4FH
INSTALLATION AND OPERATING
INSTRUCTIONS FOR
BURNHAM COMMERCIAL FIRETUBE BOILERS
Commercial Boilers
This manual must only be used by a qualied 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.
For service and repairs to the heating plant, call your local representatives. When seeking information
on the boiler, provide series and size designation shown on rating plate.
Boiler Number __________________ Type Firing________________ Type System _________
Project______________________________________________________________
Address_________________________________________________ Phone No._____________
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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.
In all cases, reference should be made to the following Standards:
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning
Equipment”, for recommended installation practices.
B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents,
and Solid Fuel Burning Appliances”, for venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety
Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety
devices.
E. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical
Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning
Equipment”, for recommended Installation Practices.
B. The equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149, and applicable Provincial Regulations for the class; which
should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical
Code and/or Local Regulations.
Hazard denitions
The following dened 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
which, if not avoided, will result in death, serious
injury or substantial property damage.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
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Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is complete. The warranty for this boiler is valid only if the boiler
has been installed, maintained and operated in accordance with these instructions.
DO NOT store or use gasoline or other ammable 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. Immediately call the gas or oil supplier from a remotely
located phone.
Burner/boiler systems produce steam or hot water in a pressurized vessel by mixing extremely ammable
gaseous, liquid or solid fuels with air to produce combustion and very hot products of combustion.
Explosions, res severe personal injury, death and/or property damage will result from improper, careless
or inadequate installation, operation or maintenance of fuel-burning and boiler equipment.
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. Keep this manual and literature in legible condition and posted near appliance
for reference by owner and service technician.
Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors and
liquids.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable
installer or service agency.
All heating systems should be designed by competent contractors and only persons knowledgeable in
the layout and installation of heating systems should attempt installation of any boiler.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is completed.
Installation is not complete unless a pressure relief valve is installed.
This boiler is NOT suitable for installation on combustible ooring.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to
assure that the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale.
The inside of the combustion chamber should also be cleaned and inspected at the same time.
Have Burner and Controls checked at least once a year or as may be necessitated. Do not operate
unit with jumpered or absent controls or safety devices. Do not operate unit if any control, switch,
component, or device has been subject to water.
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Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy
metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which
can cause death or serious injury and which are known to the state of California to cause cancer, birth
defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when
servicing or working nearby the appliance.
This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
This appliance must be properly vented and connected to an approved vent system in good condition.
Do not operate boiler with the absence of an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of the
heating season and should be inspected periodically throughout the heating season for any obstructions.
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efciency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without
service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in
cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent
damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil, natural and/or LP gas only. Do not use gasoline, crankcase
drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to
any solid fuel (i.e. wood, coal). All ammable debris, rags, paper, wood scraps, etc., should be kept clear
of the boiler at all times. Keep the boiler area clean and free of re hazards.
Always keep the oil supply valve shut off if the burner is shut down for an extended period of time.
Probe and oat type low water cutoff devices require annual inspection and maintenance. Refer to
instructions in Section IV for inspection and cleaning instructions.
Burner/boiler system, as used throughout
this manual, shall mean all mechanical and/or
electrical equipment including the boiler, burner,
pumps, compressors, feed water systems and all
associated piping, electrical and control systems
used and maintained in the boiler room.
