Burnham 8H Series Installation And Operation Manual

Gas-fired boiler
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Commercial Boilers
www.burnhamcommercialcastiron.com
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3050579
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Price - $5.00


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Summary of Contents for Burnham 8H Series

  • Page 1 3050579 Commercial Boilers www.burnhamcommercialcastiron.com Price - $5.00 84602R3-6/0...
  • Page 2 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 also offers Safety Relief Valves set for 30 psi (By Special Order Only).
  • Page 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 before attempting installation, start-up operation, or service.
  • Page 4: Table Of Contents

    Table of Contents I. Pre-Installation .............6 II. Boiler Assembly ............8 III. Gas Control System Assembly ........15 (Knockdown Boilers) IV. Water Trim and Piping ..........25 V. Gas Piping ..............29 VI. Venting ...............31 VII. Electrical ..............34 VIII. System Start-up ............52 IX. Service ...............61 X.
  • Page 5 Figure : Dimensional Data Table : Dimensional Data Dimensions (Inches) Recommended Water Approx. Boiler Chimney Size Content Shipping Model (Round) (Gallons) Weight (LB.) Canada Canada 805H 24-13/16 24-13/16 16-1/8 16-1/8 7” dia. x 15 ft. 11.9 806H 23-3/4 11-7/8 27-13/16 25-3/4 8”...
  • Page 6: Pre-Installation

    I. Pre-Installation 2. USA, 808H-810H: for installation in room which is WARNING large in comparison with size of boiler. a. Front: 18” Carefully read all instructions before installing b. Top: 51½” boiler. Failure to follow all instructions in proper order can cause personal injury or death. c.
  • Page 7 Duct cross-sectional area shall be same as opening free area. and accelerated component failure. Burnham DOES NOT warrant failures caused by mis-sized b. One permanent opening shall be permitted where boiler applications. DO NOT oversize the boiler the boiler has clearances of at least 1”...
  • Page 8: Boiler Assembly

    II. Boiler Assembly Remove Crate 1. Remove all fasteners at crate skid. 2. Lift outside container and remove with all other inside protective spacers and bracing. Remove boiler from skid. See Figure 2. Exercise care to avoid dropping boiler. 1. Place boiler in approximate location. Refer to Section I: Pre-Installation.
  • Page 9 6. Lift boiler with pry bar. Remove wood blocks. water pressure of at least 10 psi but less than 50 psi Lower boiler. gauge pressure. 6. Examine boiler for leaks or damage due to shipment For Packaged Boiler only, proceed to Paragraph E. or handling.
  • Page 10 Figure 5: General Assembly (Knockdown Boilers) Move boiler to permanent location by sliding or 1. Attach Base Front Panel to Section Assembly using walking. Do not drop. ¼” - 20 x 1¼” carriage bolts, washers and nuts. For Packaged Boiler, proceed to Paragraph L. 2.
  • Page 11 Figure 6: Flame Roll-out Switch Installation Figure : Burner/Burner Access Panel Installation...
  • Page 12 Combustible Clearance Label from Combination Attach Flame Roll-out Switch to Burner Access Panel. Boiler Parts and Controls Carton. Attach to See Figure 6. Flame Roll-out Switch and hardware are located in Combination Boiler Parts and Control Vestibule Panel in locations shown. Carton.
  • Page 14 Figure : EP/OP Control Installation...
  • Page 15: Gas Control System Assembly

