Burnham 8H Series, 805H, 806H, 807H, 808H Installation And Operation Manual

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Commercial Boilers

3050579

81416021R3-6/10

www.burnhamcommercialcastiron.com

Price - $5.00

IMPORTANT INFORMATION - READ CAREFULLY

NOTE: The equipment must be installed in accordance with those installation regulations enforced in the area where the

installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.

All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.

The following terms are used throughout this manual to bring attention to the presence of

hazards of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

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.

CAUTION

NOTICE

DANGER

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 vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the

gas supplier’s instructions or if the supplier is unavailable, contact the re department.

DO NOT install this boiler on combustible ooring, carpet, concrete over combustible ooring or wood,

nor on concrete over any heat affected material such as plastic piping or wiring without a properly in-

stalled combustible oor shield.

All Series 8H cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler and Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each 8H jacket, which indicates the boiler Maximum Allowable working Pressure (MAWP). Each cast iron section is permanently marked with the MAWP listed on the boiler’s ASME Data Label. The MAWP for all Series 8H Boiler is 50 psi (Water Only). 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).

NOTICE

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. Installation and service must be performed only by an knowledgeable, experienced, and skilled installer or service agency.

This boiler must be properly vented.

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 system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life

to vent safely and will contribute toward maintaining the boiler’s efciency.

Installation is not complete unless a pressure relief valve is installed into the tapping located on the top of boiler - See the Water Trim and Piping Section of this manual for details.

This boiler is supplied with safety devices 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 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.

Boiler 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. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions,

including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or liquids.

Do not operate boiler with control which has been subject to water. All cover plates, enclosures and guards must be in place at all times.

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.

USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially

oriced to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orice sizing is indicated on the

rating label.

NOTICE

Table of Contents

I. Pre-Installation .............................................................6

II. Boiler Assembly ...........................................................

III. Gas Control System Assembly ..................................

(Knockdown Boilers)

IV. Water Trim and Piping ...............................................

V. Gas Piping ..................................................................

VI. Venting .......................................................................

VII. Electrical ....................................................................

VIII. System Start-up ..........................................................

IX. Service .......................................................................

X. Repair Parts ................................................................

Figure 1: Dimensional Data

Table 1: Dimensional Data

Dimensions (Inches)

Boiler

Model

D E

A B C

Recommended

Chimney Size

(Round)

USA Canada USA Canada

805H 20 10 7 24-13/16 24-13/16 16-1/8 16-1/8 7” dia. x 15 ft. 11.9 705

806H 23-3/4 11-7/8 8 27-13/16 25-3/4 18 16 8” dia. x 15 ft. 13.9 785

807H 27-1/2 13-3/4 9 28-13/16 25-3/4 18 16 8” dia. x 15 ft. 15.9 890

808H 31-1/4 15-5/8 9 30-13/16 26-11/16 20 16 8” dia. x 15 ft. 17.9 1000

809H 35 17-1/2 10 33-1/2 26-7/16 22 15 10” dia. x 15 ft. 19.9 1100

810H 38-3/4 19-3/8 10 33-1/2 26-7/16 22 15 10” dia. x 15 ft. 21.9 1220

Water

Content

(Gallons)

Weight (LB.)

Approx.

Shipping

I. Pre-Installation

WARNING

Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death.

A. Inspect shipment carefully for any signs of damage.

All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of boiler to carrier in good condition. Any claim

for damage or shortage in shipment must be led

immediately against carrier by consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment.

B. Installation must conform to the requirements of

the authority having jurisdiction. In the absence of such requirements, installation must conform to the National Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or CAN/CSA B149.1 Installation Codes. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME No CSD-1.

C. Provide clearance between combustible material and

boiler jacket (following clearances are minimums):

1. USA, 805H-807H: listed for Alcove installation

a. Front: 18”

b. Top: 36”

c. Draft hood, rear, sides and ue connector: 6”

WARNING

Appliance is design certied for installation on noncombustible ooring only. For installation on combustible ooring only when installed on

special base listed in Table 2. Boiler must not be installed on carpeting. When boiler is installed on concrete which is over a material that is subject to melting (PVC, PEX radiant tubing, etc.), the special base must be used. A concrete pad is not

sufcient to protect combustible ooring.

