Burnham Series 5B Installation, Operating And Service Instructions
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Burnham Series 5B Installation, Operating And Service Instructions

Burnham series 5b gas-fired boiler
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Download this manual See also: User's Information Manual, Operation & Installation Manual
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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.
8141302R18 - 1/15
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Commercial Boilers
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  • Page 1 3050579 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.

  • Page 2: Hazard Definitions

    IMPORTANT INFORMATION - READ and save these instructions for reference Hazard definitions The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product. indicates an imminently hazardous situation indicates a potentially hazardous situation which, which, if not avoided, will result in death, serious...
  • Page 3 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.
  • Page 4 Section V, Paragraph 7 for inspection and cleaning instructions. Series 5B 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 Series 5B jacket, which indicates the boiler Maximum Allowable Working Pressure (MAWP).

  • Page 5: Section I - Equipment Check List

    SecTiON i – eQUiPMeNT cHecK LiST U.S.A. EQUIPMENT CHECK LIST (For Canadian Equipment Check List, Turn to Pages 7 and 8) This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered. It covers standard equipment for both steam and water boilers without Tankless Heaters.
  • Page 6 Carton 9 is standard on sizes 5006B thru 5009B for EI systems. This Series 5B Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters: Approval No. G1-0202-11A. The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.
  • Page 7 SecTiON i – eQUiPMeNT cHecK LiST (continued) cANADiAN eQUiPMeNT cHecK LiST This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered. It covers standard equipment for both steam and water boilers without Tankless Heaters. Heaters or optional equipment ordered will be in addition to, or in lieu of, equipment shown below.
  • Page 8 SECTION I – EQUIPMENT CHECK LIST (continued) CANADIAN EQUIPMENT CHECK LIST 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 Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler 67 BC-2 Low Water Cut-off Carton (Steam Boilers Only) One Per Boiler Water Trim Carton (Water Boilers Only - Includes L4006A Temp.

  • Page 10: Section Ii - General Information

    SecTiON ii – GeNeRAL iNFORMATiON BOILER INSTALLATION must conform to the requirements of the authority having jurisdiction, or in Adequate combustion and ventilation air must be the absence of such requirements, to: provided to assure proper combustion. USA – “National Fuel Gas Code, ANSI Z223.1”. When required by the authority having jurisdiction, a.