    III. Gas Control System Assembly (Knockdown Boilers) 1. Install Gas Control Assembly on Manifold. See 24V Standing Pilot Control System Figure 14. Use thread (joint) compound (pipe dope) Install Gas Control System. All components are resistant to action of liquefied petroleum gas. located in Combination Boiler Parts and Control 2.
  • Page 16 b. Connect Ignition Lead from Pilot to Ignition EP-CSD-1 Control System Transformer. Install Gas Control System. All components are 4. Mount Transformer (continuous circulation) or located in Combination Boiler Parts and Control Control Center (intermittent circulation) to Junction Carton. Box. 1.
  • Page 25: 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’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 26 Figure : Drain Piping Installation Install Drain Valve in rear of Left End Section, Tapping “G”. See Figure 19. Components are located in Water Trim Carton. Install Temperature-Pressure Gauge. Components are located in Water Trim Carton. 1. Standard Temperature - Pressure Gauge Piping. See Figure 2: Alternate Temperature-Pressure Gauge Figure 20.
  • Page 27 Pump flow rates and minimum boiler supply and Burnham Commercial recommends maintaining return pipe sizes are shown in Table 4. temperature differential (drop) across the system Figure 23: Recommended Boiler Piping for Circulator Zoned Heating Systems Detail “B”: Primary/Secondary Piping...
  • Page 28 WARNING Burnham Commercial recommends maintaining temperature differential (drop) across the system at 40°F or less and return water temperature at minimum of 35°F. Continued boiler operation for prolonged periods of time under conditions when temperature differential across the system exceeds 40°F and/or return water temperature stays below 35°F, may result in premature...
  • Page 29: Gas Piping

    V. Gas Piping 4. Specific gravity of gas. Gas piping systems for WARNING gas with a specific gravity of 0.70 or less can be sized directly from Table 6, unless authority having Failure to properly pipe gas supply to boiler may jurisdiction specifies a gravity factor be applied.
  • Page 30 Table 6: 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 ½ ¾ 1¼ 1,050 1,400 Table 7: Equivalent Lengths of Standard Pipe Fittings & Valves Valves (Fully Open) Threaded Fittings Pipe...
  • Page 31: Venting

    VI. Venting 1. Uncoil power cord. Install vent system in accordance with local building codes; or local authority having jurisdiction; or 2. Position mounting bracket onto lower edge of Draft National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part Hood skirt. Locate center tooth (with #10 sheet 7, Venting of Equipment and/or CAN/CSA B149.1, metal screw) on outside and other two teeth inside Venting Systems and Air Supply for Appliances.
  • Page 32 2. Where two or more appliances vent into a common Boiler Equipped With Vent Damper. See Figure 26. vent, the area of the common vent should at least 1. Open Vent Damper Carton and remove Installation equal the area of the largest vent plus 50 % of the Instructions.
  • Page 33 9. Design vent system for sea level input. venting system are located and other spaces of the building. Turn on clothes dryers and any appliance 10. Provide adequate ventilation of Boiler Room. See not connected to the common venting system. Section I: Pre-Installation.
  • Page 34: Electrical