Table 2: Special Base Required for Installation on

Combustible Flooring

Boiler Model Special Base Part Number

805H 61816055

806H 61816065

807H 61816075

808H 61816085

809H 61816095

810H 61816105

2. USA, 808H-810H: for installation in room which is large in comparison with size of boiler.

a. Front: 18”

b. Top: 51½”

c. Draft hood, rear, sides, and ue connector: 6”

3. Canada, 805H-810H:

a. Top and front: 18” (45.7 cm)

b. Flue, rear and sides: 6” (15.2 cm)

D. Provide clearance for servicing and proper operation

(following clearances are recommended and may be reduced to minimum clearances shown above):

1. Single boiler, 805H-807H, Front/Top: 24” (61.0 cm)

2. Single boiler, 808H-810H, Front/Top: 48”

(122.0 cm)

3. Multiple/modular boiler, USA /Canada, Sides: 1” (2.5 cm)

E. Install boiler on level oor as close to chimney as

possible. For basement installation provide a solid base

such as concrete or masonry construction if oor is not level or if water may be encountered on oor around

boiler.

F. Protect gas ignition system components from

water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, control replacement, etc.).

G. Provide combustion and ventilation air in accordance

with applicable provisions of local building codes, or the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Air for Combustion and Ventilation; or CAN/ CSA B149.1, Venting Systems and Air Supply for Appliances.

WARNING

Adequate combustion and ventilation air must be

provided to assure proper combustion.

The following guideline is based on the

Gas Code, NFPA 54/ANSI Z223.1.

1. Determine volume of space (boiler room). Rooms communicating directly with space (through permanent openings not furnished with doors) are considered part of space.

Volume [ft3] = Length [ft] x Width [ft] x Height [ft]

2. Determine Total Input of all appliances in space.

Round result to nearest 1,000 Btu per hour (Btuh).

3. Determine type of space. Divide Volume by Total Input.

a. If result is greater than or equal to 50 ft3 per

1,000 BtuH, space is considered an unconned

space.

National Fuel

b. If result is less than 50 ft3 per 1,000 Btuh, space

is considered a conned space.

4. Determine building type. A building of unusually tight construction has the following characteristics:

a. Walls and ceiling exposed to outside atmosphere

have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed, and

b. Weather-stripping has been added on openable

windows and doors, and

c. Caulking or sealants applied in joints around

window and door frames, between sole

plates and oors, between wall-ceiling joints,

between wall panels, at plumbing and electrical penetrations, and at other openings.

5. For boiler located in an unconned space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally

provided by fresh air inltration through cracks

around windows and doors.

6. For boiler located in an unconned space in a building of unusually tight construction or in a conned space, provide outdoor air through permanent opening(s) which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Minimum dimension of air opening(s) is 3” (7.6 cm).

a. Two permanent openings: Locate one opening

within 12 inches (30.5 cm) of top of space. Locate remaining opening within 12 inches (30.5 cm) of bottom of space. Size each opening per following:

i. Direct communication with outdoors.

Minimum free area of each opening must be 1 square inch per 4,000 Btu per hour input of all equipment in space.

ii. Vertical ducts. Minimum free area of each

opening must be 1 square inch per 4,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

iii. Horizontal ducts. Minimum free area of each

opening must be 1 square inch per 2,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

b. One permanent opening shall be permitted where

the boiler has clearances of at least 1” (2.5 cm) from the sides and rear and 6” (15.2 cm) from the front. Locate the opening within 12 inches (30.5 cm) of top of space. Size opening per following:

i. Minimum free area of 1 square inch per

3,000 Btu per hour input of all equipment in space.

ii. Free area shall not be less than the sum

of the areas of all vent connectors in the

conned space.