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TABLE OF CONTENTS
SECTION I General information
Introduction ...................................................................................................................................... 6
Setting the Unit ................................................................................................................................ 6
Air Supply/Venting ........................................................................................................................... 7
SECTION II Installation Instructions
Boiler Piping .................................................................................................................................... 8
Tankless Heater Piping .................................................................................................................... 8
Flow Regulation ............................................................................................................................... 8
Hot Water Tempering ....................................................................................................................... 9
Heater Flushing ............................................................................................................................... 9
Hard Water ...................................................................................................................................... 9
Boiler Installation ............................................................................................................................. 10-13
SECTION III Operating Instructions
Filling System .................................................................................................................................. 14
Adjusting Burner .............................................................................................................................. 14
Testing Controls ............................................................................................................................... 14
Initial Cleaning, Steam Boilers......................................................................................................... 15
Initial Cleaning, Water Boilers ......................................................................................................... 15
Water Boiler Operation .................................................................................................................... 15-16
Boiler Water Treatment .................................................................................................................... 16
pH or Alkalinity Test ......................................................................................................................... 16
Warnings about Frequent Water Addition ........................................................................................ 16
SECTION IV Service Instructions
Boiler Shutdown and Cool Down Procedures ................................................................................. 17
Cleaning Boiler Heating Surfaces.................................................................................................... 17-18
Maintenance of Low Water Cutoff Devices...................................................................................... 18
Checking Burner & Controls ............................................................................................................ 18
Lubrication ....................................................................................................................................... 18
Checking Safety Valve ..................................................................................................................... 18
Attention to Boiler while not in Operation ........................................................................................ 18-19
Ordering Repair Parts...................................................................................................................... 19
Periodic Testing Recommended Check List .................................................................................... 20-21
WARRANTY...................................................................................................................... Back Cover
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SECTION I — GENERAL INFORMATION
INTRODUCTION
1. Refer to burner manufacturer’s installation
manual provided for proper venting of the
gas train components that require atmospheric
pressure to balance a diaphragm.
2. All cover plates, enclosures and guards
must be in place at all times, except during
maintenance and service.
3. Insulate all steam and hot water piping, ttings
and connections and all other hot components
and equipment from personnel contact..
4. Assure all pipes, ttings, electrical controls and
all other associated burner/boiler equipment
is of proper design and construction for the
intended use and provides adequate protection
from electrical shock and harmful physical
contact to personnel.
5. A leak-tight fuel delivery conduit and control
system must be maintained at all times.
6. Products of combustion must be transported
from the boiler/burner system to the outdoors
in an approved, leak tight, insulated venting
system. The boiler room must be positively
ventilated to prevent a concentration of
products of combustion and a reduction in the
amount of oxygen in the air.
7. For optimum performance and serviceability
from this unit adhere to the following
recommendations:
A. Clean retubes at least once a year,
preferably at the end of the heating season
to remove soot and scale. Inside surfaces of
the furnace, front and rear smokeboxes, and
reversing chamber should also be cleaned
at the same time.
B. Have the burner and controls checked at
least once a year or as necessary.
C. Retain your contractor or a competent
serviceman to assure that the unit is
properly adjusted and maintained.
1. GENERAL INFORMATION
The boiler is designed specically for forced draft
ring, is available with oil, gas or combination gas/oil
burners, and operates with a combustion efciency of
over 80%.
This manual gives the necessary information for
the proper installation, operation, maintenance and
service of units. For special installation problems,
contact Burnham Commercial, P.O. Box 3939
Lancaster, PA 17604, Phone: 888-791-3790.
2. INSPECT SHIPMENT carefully for any signs of
damage.
A. All Equipment is carefully manufactured,
inspected and packed. Our responsibility
ceases upon delivery of boiler to the carrier in
good condition.
B. Any Claims for damage or shortage in
shipment must be led immediately against
the carrier by the consignee. No claims for
variances from, or shortage in, orders will be
allowed by the manufacturer unless presented
within sixty (60) days after receipt of goods.
3. SETTING THE UNIT
Most boilers are equipped with lifting lugs to be
used in maneuvering the boiler into position. On large
boilers, where four lifting lugs are supplied, all four lugs
should be used when lifting the boiler. Scotch boilers
can also be rolled into position using roller skids under
the leg supports, pipe rollers may cause damage.
The unit should be located in the boiler room so as to
provide ease of venting and adequate clearance for
maintenance, serviceability and installation of piping.
The tube pull space listed in the Burnham
Commercial product catalog must be provided at
the front of the boiler. The coil pull space must be
maintained at the front of units equipped with tankless
coils. Floor construction should have adequate load
bearing characteristics to bear the weight of the boiler
lled with water. A boiler foundation is recommended
if the boiler room oor is weak, uneven or if a water
condition exists. These boilers are not for installation
on combustible ooring. If desiccant package was
ordered, be sure to remove from the boiler furnace
using the rear access, and from the waterside using
the manhole cover.
4. CHIMNEY OR VENT
On installations where a natural draft stack is
used, causing high breeching drafts, the boiler locking
blade damper (on boilers equipped with one) may
require adjusting, or one may need to be installed at
the boiler breeching. In multiple boiler installations,
or in installations where the breeching draft may vary
considerably, automatic draft controls in combination
with a motorized damper may be required.
When considering the stack and breeching, the
design should take into account that the boiler/burner
combination will work best when the pressure at the
boiler ue outlet is in the range of + or - 1/10 inch WC.
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5. AIR SUPPLY
A sufcient air supply must be maintained at all
times to the boiler room for proper performance of the
unit. A permanent opening or duct should be provided so
that the boiler input will not exceed 4,000 Btuh/in2 of free
area.
Example: Firing Rate (Gas) = 528 MBH
2
528,000 BTUH = 132 In
4,000 BTUH/In
Follow local building codes if they exceed these minimum requirements.
THIMBLE
2
Free Area
FRONT
OF
BOILER
SMOKEPIPE - DO NOT REDUCE BELOW
SIZE OF COLLAR ON REAR
SMOKEBOX
FIGURE 1
TYPICAL ARRANGEMENT FOR STUB VENT
TS-71-129-B
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SECTION II — INSTALLATION INSTRUCTIONS
1. BOILER PIPING
Attach supply and return piping lines and insert plugs
and bushings in connections as required. Supply and
return piping headers are detailed in Figure 2.
It is important to comply with the minimum
piping requirements in order to ensure maximum
performance and reliability on steam boilers,
particular attention should be given to the
construction of the supply header.
The nominal temperature differential between supply
and return water recommended for Burnham retube
water boilers is 20°F. As a precaution against thermal
shock, this differential should never exceed 40°F.
When differentials in excess of 30°F are anticipated
on rebox boilers, the return water should enter the
boiler at the top tting (normally the supply) and
the supply water should leave the boiler through
the bottom tting (normally the return). This ow
pattern directs the return water over the relatively
cool third pass rather than directly against the rear
of the furnace.
The boiler should not be operated for any length
of time at a temperature setting that allows the
formation of condensation in the tubes or smokebox.
This generally dictates a minimum setting of
approximately 140°F on the low limit on systems
with a 20°F system differential. On cold start up,
condensation can be expected until the boiler warms
up. If formation of condensate persists, the low limit
should be adjusted upward until condensate no
longer forms.
Water boilers and low pressure steam boilers
must have a set LFH at 120° minimum to avoid
condensation. High pressure steam should have a
minimum LFH temperature of 180°F.
2. RECOMMENDED WATER BOILER
RECIRCULATION LOOP
The following guidelines relating to system water
temperature uctuation and ow through the boiler
must be observed.
A. It is important to operate your boiler in such a
manner as to prevent temperature uctuation of
more then 40°F at any time. Rapid temperature
changes within the boiler can create stresses
in the boiler metal. These stresses can cause
damage to the boiler by loosening tubes, or
in more severe instances can crack tube sheet
ligaments,furnaces, or waterlegs.
B. If temperature differentials approach 40°F,
to help prevent temperature uctuations and
insure proper circulation through the boiler, a
recirculation loop as shown in Figure 10 should
be considered. The recirculation ow should be at
least 1/2 GPM/BHP at all times when the boiler is
online for operation.
3. TANKLESS HEATER
Install an automatic mixing valve at the tankless
heater outlet to avoid risk of burns or scalding due
to excessively hot water at the xtures. Adjust and
maintain the mixing valve in accordance with the
manufacturer’s instructions.
A. If boiler is ordered with tankless heater, connect
tankless heater piping as shown in Figure 2.
B. The following guidelines should be followed when
piping the tankless heaters:
4. FLOW REGULATION
If ow through the heater is greater than its rating,
the supply of adequate hot water may not be able to keep up
with the demand. For this reason a ow regulator matching
the heater rating should be installed in the cold water line to
the heater. The ow regulator should preferably be located
below the inlet so it's not subjected to excess temperatures
that may occur during “off” periods when it is possible for
the heat to be conducted back through the supply line. The
ow regulator also limits the ow of supply water regardless
of inlet pressure variations in the range of 20 to 120 psi.
FIGURE 2
SCHEMATIC TANKLESS HEATER PIPING
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