    VII. 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. 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.
  • Page 35 through Terminal 2 and the damper motor is de- Alliance SL™ Water Heater (if used). May be used energized. with Intermittent Circulation only. 5. When the call for heat is satisfied, the damper Refer to Alliance SL™ Installation, Operating relay coil is de-energized - closing contacts which and Service Instructions for wiring, piping and energize the damper motor.
  • Page 36 Table 10: Sequence of Operation and Wiring Diagrams Wiring Diagram Figure Sequence of Ignition System Country Fuel Boiler Sizes Operation Continuous Intermittent Natural Gas USA & Standing Pilot (24V) 6 & 7 Sect. Figure 29 Figure 30 Page 36 Canada LP Gas Natural Gas Standing Pilot...
  • Page 37 Figure 2: Wiring Diagram, Standing Pilot (24V), USA and Canada, Continuous Circulation...
  • Page 38 Figure 30: Wiring Diagram, Standing Pilot (24V), USA and Canada, Intermittent Circulation...
  • Page 39 2. Electronically Supervised Standing Pilot (OP) 3. Electronically Supervised Standing Pilot (OP-CSD-1) Sequence of Operation Sequence of Operation a. Normal Operation a. Normal Operation Thermostat or operating control calls for Thermostat or operating control calls for heat. heat. ii. Terminal #6 of RM7890C Burner Control ii.
  • Page 40 Figure 3: Wiring Diagram, OP/OP-CSD- Ignition System, Continuous Circulation...
  • Page 41 Figure 32: Wiring Diagram, OP/OP-CSD- Ignition System, Intermittent Circulation...
  • Page 42 4. Honeywell EI Sequence of Operation Circulator continues to operate and Vent Damper (if used) remains open with call a. Normal Operation for heat. If blocked vent switch is activated Thermostat or operating control calls for do not attempt to place boiler in operation. heat.
  • Page 43 Figure 33: Wiring Diagram, Honeywell EI, USA, Continuous Circulation...
  • Page 44 Figure 34: Wiring Diagram, Honeywell EI, USA, Intermittent Circulation...
  • Page 45 Figure 35: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation...
  • Page 46 Figure 36: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation...
  • Page 47 ii. Blocked Vent Switch: Automatically 6. Electronically Supervised Intermittent Ignition (EP/EP-CSD-1) Sequence of Operation interrupts main burner operation when excessive flue gas spillage occurs. a. Normal Operation Circulator continues to operate with call for Thermostat or operating control calls for heat.
  • Page 48 Figure 3: Wiring Diagram, EP/EP-CSD- Ignition System, USA, Continuous Circulation...
  • Page 49 Figure 38: Wiring Diagram, EP/EP-CSD- Ignition System, USA, Intermittent Circulation...
  • Page 50 Figure 3: McDonnell & Miller 50P-MT (20V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits Figure 40: McDonnell & Miller 50P-MT (20V) L.W.C.O. Wiring for Boilers with 20V Limit Circuits (OP & EP)
  • Page 51 Figure 4: Hydrolevel OEM - 0/550/650/50 (20V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits Figure 42: Hydrolevel OEM - 0/550/650/50 (20V) L.W.C.O. Wiring for Boilers with 20V Limit Circuits...
  • Page 52: System Start-Up

    VIII. System Start-Up 9. Close purge valve, continue filling the system WARNING until the pressure gauge reads the desired cold fill pressure. Close fill valve. Completely read, understand and follow all instructions in this manual before attempting (Note - If make-up water line is equipped with start-up.
  • Page 53 Figure 43: Lighting Instructions (24V Standing Pilot)
  • Page 54 Figure 44: Operating Instructions (EI)
  • Page 55 Figure 45: Lighting Instructions (OP)
  • Page 56 Figure 46: Operating Instructions (EP)
  • Page 57 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.
  • Page 58 Figure 48: Honeywell Q34 Pilot Flame (24V Standing Pilot) Figure 50: Honeywell QD Pilot Flame (OP) Figure 5: Honeywell QC Pilot Flame (EP) Figure 4: Honeywell Q348 Pilot Flame (24V Electronic Ignition) Check pilot burner flame and main burner flames through observation port.
  • Page 59 Do not reduce If less than minimum gas supply pressure listed on more than 0.3 inch w.c. If boiler is still overfired, rating label, contact gas supplier for assistance. contact your Burnham distributor or Regional Office for replacement Gas Orifices.
  • Page 60 b. Increase input rate if less than 98% of rating reworked system should be boiled out, and then plate input. Increase manifold gas pressure no thoroughly flushed. A qualified water treatment more than 0.3 inch w.c. If measured input rate is chemical specialist should be consulted for still less than 98% of rated input: recommendations regarding appropriate chemical...
  • Page 61: 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. General. Inspection and service must be conducted 4.
  • Page 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 contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 63 Figure 53: Boiler Flueway Cleaning Clean Combustion Chamber by vacuuming. Exercise care to avoid damaging Base Insulation. Install Burners by reversing procedures used to Table 3: Pilot Burner Location remove burners. Verify Main Burners are properly located on support bracket in Base Rear Panel, seated Boiler Model Pilot Located Between Burners* on Main Burner Orifices, and secured with hitch pin...
  • Page 64 Honeywell EI Ignition Module Yellow LED Flame Codes Yellow LED Indicates Recommended Service Action Flash Code Heartbeat Normal Flame Signal Weak Flame Signal - System will operate reliably but flame signal is less than Perform routine maintenance to desired. assure optimum flame signal. Note: This indication may flash temporarily during or shortly after lightoff on some applications.
  • Page 65 Honeywell EI Ignition Module Green LED Status Codes Green LED Flash Code Indicates Next System Action Recommended Service Action (X + Y) No “Call for Heat” None Startup - Flame sense Flash Fast None calibration Heartbeat Normal operation None If system fails to light on next trial for 5 minute Retry Delay- ignition check gas supply, pilot burner, Initiate new trial for ignition after...
  • Page 66 Honeywell EI Trouble Shooting Guide...
  • Page 67: Repair Parts

    All Series 8H 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:...
  • Page 68 Quantity Item No. Description Part No. 805H 806H 807H 808H 809H 810H . Heat Exchanger Assembly 6171605 6171606 6171607 Complete (Less Flue Baffles) 6171608 6171609 6171610 Left End Section 7171601 Intermediate Section 7171603 Right End Section 7171602 80861032 80861033 80861013 Tie Rod 80861034 80861035...
  • Page 69 Quantity Item No. Description Part No. 805H 806H 807H 808H 809H 810H 2. Canopy 6111605 6111606 6111607 Canopy 6111608 6111609 6111610 Bolt, Carriage, ¼ - 20 x 1” 80860115 Washer, ¼” Flat 80860603 Nut, ¼” - 20 80860407...
  • Page 70 Quantity Item Description Part No. 805H 806H 807H 808H 809H 810H 3. Base Assembly Base End Panel 7181601 61816052 61816062 61816072 Base Channel Assembly 61816082 61816092 61816102 61816051 61816061 61816071 Base Rear Panel Assembly 61816081 61816091 61816101 61816053 61816063 61816073 Base Front Panel Assembly 61816083 61816093...
  • Page 71 Quantity Item Description Part No. 805H 806H 807H 808H 809H 810H 4. Manifold and Main Burners Main Burner 8231602 Main Burner with Pilot Bracket, Standing Pilot (24V) 8231601 Main burner with Pilot Bracket, Honeywell EI 8231604 Main Burner with Pilot Bracket, OP 8231603 Main burner with Pilot Bracket, EP 82216051...
  • Page 72 Item 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 Gas Valve, Robertshaw 7000ERHC-S7C, Natural Gas, 1” NPT 81660156 806H - 810H Gas Valve, Robertshaw 7000ERHC-LP-S7C, LP Gas, 1”...
  • Page 73 Item Description Part No. Quantity 5-2 Gas Train -- Standing Pilot (OP-CSD-) OP-CSD-: USA Only, 8-0 Section, LP Gas Only Gas Valve, Robertshaw 7000GVERHC-S7C, LP Gas, 1” NPT 81660271 Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 Lubricated Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT 822615 Leak Test/Shut-off Valve, Conbraco #56-221-01, 1/8”...
  • Page 74 Item 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 Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT 81660151 805H-810H USA: 805H-810H...
  • Page 75 Item Description Part No. Size Quantity 5-4 Gas Train -- Intermittent Ignition (EP) USA & Canada: 6 - 0 Section, Natural Gas Only Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 806H-810H Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT 81660235 806H-807H Solenoid Gas Valve, Honeywell V8295A1032, 1”...
  • Page 76 Item Description Part No. Quantity 5-5 Gas Train -- Intermittent Ignition (EP-CSD-) USA Only: 8 - 0 Section, Natural Gas Only Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 Lubricated Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT 822615 Leak Test/Shut-Off Valve, Conbraco #56-221-01, 1/8”...
  • Page 77 Item Description Part No. Size Quantity 5-6 Pilot Assembly and Piping -- Standing Pilot (24V) USA & Canada: 6 &  Section, Natural and LP Gas Pilot Burner, Honeywell Q314A3687, Natural Gas 8236033 Pilot Burner, Honeywell Q314A3828, LP Gas 8236034 Thermocouple, Honeywell Q309A1996 w/36”...
  • Page 78 Item Description Part No. Size Quantity 5- Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) USA 5 - 0 Section, Natural and LP Gas Pilot Burner, Honeywell Q348A1002, Natural Gas 8236072U Pilot Burner, Honeywell Q348A1010, LP Gas 8236081 Igniter/Sensor Cable, 36” Lg., Honeywell 394803-2 8236121 805H-810H Ground Wire Assembly...