Alternate method for boiler located within conned

space. Use indoor air if two permanent openings communicate directly with additional space(s) of

sufcient volume such that combined volume of all spaces meet criteria for unconned space. Size each

opening for minimum free area of 1 square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches.

7. Ventilation Duct Louvers and Grilles. Equip outside openings with louvers to prevent entrance of rain and snow, and screens to prevent entrance of insects

and rodents. Louvers and grilles must be xed in

open position or interlocked with equipment to open automatically before burner operation. Screens must not be smaller than ¼ inch mesh.

Consider the blocking effect of louvers, grilles and

screens when calculating the opening size to provide the required free area. If free area of louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area.

8. For Specially Engineered Installations. The above requirements shall be permitted to be waived where special engineering, consistent with good engineering practice and approved by the authority having jurisdiction, provides an adequate supply of

air for combustion, ventilation, and dilution of ue

gases.

WARNING

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.

NOTICE

Mis-sizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. Burnham DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system. Modular/multiple boilers greatly reduce the likelihood of boiler oversizing.

II. Boiler Assembly

A. Remove Crate

1. Remove all fasteners at crate skid.

2. Lift outside container and remove with all other inside protective spacers and bracing.

B. 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. Remove base hold down bolts.

2. Using pry bar under rear corner of Base End Panel, raise boiler and install 1½” wood blocks under rear corners. Install ¾” pipe roller between Base and skid.

3. Remove 1½” wood blocks. Place 3” pipe roller on

oor behind skid.

4. Roll boiler off skid. Move skid out of way.

5. Roll boiler until 3” roller is located as shown. Use pry bar to install wood blocks under front corners of base. Remove 3” roller.

Figure 2: Skid Removal

Table 3: Purpose of Tappings

Tapping Size Purpose

Figure 3: Tapping Locations

A 2” Supply

B 2” Return

C 3/4” Relief Valve

D 3/4” Limit

E 3/4” Auxiliary Limit

F 3/4” Washout

G 3/4” Drain

6. Lift boiler with pry bar. Remove wood blocks. Lower boiler.

C. For Packaged Boiler only, proceed to Paragraph E.

D. Test Section Assembly for leaks before connecting to

system and installing controls, trim and jacket. Refer to Figure 3 and Table 3.

1. Plug Tappings C & E (¾ NPT) and Return Tapping B (2 NPT).

2. Insert ¾” NPT x ¼” NPT bushing in Tapping D. Install pressure gauge capable of indicating 50 psi.

3. Insert 2” NPT x ¾” NPT bushing in Supply Tapping A. Install purge valve with a hose that runs to a drain.

4. Connect ll valve and piping to Drain Tapping G.

WARNING

Do not use air to leak test boiler.

5. Fill boiler completely with water by venting air through purge valve. Close purge valve and apply

water pressure of at least 10 psi but less than 50 psi gauge pressure.

6. Examine boiler for leaks or damage due to shipment or handling.

7. Remove plugs from Return Tapping B, Tapping C, and Tapping E (if second limit or operating control

is used). Also remove ll valve and piping, purge

valve and piping, and pressure gauge.

E. Install special base if installation is on combustible

ooring. See Figure 4. Floor shield adds 4¾” to boiler

height.

1. Place special base on combustible oor with surface

marked “FRONT” in upward position.

2. Locate special base with spacing to combustible materials as shown in Figure 4.

3. Place boiler on special base. Boiler must rest inside locating brackets. Boiler jacket panels will overhang special base.

4. Do not enclose boiler (including special base) on all four sides. Models 805H - 807H may be enclosed on three sides (alcove) while maintaining clearances shown in Figure 4.

Figure 4: Installation of Special Base for Combustible Flooring

Figure 5: General Assembly (Knockdown Boilers)

F. Move boiler to permanent location by sliding or

walking. Do not drop.

For Packaged Boiler, proceed to Paragraph L.

G. Conrm that one (1) Flue Bafe is properly

positioned in each Boiler Flueway. Tabs at the top

of each Flue Bafe should be resting on top row of Flue

Pins on each adjoining section.

