Burnham 805H Installation, Operating And Service Instructions
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Burnham 805H Installation, Operating And Service Instructions

Burnham 805H Installation, Operating And Service Instructions

Gas - fired boiler series 8h; series 8he
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See also: Operation & Installation Manual
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
SERIES 8H / 8HE
GAS - FIRED BOILER
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.
Commercial Boilers
www.burnhamcommercial.com
Price - $5.00
81416023R5 - 4/15
1

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  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 8H / 8HE GAS - FIRED BOILER 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.

  • Page 2: Important Information

    IMPORTANT INFORMATION - READ AND sAvE ThEsE INsTRucTIONs FOR REFERENcE All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made.
  • Page 3 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 or fuel oil vapors, 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 also offers Safety Relief Valves set for 30 psi (By Special Order Only).
  • Page 5 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 6: Table Of Contents

    Table of Contents I. Pre-Installation .............8 II. Boiler Assembly ............10 III. Gas Control System Assembly ........17 (Knockdown Boilers) IV. Water Trim and Piping ..........24 V. Gas Piping ..............28 VI. Venting ...............30 VII. Electrical ..............33 VIII. System Start-up ............49 IX. Service ...............57 X.
  • Page 7 Approx. Shipping Weight Recommended Water Dimensions (Inches) Boiler Input (LB.) Chimney Size Content Model (MBH) (Round) (Gallons) Packaged Knockdown 805H 24-13/16 16-1/8 7” dia. x 15 ft. 11.9 806H 23-3/4 11-7/8 27-13/16 8” dia. x 15 ft. 13.9 807HE 27-1/2 13-3/4 27-13/16 8”...

  • Page 8: Pre-Installation

    Boiler reduced to minimum clearances shown above): Manufacturer, unless presented within sixty (60) days 1. Single boiler, 805H-807HE, Front/Top: 24” (61.0 after receipt of equipment. Installation must conform to the requirements of 2.
  • Page 9 Btu per hour input of all equipment in space. system load will result in excessive boiler cycling Duct cross-sectional area shall be same as and accelerated component failure. Burnham opening free area. DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler b.

  • Page 10: 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 11 6. Lift boiler with pry bar. Remove wood blocks. 6. Examine boiler for leaks or damage due to shipment Lower boiler. or handling. 7. Remove plugs from Return Tapping B, Tapping C, For Packaged Boiler only, proceed to Paragraph E. and Tapping E (if second limit or operating control Test Section Assembly for leaks before connecting to is used).
  • Page 12 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 13 Figure 6: Flame Roll-out Switch Installation Figure 7: Burner/Burner Access Panel Installation...
  • Page 14 6. Attach Vestibule Panel to Left Side and Right Side Attach Flame Roll-out Switch to Burner Access Panel. Panels. See Figure 6. Flame Roll-out Switch and hardware are located in Combination Boiler Parts and Control 7. Attach Lower Front Tie Bar to Left Side and Right Carton.
  • Page 16 Figure 9: EP Control Installation...

  • Page 17: Gas Control System Assembly

    III. Gas Control System Assembly (Knockdown Boilers) EP Control System 24V Standing Pilot Control System Install Gas Control System. All components are Install Gas Control System. All components are located in Combination Boiler Parts and Control located in Combination Boiler Parts and Control Carton.

  • Page 24: 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 25 Figure 17: Drain Piping Installation Install Drain Valve in rear of Left End Section, Tapping “G”. See Figure 17. 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 19: Alternate Temperature-Pressure Gauge Figure 18.
  • Page 26 See Figure 20. Also, consult I=B=R Burnham Commercial recommends maintaining Installation and Piping Guide No. 250. temperature differential (drop) across the system at 40°F or less, and return water temperature at 2. If boiler is connected to heating coils located in minimum of 135°F.
  • Page 27 Instructions for additional information. Install in same manner as space heating zone. 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 temperature stays below 135°F, may result in premature...