  • Page 79 Item 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 Pilot Burner, Honeywell Q348A1002, Natural Gas 8236072U 805H-810H Pilot Burner, Honeywell Q348A1010, LP Gas 8236081 805H-807H Igniter/Sensor Cable, 36”...
  • Page 80 Item Description Part No. Size Quantity 5- Pilot Assembly and Piping -- Standing Pilot (OP) USA & Canada: 6 - 0 Section, Natural and LP Gas Pilot Burner, Honeywell Q179D1008, Natural Gas 8236025 Pilot Burner, Honeywell Q179D1008 w/388146KD Orifice, LP Gas 6236039 Thermocouple, Honeywell Q309A1996 w/36”...
  • Page 81 Item Description Part No. Size Quantity 5-0 Pilot Assembly and Piping -- Standing Pilot (OP-CSD-) USA Only: 8 - 0 Section, LP Gas Only Pilot Burner, Honeywell Q179D1008 w/388146KD Orifice, LP Gas 6236039 Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead 8236004 Flame Rod Lead, Honeywell R1298020, 4 Ft.
  • Page 82 Item Description Part No. Size Quantity 5- Pilot Assembly and Piping -- Intermittent Ignition (EP) USA & Canada: 6 - 0 Section, Natural Gas Only Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017 Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 Rajah Connector, Honeywell 37356 8236021...
  • Page 83 Item Description Part No. Size Quantity 5-2 Pilot Assembly and Piping -- Intermittent Ignition (EP-CSD-) USA Only: 0 Section, Natural Gas Only Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017 Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 Rajah Connector, Honeywell 37356 8236021 Ignition Lead, Honeywell R1061012, 3 Ft.
  • Page 85 Quantity Item Description Part No. 805H 806H 807H 808H 809H 810H 6. Jacket 60416111 60416121 60416131 ---- Complete 60416141 60416151 60416161 70416053 70416063 70416073 Jacket Top Panel 70416083 70416093 70416103 72016058 72016068 72016078 Jacket Top Panel Insulation 72016088 72016098 72016108 70416056 70416066 70416076...
  • Page 86 Quantity Item Description Part No. 805H 806H 807H 808H 809H 810H 6. Jacket (Continued) 7041605 7041606 7041607 Jacket Front Removable Panel 7041608 7041609 7041610 Jacket Left Side Panel 6041601 Jacket Left Side Panel Main Insulation Piece 72016021 Jacket Left Side Panel Upper Corner Insulation Piece 72016023 Jacket Left Side Panel Lower Corner Insulation Piece 72016022...
  • Page 87 Quantity Item Description Part No. 805H 806H 807H 808H 809H 810H . Trim and Miscellaneous Controls Limit, 140-220°F, Honeywell L4080D1218 (EI & Standing Pilot); 80160251 L4080B1212 (EP * OP) 80160474 Immersion Well, ¾” NPT x 1½” Insul. Depth 80160426 Limit, Manual Reset, Honeywell L4006E1133 80160703 Immersion Well, ¾”...
  • Page 88 Quantity Item Description Part No. 805H 806H 807H 808H 809H 810H 8. Draft Hood and Automatic Vent Damper 8111605 8111604 8111607 8111603 Draft Hood 8111608 8111602 8111608 8111601 8111609 Automatic Vent Damper, 7” Effikal RVGP-7 8116324 Automatic Vent Damper, 8” Effikal RVGP-8 8116325 Automatic Vent Damper, 9”...
  • Page 89: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 90 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 91 SERVICE RECORD DATE SERVICE PERFORMED...

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