Burnham 8HE Series Installation, Operating And Service Instructions
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Burnham 8HE Series Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for
Series 8HE
Manual Contents
1. Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . . 9
3. Water Trim and Piping . . . . . . . . . . . . . . . . . . 17
4. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5. Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6. Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.
System Start-up . . . . . . . . . . . . . . . . . . . . . . . 30
8. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . 40
This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all
instructions in this manual and all other information shipped with the boiler. Post all instructions and manuals
near the boiler for reference by service personnel. Perform steps in the order given. Failure to comply could
result in severe personal injury, death or substantial property damage.
111828-01 - 1/23
8HE
Installation, Operating & Service Instructions
Page
!
WARNING
Commercial Boilers
www.burnhamcommercial.com
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  • Page 1: Table Of Contents

    Installation, Operating & Service Instructions Installation, Operating and Service Instructions for Series 8HE Manual Contents Page 1. Pre-Installation ......6 2.
  • Page 2 Installation, Operating & Service Instructions IMPORTANT INFORMATION - READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE All boilers must be installed in accordance with National, State and Local Plumbing, Heating and All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities.
  • Page 3 Installation, Operating & Service Instructions DANGER • Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. • If you smell gas, do not try to operate the burner/boiler system. Do not touch any electrical switch or use any phone in the building.
  • Page 4 It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler MAWP. Therefore, in addition to Safety Relief Valves set for 50 psi, Burnham Commercial also offers Safety Relief Valves set for 30 psi (By Special Order Only).
  • Page 5 Installation, Operating & Service Instructions Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.

  • Page 6: Pre-Installation

    Installation, Operating & Service Instructions Pre-Installation Figure 1-1: Dimensional Data Table 1-2: Dimensional Data 111828-01 - 1/23...
  • Page 7 Burnham Commercial DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system. 111828-01 - 1/23...
  • Page 8 J. For Multiple boiler installations see also Series Table 1-4: Corrosive Combustion Contaminants 8HE Multiple Boiler Application Instructions, and Sources 111924-01, available on Burnham Commercial Contaminants to avoid: website. Spray cans containing chloro/fluorocarbons (CFC’s) K. Check for and remove any potential combustion Permanent wave solutions air contaminants from area around boiler.

  • Page 9: Boiler Assembly

    Installation, Operating & Service Instructions Boiler Assembly 6. Examine boiler for leaks or damage due to WARNING shipment or handling. Use precautions and appropriate rigging 7. Remove fill valve, purge valve and piping. apparatus when moving heavy objects. WARNING Do not use air to leak test boiler. A.
  • Page 10 Installation, Operating & Service Instructions Boiler Assembly (continued) Figure 2-3: Tapping Locations Table 2-2: Purpose of Tappings J. Install Base Front Panel. See Figure 2-5. Panel Tapping Size Purpose and hardware located in Combination Boiler Parts and Control Carton. 2 in. Supply 2 in.
  • Page 11 Installation, Operating & Service Instructions Boiler Assembly (continued) Figure 2-5: General Assembly (Knockdown Boilers) K. Install Pilot/Main Burner Assembly. See Figure 2-7. 2. Attach Flame Roll-out Switch Mounting Bracket Assembly is located in Combination Boiler Parts to burner access panel with (1) #8 x ½ in. lg. and Control Carton.
  • Page 12 Installation, Operating & Service Instructions Boiler Assembly (continued) Figure 2-6: Flame Roll-out Switch Installation Figure 2-7: Burner/Burner Access Panel Installation 111828-01 - 1/23...
  • Page 13 Installation, Operating & Service Instructions Boiler Assembly (continued) P. Install Jacket. See Figure 2-9. 1. Locate four (4) Jacket Attachment Brackets in Combination Boiler Parts and Control Carton. Attach to Front Base Panel and Rear Base Panels with #8 sheet metal screws. See Figure 2-5.
  • Page 14 Installation, Operating & Service Instructions Boiler Assembly (continued) 111828-01 - 1/23...
  • Page 15 Installation, Operating & Service Instructions Boiler Assembly (continued) Figure 2-10: Main Gas Piping, Intermittent Ignition 111828-01 - 1/23...
  • Page 16 Installation, Operating & Service Instructions Boiler Assembly (continued) 111828-01 - 1/23...