  • Page 28: Gas Piping

    Model Size Natural LP / Propane 2. Use thread (joint) compound (pipe dope) resistant to action of liquefied petroleum gas. 805H 100.8 806H 126.0 3. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas valve and 807HE 136.0...
  • Page 29 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 30: 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 31 2. Where two or more appliances vent into a common Boiler Equipped With Vent Damper. See Figure 24. 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 32 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 33: Electrical

    VII. Electrical 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. 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 34 5. When the call for heat is satisfied, the damper Alliance SL™ Water Heater (if used). May be used relay coil is de-energized - closing contacts which with Intermittent Circulation only. energize the damper motor. This causes the damper Refer to Alliance SL™ Installation, Operating to close.
  • Page 35 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 27 Figure 28 Page 35 Canada LP Gas Natural Gas 5 - 10 Sect.
  • Page 36 Figure 27: Wiring Diagram, Standing Pilot (24V), Continuous Circulation (806H - 807HE)
  • Page 37 Figure 28: Wiring Diagram, Standing Pilot (24V), Intermittent Circulation (806H - 807HE)
  • Page 38 2. 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 39 Figure 29: Wiring Diagram, Honeywell EI, USA & Canada, 805 Only with Hydrostat 3200 Control...
  • Page 40 Figure 30: Wiring Diagram, Honeywell EI, USA, Continuous Circulation (806 - 810)
  • Page 41 Figure 31: Wiring Diagram, Honeywell EI, USA, Intermittent Circulation (806 - 810)
  • Page 42 Figure 32: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation (Natural: 806H - 810HE; LP: 806H - 807HE)
  • Page 43 Figure 33: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation (Natural: 806H - 810HE; LP: 806H - 807HE)
  • Page 44 ii. Blocked Vent Switch: Automatically 6. Electronically Supervised Intermittent Ignition interrupts main burner operation when (EP/EP-CSD-1) Sequence of Operation excessive flue gas spillage occurs. a. Normal Operation Circulator continues to operate with call for Thermostat or operating control calls for heat.
  • Page 45 Figure 34: Wiring Diagram, EP Ignition System, Natural Gas Only, Continuous Circulation (EP-CSD-1; Natural Gas, USA Only, 808HE - 810HE)
  • Page 46 Figure 35: Wiring Diagram, EP Ignition System, Natural Gas Only, Intermittent Circulation (EP-CSD-1; Natural Gas, USA Only, 808HE - 810HE)
  • Page 47 Figure 36: McDonnell & Miller 751P-MT (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits (806H - 810HE) Figure 37: McDonnell & Miller 751P-MT (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits (EP) (808HE - 810HE)
  • Page 48 Figure 38: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits (806H - 810HE) Figure 39: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits (808HE - 810HE)

  • Page 49: System Start-Up

    VIII. System Start-Up 9. Close purge valve, continue filling the system until the pressure gauge reads the desired cold fill Completely read, understand and follow all pressure. Close fill valve. instructions in this manual before attempting (Note - If make-up water line is equipped with start-up.
  • Page 50 Figure 40: Lighting Instructions (24V Standing Pilot)
  • Page 51 Figure 41: Operating Instructions (EI)
  • Page 52 Figure 42: Operating Instructions (EP)
  • Page 53 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 54 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.
  • Page 55 If pressure more than 0.3 inch w.c. If boiler is still overfired, can not be attained, check gas valve inlet pressure. contact your Burnham distributor or Regional If less than minimum gas supply pressure listed on Office for replacement Gas Orifices.
  • Page 56 Adjust gas input rate to boiler. LP/Propane. Check Damper Operation - If boiler is equipped with vent damper, vent damper must be in open position 1. Set thermostat to highest setting. when boiler main burners are operating. Start boiler, 2. Adjust tank regulator for gas valve inlet pressure of refer to instructions on damper to determine if damper 13.5 inches w.c.

  • Page 57: 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 2.
  • Page 58 Base Insulation. Install Burners by reversing procedures used to Boiler Model Pilot Located Between Burners* remove burners. Verify Main Burners are properly 805H 4 & 5 located on support bracket in Base Rear Panel, seated 806H 5 & 6...
  • Page 59 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 60 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 61 Honeywell EI Trouble Shooting Guide...