H. Install Canopy on section assembly. See Figure 5.

Canopy and hardware are located in Combination Boiler Parts and Control Carton.

1. Position Canopy on top of Section Assembly. Locate between end sections and sealing ledge on front and back of each section.

2. Fasten each end with ¼” - 20 x 1” carriage bolts, washers and nuts.

3. Seal between Canopy and Section Assembly with furnace cement.

I. Inspect joints between sections. They were factory

sealed. If any openings resulted during shipment or

handling, reseal with furnace cement. Conrm tie rods

are only hand tight to allow for thermal expansion.

J. Install Base Front Panel. See Figure 5. Panel and

hardware located in Combination Boiler Parts and Control Carton.

1. Attach Base Front Panel to Section Assembly using ¼” - 20 x 1¼” carriage bolts, washers and nuts.

2. Seal between top of Base Front Panel and Section Assembly with furnace cement (shipped in Combination Boiler Parts and Control Carton).

3. Seal between top of Base Rear Panel and Section Assembly with furnace cement.

K. Install Pilot/Main Burner Assembly. See Figure 7.

Assembly is located in Combination Boiler Parts and Control Carton. Verify assembly is properly located on support bracket in Base Rear Panel, seated on Main

Burner Orice, and secured with hitch pin clip.

L. Adjust Burner Air Shutters on all Burners. See

Figure 7. (On Packaged Boilers, Front Door and Burner Access Panel(s) must be removed to make adjustments.) Distance between front edge of Burner Air Shutter and burner mounting ring should be approximately 11/16”. To adjust this distance, loosen screw at top of air shutter and slide into correct position. Then tighten screw. (Replace Burner Access Panel(s) and Front Door on Packaged Boilers.)

For Packaged Boiler, proceed to Section IV: Water Trim

and Piping.

Figure 6: Flame Roll-out Switch Installation

Figure 7: Burner/Burner Access Panel Installation

M. Attach Flame Roll-out Switch to Burner Access Panel.

See Figure 6. Flame Roll-out Switch and hardware are located in Combination Boiler Parts and Control Carton. Flame Roll-out Switch is a single use device

- do not test with heat - switch cannot be reset.

1. Cut insulation from semicircular notch at right end of the burner access panel. Models 808H

- 810H have two (2) burner access panels. Remove insulation from notch of right side burner access panel only.

2. Attach Flame Roll-out Switch Mounting Bracket to burner access panel with (1) #8 x ½” lg. sheet metal screw.

3. Attach Flame Roll-out Switch to mounting bracket with (1) #8 x ¾” lg. sheet metal screw.

N. Install Burner Access Panel(s). Locate Burner Access

Panel(s) in Combination Boiler Parts and Control Carton. Engage Burner Access Panel holes with projections on Base Front Panel. See Figure 5.

O. Install Immersion Well(s).

1. Remove Immersion Well(s) from Combination Boiler Parts and Control Carton..

2. Insert Immersion Well in Tapping D. See Figure 3.

3. If second limit or operating control is used, insert immersion well in Tapping E. If vertical gas piping is to be installed inside of boiler jacket, it is recommended that second limit be installed in system piping.

P. Install Jacket. See Figure 8.

1. Locate four (4) Jacket Attachment Brackets in Combination Boiler Parts and Control Carton. Attach to Front Base Panel and Rear Base Panels with #8 sheet metal screws. See Figure 5.

2. Hang Left Side Panel and Right Side Panel onto Jacket Attachment Brackets.

3. Attach Lower Rear Panel to Left and Right Side Panels. Do not tighten sheet metal screws.

4. Attach Upper Rear Panel to Lower Rear Panel. Do not install three (3) upper screws.

5. Remove Rating Label from envelope marked “RATING LABEL ENCLOSED”. Remove

Combustible Clearance Label from Combination Boiler Parts and Controls Carton. Attach to Vestibule Panel in locations shown.