  • Page 11: Section Iii - Installation Instructions

    SecTiON ii – GeNeRAL iNFORMATiON (continued) equipment in space. Duct cross-sectional area LOUVERS AND GRILLES of Ventilation Ducts shall be same as opening free area. All outside openings should be screened and louvered. 3. Horizontal ducts. Minimum free area of 1 Screens used should not be smaller than ¼...
  • Page 12 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) fiG. 3 dual manifold bases - 5015b Thru 5026b secTion boilers Center Sections on 11 section and larger boilers. THIS IS IMPORTANT. a. Carefully join a Center Section with nipples in adjoining section and bump lightly to secure. b.
  • Page 14 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) c. Insert short end of draw-up rod through front & rear g. USING A PINCH BAR, insert WOOD WEDGES nipple ports on both sections, see Fig. 5. under last Center Section assembled so as to raise it just above Boiler Base.
  • Page 15 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) fiG. 8 insTallaTion of builT-in heaTer fiG. 9 TesTinG boiler assembly for leaks Open Steam or Water Trim Carton (2) HOT WATER BOILERS: The assembled boiler USE THE PLUGS IN THIS CARTON to plug tappings must be subjected to a hydrostatic test of 75 psig in End Sections that will not be utilized on final to 85 psig.
  • Page 16 4) galvanic corrosion of the adjoining metal may place or prevent it from reaching the boiler. Problems occur due to dissimilar metals in certain water caused by oxygen contamination of boiler water are not chemistries if dielectric unions are not used. covered by Burnham’s standard warranty.
  • Page 22 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) 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.
  • Page 23 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) Attach Hex Couplings to end of Carriage Bolts which secure flue cover plates. NOTE: Select Carriage Bolts which line up with holes in the Vestibule Panel. SECURE VESTIBULE PANEL TO HEX COUPLINGS using ¼”-20 x 3/8”...
  • Page 25 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) fiG. 22 securinG of canopy/drafT hood...
  • Page 28 #10-32 x ½” self tapping screws. (4) Minimum service clearance label (self-adhesive) InstallatIon of top front Jacket panels (5) burnham logo (self-adhesive) – apply to top a. remove knockout for supply piping. refer to panel recommended boiler piping diagrams in this manual.
  • Page 31 Install Pressure Limit Controls as follows: (4) Minimum Service Clearance Label (1) Boiler equipped with 67BC-2 Low Water Cut- (5) Burnham Logo – Apply to Top Panel Off – Connect Pressure Limit furnished to ¼” (6) Boiler Ventilation/For Your Safety Label street ell and ¼”...
  • Page 33 If boiler has been ordered with 3/8” try-valve d. TANKLESS HEATER PERFORMANCE tapping, install try-cock. Tankless heater ratings in Series 5B boilers are h. Install “Lowest Permissible Water Level Plate” based on continuous draw, temperature rise of 100ºF and “Frequent Water Addition – Caution Label” on (40-140ºF) and boiler water temperature of 200ºF.
  • Page 34 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) 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 nominal iron pipe siZe ips inches length ¾...
  • Page 35 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) A DRIP LEG SHOULD BE PROVIDED IN THE 3/4” 2.1 ft. 2” 5.2 ft. VERTICAL DROP TO EACH GAS TRAIN, see Fig. 1. An additional Manual Shut-off valve and 1” 2.6 ft. 2-1/2” 6.2 ft. ground joint union, as show in Fig.
  • Page 36 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) EI Control System INSTALLATION OF GAS VALVE TRANSFORMER AND PILOT PIPING (for Robertshaw Pilot Piping, see Fig. 32) – 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”...
  • Page 37 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) fiG. 33 piloT pipinG - ei conTrol sysTem (V88a) u.s.a. 5010b Thru 5026b - naT. Gas canada - 5006b Thru 5026b - naT. Gas COMPLETION OF WIRING – Connect power supply RM7890 Control (located in RM7890 Control Carton) onto prewired sub base.
  • Page 38 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) fiG. 34 insTallaTion of ep conTrol panel noTe - piloT pipinG duplicaTed on 15 secT. and larGer boilers. fiG. 35 piloT pipinG - ep conTrol sysTem...
  • Page 39 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) Thermocouple Control System INSTALLATION OF IGNITION TRANSFORMER AND WIRING OF PILOT – If space permits, mount INSTALLATION OF PILOT SAFETY SWITCH AND the ignition transformer on the Jacket above the Gas PILOT PIPING - Using two #10-32 x 2” MS and nuts, Train using four #8 x ½”...
  • Page 40 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) “Thermocouple conTrol sysTem” canada only fiG. 36 piloT pipinG Thermocouple conTrol sysTem canada only fiG. 37 noTe - Two piloT safeTy swiTches reQuired on 15 secT. and larGer boilers. insTallaTion of piloT safeTy swiTch Thermocouple conTrol sysTem...
  • Page 41 38 chimney constructions for Category I, draft hood sinGle VenT sysTem equipped appliances, such as this Series 5B boiler. Both standards prohibit the use of unlined masonry construction as a chimney, with the exception in ANSI Z223.1/NFPA 54 that “Where permitted by...
  • Page 42 SecTiON iii – iNSTALLATiON iNSTRUcTiONS (continued) (18) Clearances to combustible material – use of 1. Warm up is faster with type B vents than vents thimbles. having greater mass. (19) Firestops. 2. Type B vents permit closer clearance to combustible material than single wall metal (20) Flashing and storm collars.

  • Page 43: Section Iv - Operation

    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. GENERAL wasted, operate boiler only for the length of time it takes for condensate to run clear.
  • Page 44 SecTiON iV - OPeRATiON (continued) b. Draw about 5 gallons of hot water from same manner as litmus paper, except that it gives boiler into a container and dissolve into it the specific readings. A color chart on the side of appropriate amount of a recommended boilout the small hydrion dispenser gives the reading in compound.
  • Page 45 SecTiON iV - OPeRATiON (continued) appears that the boiler is leaking. This condensation CONDENSATION can be expected to stop after the boiler is hot. Following a cold start, condensation (sweating) may occur in a gas fired boiler to such an extent that it cONTROL VARiATiONS NATURAL GAS GAS VALVeS...