  • Page 17: Water Trim And Piping

    • Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham Commercial’s Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
  • Page 18 Water Trim and Piping (continued) Figure 3-3: Drain Piping Installation WARNING • Burnham Commercial recommends maintaining temperature differential (drop) across the system at 40°F or less and return water temperature at minimum of 135°F. • Continued boiler operation for prolonged periods of time under conditions when temperature differential across the system exceeds 40°F and/or return water...
  • Page 19 Installation, Operating & Service Instructions Water Trim and Piping (continued) Methods to provide boiler water protection are listed below. See also Tekmar Essay #021 “Mixing Methods and Sizing of Variable Speed Injection Pumps”, Taco #102-143 Variable Speed Circulator Instruction Sheet, and information from mixing valve manufacturer.
  • Page 20 Installation, Operating & Service Instructions Water Trim and Piping (continued) Water Quality Requirements 6. A hot water boiler installed above radiation level must be provided with a low water cutoff pH: 6.0 - 9.5 device as part of installation. The HydroStat Total hardness grains / gal: <...
  • Page 21 Installation, Operating & Service Instructions Water Trim and Piping (continued) Figure 3-7: Boiler Piping 111828-01 - 1/23...

  • Page 22: Gas Piping

    Installation, Operating & Service Instructions Gas Piping B. Connect boiler gas valve to gas supply system. WARNING 1. Use methods and materials in accordance with Failure to properly pipe gas supply to boiler may result in improper operation and damage local plumbing codes and requirements of gas supplier.
  • Page 23 Installation, Operating & Service Instructions Gas Piping (continued) Table 4-2: Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0.5 psig or Less Length 0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop (Feet) ½ ¾ 1¼...

  • Page 24: Venting

    Installation, Operating & Service Instructions Venting D. Install Draft Hood on canopy outlet. Maintain height from Jacket Top Panel to Draft Hood skirt as shown in Figure 1-1. DO NOT ALTER, CUT, OR A. Install vent system in accordance with local MODIFY DRAFT HOOD.
  • Page 25 Installation, Operating & Service Instructions Venting (continued) 4. Secure bracket in position by tightening #10 WARNING sheet metal screw against outer surface of Provide adequate clearance for servicing - Draft Hood skirt. provide 6 in. minimum clearance between 5. Insert excess power cord through Jacket Right damper and combustible construction.
  • Page 26 Installation, Operating & Service Instructions Venting (continued) 5. Test for spillage at the draft hood relief opening 7. Do not install Non-listed (AGA, CGA, CSA, after 5 minutes of main burner operation. Use ETL, or UL) vent damper or other obstruction in the flame of a match or candle, or smoke from vent pipe.

  • Page 27: Electrical

    Installation, Operating & Service Instructions Electrical DANGER • Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building • Lock out all electrical boxes with padlock once power is turned off. •...
  • Page 28 Installation, Operating & Service Instructions Electrical (continued) iii. Flame Roll-out switch: Automatically Honeywell EI Sequence of Operation interrupts main burner operation when a. Normal Operation flames or excessive heat are present Thermostat or operating control calls for in vestibule. Circulator continues to heat.
  • Page 29 Installation, Operating & Service Instructions Electrical (continued) Figure 6-1: Wiring Diagram, Honeywell EI 111828-01 - 1/23...

  • Page 30: System Start-Up

    Installation, Operating & Service Instructions System Start-up 5. Open purge valve. WARNING 6. Open fill valve (Make-up water line should • Completely read, understand and follow all be located directly after full port ball valve in instructions in this manual before attempting system supply piping between air scoop and start-up.
  • Page 31 Installation, Operating & Service Instructions System Start-up (continued) FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. If you cannot reach your gas supplier, call the A.
  • Page 32 Installation, Operating & Service Instructions System Start-up (continued) INCANDESCENT OUTER MANTLE Blue with occasional CAUTION orange flashing • Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under OUTER CONE Darker transparent blue these conditions, the burner interior and ports...
  • Page 33 Boiler must not be overfired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still overfired, contact your Burnham Commercial distributor or Regional Office for replacement Gas Orifices. b. Increase input rate if less than 98% of rating plate input.

  • Page 34: Service

    Do not allow the boiler to operate with altered, disconnected or jumpered components. Only use replacement components identical to those originally supplied by Burnham Commercial. DANGER A.
  • Page 35 Installation, Operating & Service Instructions Service (continued) 7. Hold Main Burner on throat. Lift slightly to CAUTION raise rear of burner. Push to rear of boiler until • Label all wires prior to disconnection when burner clears Main Burner Orifice. Lift burners servicing controls.
  • Page 36 Installation, Operating & Service Instructions Service (continued) Table 8-1: Pilot Burner Location Boiler Model Pilot Located Between Burners* 805HE 4 & 5 806HE 5 & 6 * Burners numbered left to right as viewed from front of boiler. Figure 8-2: Boiler Flueway Cleaning 111828-01 - 1/23...
  • Page 37 Installation, Operating & Service Instructions Service (continued) Check Electronic Ignition Module Status f. If needed, adjust pilot flame by turning the gas valve pilot adjustment screw clockwise See Figure 8-3 for the location of the status to decrease or counterclockwise to increase LED on the electronic ignition (EI) module.
  • Page 38 Installation, Operating & Service Instructions Service (continued) Table 8-5: Green LED Flame Codes Green LED Indicates Next System Action Recommended Service Action Flash Code* No “Call for Heat” None Flash Fast Power up - internal check None Heartbeat Normal startup - ignition None sequence started (including prepurge)
  • Page 39 Installation, Operating & Service Instructions Service (continued) Start Before troubleshooting, familiarize yourself with the Note: "Call for heat" 24 VAC supply is connected to the 24 V terminal on the control. Startup and Checkout procedures. Turn gas supply off. Turn thermostat (controller) to "Call For Heat".