6. Attach Vestibule Panel to Left Side and Right Side Panels.

7. Attach Lower Front Tie Bar to Left Side and Right Side Panels.

8. Engage Upper Front Panel in slots on Left Side and Right Side Panels. Place Top Panel in position. Attach Top Panel to Left Side, Right Side and Upper Rear Panels.

9. Tighten all jacket screws.

10. Afx Lighting/Operating Instructions Label and

Wiring Diagram Label to inside of Front Removable Door. Labels are located in Combination Boiler Parts and Control Carton.

Q. Install Junction Box. See Figure 8. Attach junction

box to inside of Left Side Panel with ¼” - 20 x ¼” lg. machine screw (located in Combination Boiler Parts and Control Carton).

R. Install Limit Control. Locate limit in Combination

Boiler Parts and Control Carton. Insert limit probe into left immersion well as far as possible. Tighten set screw.

S. Install Auxiliary Limit or operating control (if used).

Insert control probe into right immersion well as far as possible. Tighten set screw.

T. Install Gas Control Assembly. Refer to Section III,

Gas Control System Assembly (Knockdown Boilers).

U. EP and OP System: See Figure 9.

1. Install pre-wired EP/OP Control Cabinet Assembly to right front corner of jacket top panel.

2. Install Honeywell RM7890 Control (located in RM7890 Control Carton).

3. Remove RM7890’s Dust Cover. With a pair of side cutters, carefully snip both wire leads to the brown resistor labelled “JR2” and discard it. Replace Dust Cover.

4. Install Honeywell R7847 Flame Amplier.

5. Install heat shield.

Figure 8: Jacket Assembly

Figure 9: EP/OP Control Installation

III. Gas Control System Assembly (Knockdown Boilers)

A. 24V Standing Pilot Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control Carton.

1. Install Gas Control Assembly on Manifold. See Figure 10. Use thread (joint) compound (pipe dope)

resistant to action of liqueed petroleum gas.

2. Install pilot burner piping and controls. See Figure

10.

3. Connect Thermocouple Lead to Gas Valve.

4. Mount Transformer (continuous circulation) or Control Center (intermittent circulation) to Junction Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

B. EI (Intermittent Ignition)

Install Gas Control System. All components are

located in Combination Boiler Parts and Control Carton.

1. Install Gas Control Assembly on Manifold. See Figure 11. Use thread (joint) compound (pipe dope)

resistant to action of liqueed petroleum gas.

2. Install pilot burner piping and controls.

a. Honeywell EI

i. USA - See Figure 12. ii. Canada - See Figure 13.

3. Install Ignition Module.

a. Attach Ignition Control Mounting Bracket to

Jacket Vestibule Panel using two (2) #8 x ½” sheet metal screws.

b. Attach Honeywell Ignition Module to Mounting

Bracket using two (2) #8 x ½” sheet metal screws.

c. Connect pilot ground wire and ignitor/sensor

lead(s) to ignition module. Refer to “Section VII: Electrical” for connection details.

4. Mount Transformer (continuous circulation) or Control Center (intermittent circulation) to Junction Box. See Figure 8.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

C. OP Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control Carton.

1. Install Gas Control Assembly on Manifold. See Figure 14. Use thread (joint) compound (pipe dope)

resistant to action of liqueed petroleum gas.

2. Install pilot burner piping and controls. See Figure

14.

3. Connect Thermocouple Lead to Gas Valve.

4. Mount Transformer (continuous circulation) or Control Center (intermittent circulation) to Junction Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

D. OP-CSD-1 Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control Carton.

1. Install Gas Control Assembly on Manifold. See Figure 15. Use thread (joint) compound (pipe dope)

resistant to action of liqueed petroleum gas.

2. Mount pilot switch.

3. Install pilot burner piping and controls. See Figure

15.

4. Connect Thermocouple lead to pilot switch.

5. Mount Transformer (continuous circulation) or Control Center (intermittent circulation) to Junction Box.

6. Attach transformer/control center to junction box.

E. EP Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control Carton.

1. Install Gas Control Assembly on Manifold. See Figure 16.

2. Install pilot burner piping and controls. See Figure

16.

