean, and/or replace the probe: 1. Turn off electric service to the boiler. 2. Turn off gas ...
Page 82 - REPAIR PARTS INDEX; iTeM; Pilotstats, Transformers, Pilot; SecTiON Vi - RePAiR PARTS
82 REPAIR PARTS INDEX iTeM PAGe NOS. Base Parts ...................................................................................................................... 83 thru 86 Integral Drafthoods & Sections ..........................................................................................
Page 83 - able Relates to Corresponding Number in
83 T ABL e 2A Ser Ie S 5B BAS e P A r TS - 5006B thru 5014B Number in ( ) in T able Relates to Corresponding Number in in Figure 68 P AR T NUMBER ITEM P AR T SIZE BOILER SIZE 5006B 5007B 5008B 5009B 5010B 501 1B 5012B 5013B 5014B 7181301 High Base End Panel 12-1/2 x 25-3/4 (1) (1) (1) (1) (1) (1) (1...
Page 87 - PART SIZE
87 TABLe 3A SeRieS 5B iNTeGRAL cANOPY DRAFTHOODS - BOiLeR SiZeS PART SIZE PART NO. Canopy - Drafthood No. BOILER SIZE (QUANTITY) 5006B 5007B 5008B 5009B 5010B 36-1/2 X 25-3/4 61113063 5006B (1) 1 36-1/2 X 31-3/16 61113073 5007B (2) 1 36-1/2 X 36-5/8 61113083 5008B (3) 1 36-1/2 X 41-1/16 61113093 500...
Page 96 - ” Ground Joint Union
96 7000DERHC GAS TRAIN - EI - 5006B THRU 5009B - USA PART NO. ITEM BOILER SIZE 5006B 5007B 5008B 5009B 81660151 Robertshaw 7000DERHC-S7C 1” x 1” Gas Valve (Nat.) (1) (1) (1) (1) -- OR -- 81660158 Robertshaw 7000DERHC-LP-S7C 1” x 1” Gas Valve (LP) (1) (1) (1) (1) 806604002 1” Ground Joint Union (2) (...
Page 97 - GAS
97 V88A GAS TRAINS - USA P AR T NO. ITEM BOILER SIZE 5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B Diaphragm Gas V alve 81660008 1” Honeywell V88A1618 1 --- 1 1 --- 81660009 1¼” Honeywell V88A1626 --- 1 --- 1 1 822605 Bleed V alve Assembly - Honeywell #126590 2 2 2 2 2 Nat. Gas Regulator - S...
Page 102 - FLUID POWER GAS
02 FLUID POWER GAS TRAINS - CANADA P AR T NO. ITEM BOILER SIZE 5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B Fluid Power Gas V alve 81660010 1” - Honeywell V5055B1002 1 --- 1 1 --- 8166001 1 1¼” - Honeywell V5055B1010 --- 1 --- 1 1 Actuators for Fluid Power V alves 81660012 “Lo-Hi-Of f” Hone...
Page 105 - Heyco A25F Strain Relief Adaptor
05 TRANSFORMER, PILOT SOLENOID VALVE & PILOT LINE REGULATOR EI CONTROL SYSTEM U.S.A. - 5010B-5026B NAT. GAS CANADA - 5006B-5026B NAT. GAS PART NO. ITEM 7136001 (1) “J” Box Mounting Bracket 24V 100 VA Transformer - 120 60HZ Primary 80160016 (2) Penn Y64T22-0 Plate Mounted 822666 (3) Penn Pilot So...
Page 110 - (5) Fusetron F2H Combination Switch and Fuseholder Cover
0 CONTROL ASSEMBLY & MOUNTING BRACKET EO - EE CONTROL SYSTEMS TRANSFORMER, PILOT SOLENOID VALVE & PILOT LINE REGULATOR EE CONTROL SYSTEM PART NO. ITEM 7016003 (1) EE & EO Control Mounting Bracket 8136016 (2) Honeywell Q270A1024 Sub-Base for RA890F Protectorelay 80160008 (3) Honeywell RA8...
Page 112 - NEW
2 EI CONTROL SYSTEM - HONEYWELL Q3481 PILOT ASSEMBLY EI CONTROL SYSTEM - PILOT ASSEMBLY 100331-01 EI - 1, NAT., 5006B - 6009B Sections100332-01 EI - 2, NAT., 5010B - 5026B Sections100331-01 EI - 2, NAT., 5010B - 5026B Sections Not Available ........LP, 5010B - 5026B Sections PART NO. ITEM 100331-01 ...
Page 115 - SeRVice RecORD; DATE
Page 116 - Commercial Boilers
6 Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and/or accessories manufactured and shipped on or ...
