Burnham 4FHL-345A, 4FHL-107A, 4FHL-127A, 4FHL-209A, 4FHL-240A Installation And Operating Instructions Manual
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INSTALLATION AND OPERATING
INSTRUCTIONS FOR
BURNHAM COMMERCIAL
4FH SERIES 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.
Ce manuel ne doit être utilisé que par des techniciens qualiés en entretien et
installation d’appareil de chauffage. Lire l’ensemble des directives et toute autre
information reçue avec la chaudière AVANT l’installation. Conserver ces directives
près de la chaudière an que le personnel d’entretien puisse s’y référer. Exécuter les
étapes dans l’ordre donné. Ne pas se conformer aux directives peut engendrer des
blessures graves, la mort ou d’importants dommages matériels.
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, could 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 special instructions on installation,
operation, or maintenance which are important but
not related to personal injury hazards.
Dénitions des dangers
Les termes suivants sont utilisés tout au long de ce manuel an de souligner la présence de dangers dont le
niveau de risque varie ou de mettre en relief de l’information cruciale quant à la durée de vie du produit.
Indique une situation de danger imminent qui, si
elle n’est pas évitée, peut causer la mort, de graves
blessures ou d’importants dommages matériels.
Indique une situation de danger potentiel qui, si elle
n’est pas évitée, cause la mort, de graves blessures
ou d’importants dommages matériels.
Indique une situation de danger potentiel qui, si elle
n’est pas évitée, peut causer des blessures mineures
ou de légers dommages matériels.
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Indique des directives particulières, importantes,
mais sans risque de blessure, lors de l’installation,
de l’utilisation ou de l’entretien.
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.
Cette chaudière est sous garantie limitée, dont un exemplaire apparaît à l’arrière du manuel.
Il incombe à l’installateur de s’assurer que les dispositifs sont correctement xés et en état de marche au terme de
l’installation. La garantie pour cette chaudière est valable seulement si le produit est installé, entretenu et utilisé selon
les présentes directives.
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.
NE PAS entreposer ou utiliser de l’essence ou toute autre matière inammable gazeuse ou liquide à proximité de la
chaudière ou de tout autre appareil.
Si vous sentez une odeur de gaz ou de mazout, ne pas tenter d’utiliser le système de brûleur/chaudière. Ne pas
toucher les interrupteurs ni se servir des téléphones du bâtiment. Appeler immédiatement le fournisseur de gaz ou
de mazout à partir d’un autre endroit.
Les systèmes de brûleur/chaudière produisent de la vapeur ou de l’eau chaude en mélangeant des carburants
hautement inammables gazeux, liquides ou solides avec de l’air dans une cuve sous pression pour produire une
combustion et des résidus très chauds. Des explosions, des incendies, des blessures graves, la mort ou d’importants
dommages matériels peuvent découler d’une installation, d’une utilisation ou d’un entretien inadéquat ou négligé
de l’équipement de combustion et de la chaudière.
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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.
Toute installation, altération, réparation, ou tout réglage ou entretien inadéquat peut provoquer des dommages
matériels, une blessure ou une perte de vie. Ne pas se conformer aux directives dans l’ordre donné peut causer des
blessures ou la mort. S’assurer de bien les comprendre, y compris celles des manuels du fabricant accompagnant
les composants fournis avant d’installer, d’utiliser, de réparer, de démarrer ou d’entretenir cet appareil. Conserver ce
manuel et toute autre documentation en bonne condition près de l’appareil aux ns de référence pour le propriétaire
ou le technicien en entretien et réparation.
Garder l’espace autour de la chaudière dégagé et exempt de matières combustibles, d’essence et d’autres vapeurs
et liquides inammables.
Pour fonctionner de façon sécuritaire, cette chaudière nécessite un entretien régulier. Suivre les directives de ce
manuel.
L’installation, les réparations et l’entretien doivent être effectués uniquement par un installateur ou un organisme
de service expérimenté et qualié.
Tout système de chauffage devrait être conçu par des entrepreneurs compétents, et seules les personnes qualiées
pour l’installation de tel système devraient s’en charger.
Il incombe à l’installateur de s’assurer que les dispositifs de contrôle sont correctement xés et en état de marche
au terme de l’installation.
L’installation n’est pas terminée tant qu’une soupape de sûreté n’est pas xée.
Cette chaudière NE PEUT être installée sur un plancher combustible.
Ne pas modier la chaudière ou ses commandes. S’assurer que l’unité est correctement réglée et entretenue auprès
d’un entrepreneur ou d’un technicien compétent.
Nettoyer la suie et le tartre accumulés au moins une fois par année, si possible, au début de la saison froide. Au
même moment, nettoyer et inspecter l’intérieur de la chambre de combustion.