3. Install Ignition Transformer.

a. Attach Ignition Transformer to Jacket Vestibule

Panel using four (4) #8 x ½” lg. sheet metal screws.

b. Connect Ignition Lead from Pilot to Ignition

Transformer.

4. Mount Transformer (continuous circulation) or Control Center (intermittent circulation) to Junction Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

F. EP-CSD-1 Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control Carton.

1. Install Gas Control Assembly on Manifold. See Figure 17.

2. Install pilot burner piping and controls. See Figure

17.

3. Install Ignition Transformer.

a. Attach Ignition Transformer to Jacket Vestibule

Panel using four (4) #8 x ½” lg. sheet metal screws.

b. Connect Ignition Lead from Pilot to Ignition

Transformer.

4. Mount Transformer (continuous circulation) or Control Center (intermittent circulation) to Junction Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

Figure 10: Schematic Gas Piping, 24V Standing Pilot, 806H & 807H

Figure 11: Main Gas Piping, Intermittent Ignition (EI)

Figure 12: Schematic Pilot Piping (Honeywell EI), USA

Figure 13: Schematic Pilot Piping (Honeywell EI)

Canada: Natural Gas, 805H - 810H; LP Gas, 806H - 807H

Figure 14: Schematic Gas Piping, OP Control System, 806H - 810H

Figure 15: Schematic Gas Piping, OP-CSD-1 Control System, 808H - 810H

Figure 16: Schematic Gas Piping, EP Control System (Natural Gas Only), 806H - 810H

Figure 17: Schematic Gas Piping, EP-CSD-1 Control System, 808H - 810H

IV. Water Trim and Piping

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

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.

A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water and frequent water additions.

1. There are many possible causes of oxygen contamination such as:

a. Addition of excessive make-up water as a result

of system leaks.

b. Absorption through open tanks and ttings.

c. Oxygen permeable materials in the distribution

system.

2. In order to insure long product life, oxygen sources must be eliminated. This can be accomplished by taking the following measures:

a. Repairing system leaks to eliminate the need for

addition of make-up water.

b. Eliminating open tanks from the system.

c. Eliminating and/or repairing ttings which allow

oxygen absorption.

d. Use of non-permeable materials in the

distribution system.

e. Isolating the boiler from the system water by

installing a heat exchanger.

f. Use properly designed and operating air

elimination devices in water piping.

B. Design boiler piping and ow rate to obtain proper

temperature rise though the boiler. (See Table 4)

Table 4: Flow Rate, Temperature Rise, and

Pressure Drop

Boiler

Model

805H

806H

807H

808H

809H

810H

Flow Rate

(GPM)

21 14 10

26 17 13

31 20 15

36 24 18

40 27 20

45 30 22

Temp. Rise Thru Boiler

20° F 30° F 40° F

Min. Boiler

Piping NPT

1½” 1¼” 1¼”

1½” 1½” 1¼”

2” 1½” 1¼”

2” 1½” 1½”

2”

2” 1½”

2”

2” 1½”

Boiler

Pressure

Drop

3’ 2’ 1’

WARNING

Pressure relief valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement.

C. Install Safety Relief Valve. See Figure 18.

Components are located in Water Trim Carton. Safety Relief Valve must be installed with spindle in vertical position.

1. Install ¾” NPT x 3½” lg. nipple in tapping “C”. See Figure 3.

2. Install safety relief valve on ¾” NPT nipple.

Figure 18: Safety Relief Valve Installation

Figure 19: Drain Piping Installation

D. Install Drain Valve in rear of Left End Section,

Tapping “G”. See Figure 19. Components are located in Water Trim Carton.

E. Install Temperature-Pressure Gauge. Components

are located in Water Trim Carton.