  • Page 62: Repair Parts

    X. Repair Parts All Series 8H / 8HE 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 63 Quantity Item No. Description Part No. 805H 806H 807HE 808HE 809HE 810HE 1. 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...
  • Page 64 Quantity Item No. Description Part No. 805H 806H 807HE 808HE 809HE 810HE 2. Canopy 6111605 6111606 61116071 Canopy 6111608 61116091 61116110 Bolt, Carriage, ¼ - 20 x 1” 80860115 Washer, ¼” Flat 80860603 Nut, ¼” - 20 80860407...
  • Page 65 Quantity Item Description Part No. 805H 806H 807HE 808HE 809HE 810HE 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...
  • Page 66 Quantity Item Description Part No. 805H 806H 807HE 808HE 809HE 810HE 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, EP...
  • Page 67 Item Description Part No. Size Quantity 5-1 Gas Train -- Standing Pilot (24V) 24V: USA & Canada, 6 & 7 Section, Natural & LP Gas Gas Valve, Robertshaw 7000ERHC-S7C, Natural Gas, 1” NPT 81660156 806H - 810HE Gas Valve, Robertshaw 7000ERHC-LP-S7C, LP Gas, 1” NPT 81660157 Solenoid Gas Valve, Honeywell V8295A1024, ¾”...
  • Page 68 7 Section, LP Gas Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT 81660151 805H - 810HE USA: 805H - 810HE Gas Valve, Robertshaw 7000DERHC-LP, LP Gas, 1” NPT 81660158 Canada: 805H - 807HE Manual Shut-Off Valve, Conbraco #50GB501A, 1” NPT...
  • Page 69 Item Description Part No. Size Quantity 5-3 Gas Train -- Intermittent Ignition (EP) USA & Canada: 6 - 10 Section, Natural Gas Only Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 806H - 810HE Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT 81660235 806H - 807HE Solenoid Gas Valve, Honeywell V8295A1032, 1”...
  • Page 70 Item Description Part No. Quantity 5-4 Gas Train -- Intermittent Ignition (EP-CSD-1) USA Only: 8 - 10 Section, Natural Gas Only Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT 822615 Leak Test/Shut-Off Valve, Conbraco #50GB501A, 1/8”...
  • Page 71 Item Description Part No. Size Quantity 5-5 Pilot Assembly and Piping -- Standing Pilot (24V) USA & Canada: 6 & 7 Section, Natural and LP Gas Pilot Burner, Honeywell Q314A3687, Natural Gas 8236033 Pilot Burner, Honeywell Q314A3828, LP Gas 8236034 807HE Thermocouple, Honeywell Q309A1996 w/36”...
  • Page 72 5-6 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) USA 5 - 10 Section, Natural and LP Gas Pilot Burner, Honeywell Q3481B1206, Natural Gas 103704-01 Pilot Burner, Honeywell Q3481B1420, LP Gas 103705-01 805H - 810HE Brass Compression Union, 1/4” OD Tube 8236008...
  • Page 73 5-7 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) Canada 5 - 10 Section, Natural Gas 5 Section, LP Gas Pilot Burner, Honeywell Q3481B1206, Natural Gas 103704-01 805H - 810HE Pilot Burner, Honeywell Q348A1010, LP Gas 103705-01 807HE Brass Compression Union, 1/4” OD Tube...
  • Page 74 Item Description Part No. Size Quantity 5-8 Pilot Assembly and Piping -- Intermittent Ignition (EP) USA & Canada: 6 - 10 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 75 Item Description Part No. Size Quantity 5-9 Pilot Assembly and Piping -- Intermittent Ignition (EP-CSD-1) USA Only: 8 - 10 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 77 Quantity Item Description Part No. 805H 806H 807HE 808HE 809HE 810HE 6. Jacket 60416111 60416121 604160711 ---- Complete 604160811 604160911 604161011 70416053 70416063 70416073 Jacket Top Panel 70416083 70416093 70416103 7201625 7201627 ---- 7201611 Jacket Top Panel Main Insulation 7201613...
  • Page 79 Quantity Item Description Part No. 805H 806H 807HE 808HE 809HE 810HE 6. Jacket (Continued) 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...
  • Page 80 Quantity Item Description Part No. 805H 806H 807HE 808HE 809HE 810HE 7. Trim and Miscellaneous Controls Limit, 140-220°F, Honeywell L4080D1218 (EI & Standing Pilot); 80160251 L4080B1212 (EP) 80160474 Immersion Well, ¾” NPT x 1½” Insul. Depth 80160426 Hydrostat 3200 with Sensor (805)
  • Page 81 Quantity Item Description Part No. 805H 806H 807HE 808HE 809HE 810HE 8. Draft Hood and Automatic Vent Damper 8111605 8111604 Draft Hood 8111602 8111601 Automatic Vent Damper, 7” Effikal RVGP-7 8116324 Automatic Vent Damper, 8” Effikal RVGP-8 8116325 Automatic Vent Damper, 9”...

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