Faites vérier le brûleur et ses commandes au moins une fois par an ou lorsque nécessaire. Ne pas faire fonctionner
si les commandes ou les dispositifs de sûreté sont absents ou installés à l’aide de cavaliers. Ne pas faire fonctionner
si une commande, un interrupteur, un composant ou un dispositif est entré en contact avec de l’eau.
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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.
Les matériaux d’assemblage de l’appareil, les produits de combustion et le combustible contiennent de l’alumine, de
la silice, des métaux lourds, du monoxyde de carbone, des oxydes d’azote, des aldéhydes ou d’autres substances
toxiques ou dangereuses pouvant causer la mort ou des blessures graves, et qui ont été reconnues par l’État de
la Californie comme causes de cancer, d’anomalies congénitales et d’autres problèmes de l’appareil reproducteur.
Toujours utiliser des vêtements, des appareils respiratoires et de l’équipement de sécurité appropriés lors du travail
ou de l’entretien près de l’unité.
Cette chaudière contient de l’eau très chaude sous haute pression. Ne pas dévisser les raccords de tuyau ni tenter
de retirer tout composant sans s’assurer hors de tout doute que l’eau est froide et la pression inexistante. Toujours
porter des vêtements et de l’équipement de protection pour installer, démarrer ou réparer cet appareil an d’éviter les
échaudures. Ne pas se er aux jauges de pression et de température de la chaudière pour déterminer ces variables.
Certains composants de cet appareil deviennent très chauds lors du fonctionnement. Ne pas toucher les composants
qui ne sont pas froids.
Cet appareil doit être installé dans un endroit bien aéré et raccordé à un système de ventilation certié en bonne
condition. Ne pas faire fonctionner sans ventilation.
Pour fonctionner de façon sécuritaire, cette chaudière nécessite de l’air frais et doit être installée de façon à ce que
les conditions de combustion et de ventilation soient adéquates.
L’intérieur des prises d’air et des conduites d’évacuation doit être inspecté et nettoyé avant la saison froide, puis
inspecté régulièrement en cours de saison pour prévenir les engorgements. La propreté et l’absence d’obstruction
des prises d’air et des conduites d’évacuation sont nécessaires à l’évacuation sécuritaire des émanations toxiques
pouvant causer des blessures ou la mort, et contribuent à maintenir l’efcacité de la chaudière.
Cette chaudière est munie de commandes pouvant provoquer un arrêt qui l’empêchera de redémarrer si elle n’est pas
réparée. Si le gel des tuyaux peut causer un bris, ne pas laisser le système de chauffage sans surveillance en temps
froid, ou encore, installer une alarme ou une protection appropriée au système an de prévenir des dommages si la
chaudière est inefcace.
Cette chaudière est conçue pour n’utiliser que du mazout lourd no 2, du gaz naturel ou du gaz de pétrole liquéé. Ne
pas utiliser d’essence, de vidanges de carter de moteur ou toute huile contenant de l’essence. Ne pas faire brûler
de déchets ni de papier dans la chaudière. Ne pas utiliser de combustible solide (bois, charbon). Tenir tout débris,
tissu, papier, résidu de bois ou autre loin de la chaudière en tout temps. Garder l’espace autour de l’appareil propre
et sans risque d’incendie.
Toujours fermer la vanne d’alimentation de mazout si le brûleur est arrêté pour une durée prolongée.
Les interrupteurs à bas niveau d’eau de type sonde ou de type otteur doivent être inspectés et entretenus annuellement.
Voir les directives de la section IV concernant l’inspection et le nettoyage.
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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.
Le terme « système de brûleur/chaudière » utilisé dans ce manuel signie tout équipement mécanique ou électrique, y
compris la chaudière, le brûleur, les pompes, les compresseurs, le système d’eau d’alimentation et sa tuyauterie, ainsi
que les systèmes électriques et de contrôle utilisés ou conservés dans la chaufferie.
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TABLE OF CONTENTS
SECTION I General information
Introduction ...................................................................................................................................... 8
Setting the Unit ................................................................................................................................ 8-9
Flue Outlet, Stack, and Breeching ................................................................................................... 9
Combustion Air Requirements ......................................................................................................... 9-10
SECTION II Installation Instructions
Boiler Piping .................................................................................................................................... 11
Tankless Heater Piping .................................................................................................................... 12
Flow Regulation ............................................................................................................................... 12
Hot Water Tempering ....................................................................................................................... 13
Heater Flushing ............................................................................................................................... 13
Hard Water ...................................................................................................................................... 13
Bottom Blowdown Piping ................................................................................................................. 13
Boiler Installation ............................................................................................................................. 14-15
SECTION III Operating Instructions
Filling System .................................................................................................................................. 16
Adjusting Burner .............................................................................................................................. 16
Testing Controls ............................................................................................................................... 16-17
Initial Cleaning, Steam Boilers......................................................................................................... 17
Initial Cleaning, Water Boilers ......................................................................................................... 17-18
Water Boiler Operation .................................................................................................................... 18
Boiler Water Treatment .................................................................................................................... 18
pH or Alkalinity Test ......................................................................................................................... 18
Warnings about Frequent Water Addition ........................................................................................ 18-19
Minimum Water Quality Requirements ............................................................................................ 19
SECTION IV Service Instructions
Boiler Shutdown and Cool Down Procedures ................................................................................. 20
Cleaning Boiler Heating Surfaces.................................................................................................... 20-21
Turbulators ...................................................................................................................................... 21
Maintenance of Low Water Cutoff Devices...................................................................................... 21-22
Checking Burner & Controls ............................................................................................................ 22
Lubrication ....................................................................................................................................... 22
Checking Safety Valve ..................................................................................................................... 22
Attention to Boiler while not in Operation ........................................................................................ 23
Ordering Repair Parts...................................................................................................................... 23
Periodic Testing Recommended Check List .................................................................................... 24-25
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.