  • Page 46: Shut Down Instructions

    SecTiON iV - OPeRATiON (continued) gas valves, respectively. Thus, pilot burner and EI CONTROL SYSTEM – The EI control system main burner flames are extinguished. utilizes a solid state ignition control which lights the pilot burner by spark. Pilot gas is ignited and burns Normal operation can be resumed when the during each running cycle (intermittent electric pilot).
  • Page 48 SecTiON iV - OPeRATiON (continued) ei seQuence of operaTion - 5006b Thru 5009b when operaTinG conTrol closes, The elecTric spark and piloT ValVe are auTomaTically enerGiZed. The sensinG probe proVes The presence of The piloT flame. inTernal swiTch acTion de-enerGiZes The spark and enerGiZes The main Gas ValVes sTarTinG main burner operaTion.
  • Page 50 SecTiON iV - OPeRATiON (continued) ei seQuence of operaTion - 5010b Thru 5014b when operaTinG conTrol closes, The elecTric spark and piloT ValVe on each side are auTomaTically enerGiZed. The sensinG probe on each of The piloTs proVes The presence of The piloT flame.
  • Page 51 SecTiON iV - OPeRATiON (continued) Trouble shooTinG Guide boilers eQuipped wiTh s8610m inTermiTTenT elecTric iGniTion...
  • Page 52 SecTiON iV - OPeRATiON (continued) (7) Main gas valves open and main burners are . EP CONTROL SYSTEM – 5006B thru 5014B lighted by pilot. The EP Control System utilizes an RM7890A Relay (8) When operating control is satisfied, terminals Module and a Q179C Rectification Pilot, which in #6 and #9 are de-energized.
  • Page 53 SecTiON iV - OPeRATiON (continued) can be readily found. After the cause of operating control was satisfied. the pilot failure has been corrected, resume The EP Control System utilizes and RM7890A Relay normal operation by following the Lighting Module and a Q179C Rectification Pilot, which in Instructions.
  • Page 54 SecTiON iV - OPeRATiON (continued) fiG. 44 wirinG diaGram - 5006b Thru 5014b secTion boilers ep conTrol sysTem...
  • Page 56 SecTiON iV - OPeRATiON (continued) a. OPERATING INSTRUCTIONS extinguished. Normal operation can be resumed when the cause of the safety switch malfunction (1) Make sure all Manual Main Shut-off Valves and is corrected. Make sure all manual resets are all Pilot Valves have been off for at least five activated where applicable.

  • Page 57: Lighting Instructions

    SecTiON iV - OPeRATiON (continued) THERMOCOUPLE CONTROL SYSTEM (Canada a. LIGHTING INSTRUCTIONS Only) (1) Make sure that all main manual and pilot valves have been off for at least five (5) minutes. The 5006B thru 5014B boilers are equipped with a Thermocouple Control System that utilizes a (2) Set operating and limit controls to desired constant-burning Q327A pilot, a Q309 thermocouple,...
  • Page 58 SecTiON iV - OPeRATiON (continued) When operating control (A) calls for heat, it energizes main gas valves (B), starting burner operation. The burners will operate until operating control (A) is satisfied. The high limit control (C), will stop burner operation in case of excessive steam pressure (steam boiler) or excessive boiler water temperature (water boiler). Low water cut-off (D) will stop burner operation if the water level in boiler drops below the lowest safe level.
  • Page 59 SecTiON iV - OPeRATiON (continued) When the operating control (A) calls for heat, it energizes the main gas valves (B) in both gas trains starting burner operation. The burners will operate until the operating control is satisfied. The high limit control (C) will stop burner operation in case of excessive steam pressure (steam boiler) or excessive boiler water temperature (water boiler).