  • Page 40: Service Parts

    All Series 8HE Service Parts may be obtained through your local Burnham Commercial Wholesale distributor. Should you require assistance in locating a Burnham Commercial Distributor in your area, or have questions regarding the availability of Burnham Commercial products or repair parts, please contact Burnham Commercial Customer Service at: 888-791-3790 or Fax (717) 293-5803.
  • Page 41 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item No. Description Part No. 805HE 806HE 1. Heat Exchanger Assembly 6171605 Complete (Less Flue Baffles) 6171606 Left End Section N/A* Intermediate Section N/A* Right End Section N/A* 80861032 Tie Rod 80861033 Washer, Flat, USS, 3/8 in.
  • Page 42 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item No. Description Part No. 805HE 806HE 2. Canopy 111770-01 Canopy 111770-02 Canpoy Seal, Ceramic Fiber Blanket 102741-01 6 ft. 6 ft. Bolt, Carriage, ¼ - 20 x 1 in. Washer, ¼ in. Flat Nut, ¼...
  • Page 43 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item Description Part No. 805HE 806HE 3. Base Assembly Base End Panel 7181601 61816052 Base Channel Assembly 61816062 111756-01 Burner Air Baffle/Diverter 111756-02 111909-05 Base Rear Panel Assembly 111909-06 111912-05 Base Front Panel Assembly 111912-06 111914-05 Burner Access Panel Assembly...
  • Page 44 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item Description Part No. 805HE 806HE 4. Manifold and Main Burners Main Burner 8231602 Main burner with Pilot Bracket 8231604 82216051 Manifold 82216061 Pipe Plug, 1/8 NPT (Included with 4C) Main Burner Orifice, #41 (Natural Gas Only) * 822627 Hitch Pin Clip 822604...
  • Page 45 Installation, Operating & Service Instructions Service Parts (continued) Item Description Part No. Size Quantity 5-1 Gas Train Gas Valve, Resideo VR8304P4496, Natural Gas, 3/4 in. NPT 81660283 805HE + 806HE Reducing Street Elbow, 1 in. x 3/4 in. x 90° 805HE + 806HE ** Item to be sourced locally.
  • Page 46 Installation, Operating & Service Instructions Service Parts (continued) Item Description Part No. Size Quantity 5-2 Pilot Assembly and Piping Pilot Burner, Honeywell Q3481B1206, Natural Gas 103704-01 Brass Compression Union, 1/4 in. OD Tube 8236008 805HE + 806HE Ground Wire 6136054 111828-01 - 1/23...
  • Page 47 Installation, Operating & Service Instructions Service Parts (continued) 111828-01 - 1/23...
  • Page 48 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item Description Part No. 805HE 806HE 6. Jacket 111907-05 Complete 111907-06 704160531 Jacket Top Panel 70416063 111812-01 Jacket Top Panel Insulation 111812-02 70416056 Jacket Upper Rear Panel 70416066 111816-01 Jacket Upper Rear Panel Insulation 111816-02 60416056 Jacket Lower Rear Panel...
  • Page 49 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item Description Part No. 805HE 806HE 7. Trim and Miscellaneous Controls Hydrostat 3200 with Sensor 104873-01 Remote Mount Bracket Assembly 104877-01 Electrowell, Hydrostat 3200 105203-01 Replacement 12 in. Sensor 105944-01 Spring Clip 102422-01 Immersion Well, ¾...
  • Page 50 Installation, Operating & Service Instructions Service Parts (continued) Quantity Item Description Part No. 805HE 806HE 8. Draft Hood and Automatic Vent Damper Draft Hood 109434-01 Drafthood 8111604 Automatic Vent Damper, 7 in. Field Controls GVD-7PL 8116324 111828-01 - 1/23...
  • Page 51 Installation, Operating & Service Instructions Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604 Revised January 15, 2021 111828-01 - 1/23...
  • Page 52 Installation, Operating & Service Instructions Burnham Commercial Boilers P.O. Box 3939 Lancaster, PA 17604 1-888-791-3790 www.burnhamcommercial.com 111828-01 - 1/23...

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