C. Boiler model explanation is as follows:
Series 4FH: 4FHW-827-50-GO-PF
1 2 3 4 5
1. Medium: “W” for 30 psig water boiler, “PW”
for 31 thru 160 psig water boiler, “L” for 15
psig steam boiler.
2. Heating surface for the 4FH.
3. Heating surface: “50” designates 5.0 sq ft
heating surface per boiler horsepower.
4. Fuel: “G” for natural gas, “O” for #2 fuel oil,
“GO” for combination gas/oil.
5. Burner manufacturer: “PF” for Power Flame,
“WEB” for Webster, “WHT” for Weishaupt.
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.
A. Lifting and Rigging
Use of a spreader beam is preferred but not
mandatory. An approved, inspected, and rated
sling suitable for the total published boiler
weight shall be used. The correct WLL (working
load limit) shall be calculated based on the
sling angle used, and the WLL must not exceed
the sling rated capacity. The sling angle (angle
between the sling and the load) must not be
less than 60 deg. The boiler must be lifted as
level as practical (less than 5 degree tilt). Refer
to the boiler submittal drawing for dry boiler
weight.
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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.
B. Installation Clearance
Minimum clearances to combustible walls shall
be as follows:
1. Models 4FH-63A thru 180: 6" sides, rear and
above
2. Models 4FH-209A thru 3075A: 18" sides, rear,
and above
3. Minimum recommended service clearances:
18".
See boiler submittal drawings for tube pull
clearance requirements.
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. FLUE OUTLET, STACK, AND BREECHING
The maximum weight limit on the boiler ue outlets
is as follows:
1. Series 4FH: 250 lb
2. All stack/economizer weights exceeding the limits
above will need to be independently supported.
Stack design: The stacks shall be installed in
compliance with NFPA 54, ANSI Standard
Z223.1, state and local codes, using a category
III product for positive, non-condensing
appliances. The boiler ue outlets are generally
sized for the correct stack diameter, but there
are exceptions to this.
The 4FH Series boilers are equipped with a ue
outlet stub to accept a slip-on stack connection.
The boilers are optimally designed to run with a ue
outlet pressure of .10-.30”wc pressure. The stack
design, taking into account the draft effect and all
friction losses, should arrive at 0.0"wc +/- .10"wc
pressure at the inlet. Horizontal runs should be kept
to a minimum. This will ensure the boiler will meet
the maximum capacity, and will light off and have
stable and consistent combustion.
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.
5. COMBUSTION AIR REQUIREMENTS
All boiler rooms must be adequately vented to
provide enough combustion air to the boiler for proper
tuning and operation, to prevent oxygen depletion,
possible carbon monoxide formation, possible
accumulation of fuel fumes, and possible equipment
explosions. A free ow of combustion air will aid the
proper operation of the burner and allow for proper
venting of the boiler. The instructions below must be
followed to properly size make-up air openings in the
boiler room. Consult NFPA-54 National Fuel Gas Code,
NFPA-31 Installation of Oil Burning Equipment for more
detailed explanations, and local codes for additional
guidance for boiler rooms below grade and other
specic situations.
Two general methods may be used:
1. When one permanent opening is used: The
opening shall commence within 12" of the top
of the enclosure (boiler room) and the opening
shall communicate directly with the outdoors,
or through a vertical or horizontal duct with the
outdoors. The opening shall have a minimum
free area of 1 sq in per 3,000 BTU/hr total input
of all equipment in the enclosure, and not less
than the sum of the areas of all equipment vent
connectors.
2. When two permanent openings are used: One
opening location shall begin within 12" of the
top of the enclosure, and the other opening
location shall begin within 12" of the bottom of
the enclosure. When communication is directly
with the outdoors, or through vertical ducts, each
opening shall have a minimum free area of 1 sq
in per 4,000 BTU/hr total input of all equipment
in the enclosure. Where communicating with the
outdoors through horizontal ducts, each opening
shall have a minimum free area of 1 sq in per
2,000 BTU/hr total input of all equipment in the
enclosure.
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