  • Page 60: Section V - Service; 6. Pilot Flame

    SecTiON iV - OPeRATiON (continued) and substituting the appropriate values in the CHECK GAS INPUT RATE TO BOILER formula below, determine what the gas flow (1) Input Rate and Maximum Inlet Pressure shown on should be in this 3 minute period to give the Rating Plate must not be exceeded.
  • Page 61 SecTiON iV - OPeRATiON (continued) Fig. 49 shows the Limit Switch Cam and Scales to indicate direction to rotate cam for increasing or The following procedures should only be decreasing low fire input on the Honeywell V4062A performed by a qualified service technician. “Lo-Hi-Lo”...
  • Page 62 SecTiON iV - OPeRATiON (continued) fiG. 49 low fire adJusTmenT - V4062 acTuaTor (3) Remove the lead to V9055A terminal R. Jumper terminal R to W. This will prevent the actuator from going to the high fire position. (4) Energize the system and light the main burner. (5) Use a Phillips screwdriver, or standard type with a blade no more than 3/16 inch wide, to turn the low fire adjusting screw for the desired low...
  • Page 63 SecTiON iV - OPeRATiON (continued) c. EP Pilot Systems CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and stop Carefully remove the flame rod wire from terminal burners. “11” on the RM7890 Control. Main gas and pilot gas must shut off.

  • Page 64: Section V - Service

    SECTION V – SERVICE This boiler used flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. More than one gas shut-off valve and electrical disconnect switch are used on the boiler.
  • Page 65 important Product Safety information Refractory ceramic Fiber Product 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 above 1805°f, such as during direct flame contact, rcf changes into crystalline silica, a known carcinogen.
  • Page 66 SECTION V – SERVICE (continued) Remove the Front Cleanout Panels first by removing CARE SHOULD BE EXERCISED IN REMOVING the upper and lower nuts and washers securing these THE CLEANOUT PLATES FROM THE BOLTS SO panels to the boiler sections, see Fig. 52. THAT THE INSULATION IS NOT DAMAGED.
  • Page 67 THIS PAGE LEFT BLANK INTENTIONALLY...
  • Page 70 SECTION V – SERVICE (continued) If Burners must be removed, use the following procedure: a. Mark location on manifold of all burners with pilots. b. Using a pair of pliers, remove hitch pin clips (shaped like a hairpin) from groove in main burner orifices.
  • Page 71 SECTION V – SERVICE (continued) The EP Control Systems utilize a Honeywell Q179C Flame Rectification Pilot. Adjust pilot line regulator (5.5” WC in pilot line) so that a medium hard center flame envelops flame rod, see Fig. 57. If flame is yellow, primary air opening may be covered with dirt or lint.

  • Page 72: Frequent Water Addition

    Burnham commercial’s shut off the burners. standard warranty does not cover problems caused by oxygen contamination of boiler water or scale Refill the boiler to the normal water level.

  • Page 74: Section Vi - Repair Parts

    ........................102 pilot assemblies ......................103 and 104 All Series 5B 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 Burnham Customer Service at: 888-791-3790 or Fax (717) 293-5803.
  • Page 76 SecTiON Vi - RePAiR PARTS (continued) TABLe 2A SeRieS 5B BASe PARTS - 5006B thru 5014B number in ( ) in Table relates to corresponding number in in figure 60 boiler siZe parT iTem parT siZe number 5006b 5007b 5008b...
  • Page 80 SecTiON Vi - RePAiR PARTS (continued) TABLe 3A SeRieS 5B iNTeGRAL cANOPy DRAFT HOODS - BOiLeR SizeS boiler siZe (QuanTiTy) canopy - parT siZe parT no. draft hood no. 5006b 5007b 5008b 5009b 5010b 36-1/2 X 25-3/4 61113063 5006b (1)

  • Page 88: Water Trim

    SecTiON Vi - RePAiR PARTS (continued) TABLe 4F Water Trim water Trim carton number: description 5006b-5011b 5012b-5022b 5024b-5026b parT no. Temperature control, honeywell l4006a2015 80160400 immersion well, honeywell #123871a, 3/4” 80160452 Temperature pressure Gauge, 100 psi, 80-320°f, 1/2” npT 8056028 relief Valve piping: nipple, 3/4”...

  • Page 89: Steam Trim

    SecTiON Vi - RePAiR PARTS (continued) TABLe 4G Steam Trim steam Trim carton number: description 5006b-5008b 5009b-5011b 5012b-5020b 5021b-5026b parT no. pressuretrol, honeywell l404f1060 80160942 steam Gauge, 4" dia., 30" -0-30 psi, 1/4" 8056022 Gauge Glass set, conbraco #20-104-10 (6¾") 8056019 safety Valve piping: nipple, 1½"...

  • Page 90: Boiler Size

    SecTiON Vi - RePAiR PARTS (continued) 7000derhc Gas Train - ei - 5006b Thru 5009b - usa boiler siZe parT no. iTem 5006b 5007b 5008b 5009b 81660151 robertshaw 7000derhc-s7c 1” x 1” Gas Valve (nat.) -- or -- 81660158 robertshaw 7000derhc-lp-s7c 1” x 1” Gas Valve (lp) 806604002 1”...
  • Page 99 SecTiON Vi - RePAiR PARTS (continued) Transformer, penn #h91wG 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...
  • Page 100 SecTiON Vi - RePAiR PARTS (continued) Transformer & piloT line reGulaTor Thermocouple conTrol sysTem - canada parT no. iTem (1) “J” box mounting bracket 7016001 24V - 40 Va Transformer - 120 60hZ primary 80160039 (2a) usa - honeywell plate mounted aT140d1012 80160014 (2b) canada - honeywell foot mounted aT72d1089 (3) pilot line regulator...
  • Page 101 SecTiON Vi - RePAiR PARTS (continued) Transformer, penn #h91wa-4 piloT solenoid ValVe & piloT line reGulaTor ep conTrol sysTem parT no. iTem (1) ep control mounting bracket 7016003 24V - 40 Va Transformer - 120V 60hZ primary 80160039 (2a) usa - honeywell plate mounted aT140d1012 80160014 (2b) canada - honeywell foot mounted aT72d1089 822662...
  • Page 102 SecTiON Vi - RePAiR PARTS (continued) conTrol assembly and mounTinG brackeT ep conTrol sysTems...
  • Page 103 SecTiON Vi - RePAiR PARTS (continued) ei conTrol sysTem - honeywell Q3481 piloT assembly ei conTrol sysTem - piloT assembly 6236072 ei - 1, naT., 5006b - 5009b sections 6236075 ei - 1, lp., 5006b - 5009b sections 6236076 ei - 2, naT., 5010b - 5026b sections not available ..lp, 5010b - 5026b sections parT no.
  • Page 104 SecTiON Vi - RePAiR PARTS (continued) ep conTrol sysTem - piloT assembly 6236003 naT. Gas not available for lp parT no. iTem 8236017 (1) Flame Rectification Pilot Ass’y Natural Gas - Honeywell Q179C1009 w/388146 AG Orifice 7136255 (2) ignition lead - honeywell r1061012 - 6’ long 7136256 (3) flame rod lead - honeywell r1298020 - 6’...
  • Page 105 APPeNDix A - FiGUReS Figure Page Description Number Number Section i - Equipment Check List 5 & 6 u.s.a. equipment check list kd boilers canada 7 & 8 canadian equipment check list kd boilers fig. 1 dimensional data Section ii - General information Section iii - installation instructions fig.
  • Page 106 APPeNDix A - FiGUReS (continued) Figure Page Description Number Number Section iii - installation instructions (continued) fig. 36 pilot piping, Thermocouple control system - canada only fig. 37 installation of pilot safety switch, Thermocouple control system fig. 38 single Vent system fig.
  • Page 107 APPeNDix A - FiGUReS (continued) Figure Page Description Number Number Section Vi - Repair Parts (continued) honeywell ignition ignition module #s8610m and support bracket, ei control system module penn Johnson pilotstat #l62Gb & support bracket, Thermocouple control system control system Transformer, penn #h91wG-5 pilot solenoid Valve and pilot line regulator ei control system, penn pilot solenoid usa (5010b - 5026b) natural Gas;...
  • Page 108 5b base parts - 5006b Thru 5014b Table 2b series 5b base parts - 5015b Thru 5026b Table 3a series 5b integral canopy draft hoods - boiler sizes 5006b Thru 5010b Table 3b series 5b section replacement chart Table 3c...
  • Page 109 APPeNDix B - TABLeS (continued) Table Page Description Number Number Section Vi - Repair Parts (continued) penn Johnson pilotstat #l62Gb & support bracket, Thermocouple control system control system Transformer, penn #h91wG-5 pilot solenoid Valve and pilot line regulator ei control system, penn pilot solenoid usa (5010b - 5026b) natural Gas;...

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