1. Standard Temperature - Pressure Gauge Piping. See Figure 20.

Figure 21: Alternate Temperature-Pressure Gauge

Installation

b. Install 2 NPT x ¾ NPT x 2 NPT Tee (provided)

or 2 NPT x 2 NPT x ¾ NPT Tee (installer furnished). ¾ NPT leg should face forward.

c. Install ¾ NPT x ¼ NPT Bushing.

d. Insert Temperature-Pressure Gauge. Tighten

by applying pressure to square shank on back of gauge. DO NOT APPLY PRESSURE ON GAUGE CASE since this may ruin gauge calibration.

F. Connect system supply and return piping to boiler.

See Figure 23. Also consult I=B=R Installation and Piping Guides. Maintain minimum ½ inch clearance from hot water piping to combustible materials.

1. If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure 22. Also consult I=B=R Installation and Piping Guides.

Figure 20: Temperature-Pressure Gauge

Installation

a. Install 2” NPT x 10” lg. nipple with gauge

tapping into Supply Tapping “A”. See Figure 3. Gauge tapping should face forward.

b. Insert Temperature-Pressure Gauge. Tighten

by applying pressure to square shank on back of gauge. DO NOT APPLY PRESSURE ON GAUGE CASE since this may ruin gauge calibration.

2. Alternate Temperature-Pressure Gauge Piping. See Figure 21.

a. Install 2 NPT x 10” Nipple into Supply Tapping

“A”. See Figure 3.

Figure 22: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

2. If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, boiler piping must be equipped with

ow control valves to prevent gravity circulation of

boiler water during cooling system operation.

3. The piping diagrams shown (Figure 23, Detail “A” and Detail “B”) are recommended for optimum operation and long term reliability.

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 boiler failure due to ue gas condensation

and/or thermal shock.

Pump ow rates and minimum boiler supply and

return pipe sizes are shown in Table 4.

Figure 23: Recommended Boiler Piping for Circulator Zoned Heating Systems

Detail “A”: Blend Pump Piping

Detail “B”: Primary/Secondary Piping

with By-Pass

a. A boiler by-pass is recommended for any

installation for improved system temperature balance, while serving to protect the boiler from sustained condensing operation. The by-pass also provides some measure of low return water

temperature protection by reducing ow through

the boiler. See Figure 23.

b. A blend pump is recommended to divert hot

supply water into the return when system return temperatures can periodically dip below 135°F or when delta T’s rise beyond 40°F because of control schemes that shut off zone pumps for extended periods. See Figure 23, Detail “A”.

c. Primary/secondary piping with a by-pass is

recommended to provide two points of mixing when dual temperature systems are used (i.e. baseboard and radiant heat, outdoor reset and domestic hot water production, systems incorporating night setback or multiple zone pumps on clock schedules). See Figure 23, Detail “B”.

d. If system three-way valves are used for

temperature modulation, or if the system will

continuously run below 135°F for extended periods (due to low temperature applications like snowmelt, heat pump systems or others), primary/secondary boiler piping with a threeway valve and return temperature sensor is recommended. Refer to Burnham RTC Return Temperature Control Manual and Tekmar Essay #021 “Mixing Methods and Sizing of Variable Speed Injection Pumps” for more information on mixing devices and boiler protection from low return water temperature.

4. A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of installation.

5. A start-up strainer is recommended for all installations (new and replacement alike) to prevent system debris and sediment from ending up in the boilers where it will inhibit heat transfer and may eventually cause a cast iron section to crack from overheating.

G. Alliance SL™ Water Heater (if used). Refer to

Alliance SL™ Installation, Operating and Service Instructions for additional information. Install in same manner as space heating zone.

WARNING

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

boiler failure due to ue gas condensation and/or thermal shock.

If the above conditions exist, to protect a boiler from sustained ue gas condensation and/or thermal

shock, the above-recommended temperatures may be maintained by employing common industry-accepted mixing methods to provide boiler protection.

Some common methods are boiler by-pass piping, blend pumps, primary secondary piping with a bypass, mixing valves and/or variable speed injection pumps.

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Burnham 8H Series, 805H, 806H, 807H, 808H Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual