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

1

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).

2

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

3

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 .......................................................................

8

15

25

29

31

34

52

61

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

4

67

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

5

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

6

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.

7

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

8

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

9

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.

10

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

11

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.

12

Figure 8: Jacket Assembly

13

14

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.

15

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.

16

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

17

18

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

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

19

20

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

21

22

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

23

24

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

20° F
30° F
40° F

20° F
30° F
40° F

20° F
30° F
40° F

20° F
30° F
40° F

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’

3’
2’
1’

3’
2’
1’

3’
2’
1’

3’
2’
1’

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

25

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.

26

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

27

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.

28

V. Gas Piping

WARNING

Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.

An additional gas pressure regulator may be
needed. Consult gas supplier.

A. Size gas Piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum allowable gas valve inlet pressure is
indicated on rating label.

2. Maximum gas demand. Table 5 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).

3. Length of piping and number of ttings. Refer to

Table 6 for maximum capacity of Schedule 40 pipe.

Table 7 lists equivalent length for standard ttings.

Table 5: Rated Input

Boiler

Model

805H 252 100.8 1

806H 315 126 1

807H 374 149.6 1

808H 433 173.2 1

809H 491 196.4 1

810H 550 220 1

Rated Capacity

(cubic feet per hour)

Natural LP / Propane

Gas

Connection

Size

4. Specic gravity of gas. Gas piping systems for
gas with a specic gravity of 0.70 or less can be

sized directly from Table 6, unless authority having

jurisdiction species a gravity factor be applied.
For specic gravity greater than 0.70, apply gravity
factor from Table 8. If exact specic gravity is not

shown choose next higher value.

For materials or conditions other than those listed

above, refer to the National Fuel Gas Code,
NFPA 54/ANSI Z223.1 and/or CAN/CSA B149.1
Installation Codes, or size system using standard
engineering methods acceptable to authority having
jurisdiction.

WARNING

Failure to use proper thread compounds on all

gas connectors may result in leaks of ammable

gas.

WARNING

Gas supply to boiler and system must be
absolutely shut off prior to installing or servicing
boiler gas piping.

B. Connect boiler gas valve to gas supply system.

1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow the National
Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or
CAN/CSA B149.1 Installation Codes.

2. Use thread (joint) compound (pipe dope) resistant to

action of liqueed petroleum gas.

3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas valve and
outside jacket. See Figure 24.

4. All above ground gas piping upstream from
manual gas valve must be electrically continuous
and bonded to a grounding electrode. Do not use
gas piping as a grounding electrode. Refer to the
National Electrical Code, ANSI/NFPA 70 and/or
CSA C22.1 Electrical Code.

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. High altitude boiler models are identiable by the model number’s tenth digit on the rating label.

(4=2000’ - 4500’, 5= 2000’ - 5000’)

NOTICE

29

Table 6: Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0.5 psig or Less

Length

(Feet)

10 132 278 520 1,050 175 360 680 1,400

20 92 190 350 730 120 250 465 950

30 73 152 285 590 97 200 375 770

40 63 130 245 500 82 170 320 660

50 56 115 215 440 73 151 285 580

60 50 105 195 400 66 138 260 530

70 46 96 180 370 61 125 240 490

80 43 90 170 350 57 118 220 460

90 40 84 160 320 53 110 205 430

100 38 79 150 305 50 103 195 400

0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop

½ ¾ 1 1¼ ½ ¾ 1 1¼

Table 7: Equivalent Lengths of Standard Pipe Fittings & Valves

Pipe
Size

½” 0.622 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.1

¾” 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 4.1

1” 1.049 0.56 29.4 14.7 6.8 2.6 1.23 1.8 5.3

1¼” 1.380 0.74 38.6 19.3 8.9 3.5 1.6 2.3 6.9

I.D.

(Inches)

Gate Globe Angle

Valves (Fully Open) Threaded Fittings

Swing

Check

90°

Elbow

45°

Elbow

90° Tee, Flow

Through Run

90° Tee, Flow

Through Branch

Table 8: Specic Gravity Correction Factors

Specic

Gravity

0.50 1.10 1.30 1.07

0.55 1.04 1.40 1.04

0.60 1.00 1.50 1.00

0.65 0.96 1.60 0.97

0.70 0.93 1.70 0.94

0.75 0.90 --- ---

0.80 0.87 --- ---

Correction

Factor

Specic

Gravity

Correction

Factor

C. Pressure Test. The boiler and its gas connection must

be leak tested before placing boiler in operation.

1. Protect boiler gas valve. For all testing over ½ psig,
boiler and its individual shut-off valve must be
disconnected from gas supply piping. For testing at
½ psig or less, isolate boiler from gas supply piping
by closing boiler’s individual manual shut-off valve.

2. Locate leaks using approved combustible gas

detector, soap and water, or similar nonammable

solution.

WARNING

Do not use matches, candles, open ames, or

other ignition source.

Figure 24: Recommended Gas Piping

30

VI. Venting

A. Install vent system in accordance with local building

codes; or local authority having jurisdiction; or
National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part
7, Venting of Equipment and/or CAN/CSA B149.1,
Venting Systems and Air Supply for Appliances. Install
any of the following for this Series 8H Category I, draft
hood equipped appliance:

1. Type B or Type L gas vent. Install in accordance
with listing and manufacturer’s instructions.

2. Masonry or metal chimney. Build and install in
accordance with local building codes; or local
authority having jurisdiction; or Standard for

Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances, ANSI/NFPA 211 and/or
National Building Code of Canada.

Masonry chimney must be lined with approved

clay ue lining or listed chimney lining system

except as provided in ANSI Z223.1/NFPA 54,
Paragraph 7.5.4(a): Exception: Where permitted by

the authority having jurisdiction, existing chimneys
shall be permitted to have their use continued when
an appliance is replaced by an appliance of similar

type, input rating, and efciency.

3. Single wall metal vent. Allowed by ANSI Z223.1/
NFPA 54 under very restrictive conditions.

B. Inspect chimney and remove any obstructions or

restrictions. Clean chimney if previously used for solid

or liquid fuel-burning appliances or replaces.

1. Uncoil power cord.

2. Position mounting bracket onto lower edge of Draft
Hood skirt. Locate center tooth (with #10 sheet
metal screw) on outside and other two teeth inside
Draft Hood skirt. See Figure 25.

3. Slide mounting bracket tight against lower edge of
Draft Hood skirt. Position #10 sheet metal screw
above skirt’s stiffening rib.

4. Secure bracket in position by tightening #10 sheet
metal screw against outer surface of Draft Hood
skirt.

5. Insert excess power cord through Jacket Right Side
Panel hole. Remove slack.

6. Position strain relief bushing around power cord.
Pinch bushing’s two halves together and snap back
into hole in Jacket Right Side Panel.

7. Verify power cord, mounting bracket, and Blocked
Vent Switch are secure and located as shown in
Figure 25.

WARNING

Do not operate boiler without Blocked Vent Switch
Properly installed.

DANGER

Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.

C. Install Draft Hood on canopy outlet. Maintain height

from Jacket Top Panel to Draft Hood skirt as shown
in Figure 1. DO NOT ALTER, CUT, OR MODIFY
DRAFT HOOD.

WARNING

Do not alter boiler draft hood or place any
obstruction or non-approved damper in the
breeching or vent system. Flue gas spillage can
occur. Unsafe boiler operation will occur.

D. Install Blocked Vent Switch. The Blocked Vent

Switch Assembly consists of a strain relief bushing,
power cord, and switch attached to mounting bracket.
On Packaged boilers, the assembly is shipped attached
to top of boiler. On Knocked Down boilers, the
assembly is located in Combination Boiler Parts and
Control Carton.

Figure 25: Blocked Vent Switch Installation

31

E. Boiler Equipped With Vent Damper. See Figure 26.

1. Open Vent Damper Carton and remove Installation
Instructions. Read Installation Instructions
thoroughly before proceeding.

CAUTION

Do not use one vent damper to control two or
more heating appliances.

2. Vent damper must be same size as draft hood
outlet. See Figure 1. Unpack vent damper carefully.
Forcing vent damper open or closed may damage
gear train and void warranty. Vent damper assembly
includes pre-wired connection harness with
polarized plug.

3. Mount vent damper assembly on draft hood without

modication to either (Refer to instructions packed
with vent damper for specic instructions). Vent

damper position indicator to be visible to users.

WARNING

Provide adequate clearance for servicing -

provide 6” minimum clearance between damper
and combustible construction.

F. Install Vent Connector from draft hood or vent

damper to chimney. See Figure 27.

1. Do not connect into same leg of chimney serving an

open replace.

2. Where two or more appliances vent into a common
vent, the area of the common vent should at least
equal the area of the largest vent plus 50 % of the
area of the additional vents. Do not connect the
vent of this appliance into any portion of mechanical
draft system operating under positive pressure.

3. Vent connector should have the greatest possible
initial rise above the draft hood consistent with the
head room available and the required clearance from
adjacent combustible building structure.

4. Install vent connector above bottom of chimney to
prevent blockage - inspect chimney for obstructions
or restrictions and remove - clean chimney if
necessary.

5. Vent connector should slope upward from draft hood
to chimney not less than one inch in four feet. No
portion of vent connector should run downward or
have dips or sags. Vent connector must be securely
supported.

6. Use thimble where vent connector enters masonry

chimney - keep vent connector ush with inside of
ue liner.

7. Do not install Non-listed (AGA, CGA, CSA, ETL,
or UL) vent damper or other obstruction in vent
pipe.

8. Locate Boiler as close to Chimney as possible
consistent with necessary clearances. See Section I:
Pre-Installation.

32

Figure 26: Vent Damper Installation

9. Design vent system for sea level input.

10. Provide adequate ventilation of Boiler Room. See
Section I: Pre-Installation.

11. Never pass any portion of vent system through a
circulating air duct or plenum.

WARNING

When an existing boiler is removed from a
common venting system, the common venting
system is likely to be too large for proper venting
of the appliances remaining connected to it.

G. If an Existing Boiler is Removed:

At the time of removal of an existing boiler,

the following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the other
appliances remaining connected to the common
venting system are not in operation:

1. Seal any unused openings in the common venting
system.

2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, or other

deciencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common

venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close

replace dampers.

4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.

5. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame

of a match or candle, or smoke from a cigarette,
cigar or pipe.

6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return

doors, windows, exhaust fans, replace dampers and

any other gas-burning appliance to their previous
condition of use.

7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of
the common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 7 and Part 11 in the National Fuel Gas Code,
NFPA 54/ANSI Z223.1.

Figure 27: Typical Vent System

33

VII. Electrical

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of
electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock
once power is turned off.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any
electrical work.

Each boiler must be protected with a properly sized fused disconnect.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with

a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls
used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

A. Install Boiler Wiring

1. Knockdown boilers only. Locate wiring harnesses
in Combination Boiler Parts and Control Carton.
Refer to Table 10 and connect wiring as shown on
the appropriate wiring diagram.

2. Connect supply wiring and electrically ground boiler
in accordance with requirements of authority having
jurisdiction, or in absence of such requirements the
National Electrical Code, ANSI/NFPA 70 and/or
CSA C22.1 Electrical Code.

B. Wire Vent Damper (if used; required on 805H,

optional on 806H - 810H). See Figure 26.

1. Attach Vent Damper Harness to mounting hole in
Jacket Left Side Panel. Install Cable Clamp around

exible conduit and attach to Jacket Top Panel.

2. Remove factory installed Jumper Plug from Vent
Damper Receptacle on Vestibule Wiring Harness
and discard.

3. Plug Vent Damper Harness Plug into Vent Damper
Receptacle. See Figure 26.

C. Install thermostat. Locate on inside wall

approximately 4 feet above oor. Do not install on
outside wall, near replace, or where inuenced
by drafts or restricted air ow, hot or cold pipes,
lighting xtures, television, or sunlight. Allow free air

movement by avoiding placement of furniture near
thermostat.

Set heat anticipator to match control system

requirements. Refer to Table 9.

D. Wire thermostat. Provide Class II circuit between

thermostat and boiler. Refer to appropriate wiring
diagram for control system being used.

Figure 28: Vent Damper Schematic Wiring Diagram

34

E. Alliance SL™ Water Heater (if used). May be used

with Intermittent Circulation only.

Refer to Alliance SL™ Installation, Operating

and Service Instructions for wiring, piping and
additional information.

F. Vent Damper Sequence of Operation. See Figure 28

for schematic wiring diagram.

1. The Vent Damper is continuously powered at
Terminal 1.

2. When there is a call for heat, the damper relay coil
is energized through Terminal 5 if all limits ahead of

the damper are satised.

3. The relay coil closes contacts which energize the
damper motor, causing the damper to open.

4. When the damper blade reaches the fully open
position, power is sent back to the ignition circuit

through Terminal 2 and the damper motor is de­energized.

5. When the call for heat is satised, the damper

relay coil is de-energized - closing contacts which
energize the damper motor. This causes the damper
to close. When the damper blade reaches the fully
closed position, the damper motor is de-energized.

POWER FAILURE - The damper blade will stop in the

position it was in when power failed. (Combustion
can never take place unless the damper blade is in
the fully open position).

G. Sequence of Operation and Wiring. Refer to Table

10 for the appropriate control system.

H. Optional Low-Water Cut-Off Wiring. See Figures 45

through 48.

Table 9: Heat Anticipator Settings

Control System

24V Standing Pilot 1.1 0.3

24V Electronic Ignition

* If room is heated above thermostat temperature setting, reduce heat anticipator setting by 0.1 or

0.2 amps. If boiler short cycles without room reaching desired temperature, increase heat anticipator
by 0.1 or 0.2 amps.

Continuous Circulation Intermittent Circulation

USA: 0.9

Canada: 1.2

Heat Anticipator Setting *

0.3

35

Table 10: Sequence of Operation and Wiring Diagrams

Ignition System Country Fuel Boiler Sizes

Standing Pilot (24V)

Standing Pilot

(OP - 120V)

Standing Pilot

(OP-CSD-1 - 120V

Intermittent Ignition

(Honeywell EI - 24V)

Intermittent Ignition

(EP - 120V)

Intermittent Ignition
(EP-CSD-1 - 120V)

USA &

Canada

USA &

Canada

USA LP Gas 8 - 10 Sec. Figure 31 Figure 32 Page 39

USA

Canada

USA &

Canada

USA Natural Gas 8 - 10 Sect. Figure 37 Figure 38 Page 47

Natural Gas

6 & 7 Sect. Figure 29 Figure 30 Page 36

LP Gas

Natural Gas

6 - 10 Sect. Figure 31 Figure 32 Page 39

LP Gas

Natural Gas

5 - 10 Sect. Figure 33 Figure 34

LP Gas

Natural Gas 5 - 10 Sect.

LP Gas 5 - 7 Sect.

Natural Gas 6 - 10 Sect. Figure 37 Figure 38 Page 47

LP Gas Not Available

Wiring Diagram Figure

Continuous Intermittent

Figure 35 Figure 36

Sequence of

Operation

Page 42

1. Standing Pilot (24) Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat. Vent Damper (if used) opens.

ii. Gas valves are energized allowing main gas

ow and ignition of main burners.

iii. Call or heat ends. Gas valves are de-

energized, extinguishing main ame. Vent

Damper (if used) closes.

b. Safety Shutdown

i. Limit: Automatically interrupts main burner

operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat, Vent Damper (if used)
closes. Normal operation resumes when
water temperature falls below set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate and Vent
Damper (if used) remains open with call
for heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.

iii. Flame Roll-out Switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate
and Vent Damper (if used) remains open
with call for heat. Control is single use

device. If ame roll-out switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and replace ame

roll-out switch.

iv. Thermocouple: Senses pilot ame and

causes gas valves to turn off main burner

and pilot burner gas ow should pilot burner
ame extinguish. Circulator continues to

operate and Vent Damper (if used) remains
open with call for heat.

36

Figure 29: Wiring Diagram, Standing Pilot (24V), USA and Canada, Continuous Circulation

37

Figure 30: Wiring Diagram, Standing Pilot (24V), USA and Canada, Intermittent Circulation

38

2. Electronically Supervised Standing Pilot (OP)
Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat.

ii. Terminal #6 of RM7890C Burner Control

is energized, initiating a microcomputer
monitored circuit test.

iii. Pilot Flame Establishing Period (PFEP)

begins.

iv. After pilot ame is proven, terminal #9 of

RM7890C is energized, allowing main gas

ow and ignition of main burners. “Main”

gas light will be illuminated.

v. Call for heat ends. Terminal #6 of

RM7890C is de-energized, in turn de­energizing gas valves and extinguishing

main ame. “Main” gas light is de-

energized.

b. Safety Shutdown

i. Limit: Automatically interrupts main burner

operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat. Normal operation
resumes when water temperature falls below
set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate with call for
heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.

iii. Flame Roll-out Switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate
with call for heat. Control is single use

device. If ame roll-out switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and replace ame

roll-out switch.

iv. RM7890C Burner Control: Automatically

interrupts main burner operation if a pilot

ame is not detected during the four or ten
second pilot ame establishing period. The

RM7890C will lockout or recycle based
on jumper settings. “Alarm” light will be
illuminated. Refer to instructions supplied
with RM7890C for additional control
information.

3. Electronically Supervised Standing Pilot (OP-CSD-1)
Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat.

ii. Terminal #6 of RM7890C Burner Control

is energized, initiating a microcomputer
monitored circuit test.

iii. Pilot Flame Establishing Period (PFEP)

begins.

iv. After pilot ame is proven, terminal #9 of

RM7890C is energized, allowing main gas

ow and ignition of main burners. “Main”

gas light will be illuminated.

v. Call for heat ends. Terminal #6 of

RM7890C is de-energized, in turn de­energizing gas valves and extinguishing

main ame. “Main” gas light is de-

energized.

b. Safety Shutdown

i. Limit: Automatically interrupts main burner

operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat. Normal operation
resumes when water temperature falls below
set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate with call for
heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.

iii. Flame Roll-out Switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate
with call for heat. Control is single use

device. If ame roll-out switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and replace ame

roll-out switch.

iv. RM7890C Burner Control: Automatically

interrupts main burner operation if a pilot

ame is not detected during the four or ten
second pilot ame establishing period. The

RM7890C will lockout or recycle based
on jumper settings. “Alarm” light will be
illuminated. Refer to instructions supplied
with RM7890C for additional control
information.

v. Pilot Safety Switch: Automatically de-

energizes main gas valve and interrupts pilot

gas supply if pilot ame is not detected at

any time.

39

Figure 31: Wiring Diagram, OP/OP-CSD-1 Ignition System, Continuous Circulation

40

Figure 32: Wiring Diagram, OP/OP-CSD-1 Ignition System, Intermittent Circulation

41

4. Honeywell EI Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat. Vent Damper (if used) opens.

ii. Ignition Module Terminals PV, MV/PV

and the Ignition Terminal are energized.
Terminals PV and MV/PV power the Pilot
Valve in the Gas Valve supplying gas to
the Pilot. The Ignition Terminal supplies
voltage to the Ignition Electrode creating an
electric spark to ignite the Pilot.

iii. The sensing Circuit between the Q348

Pilot Burner and the IGNITION MODULE
proves the presence of the Pilot Flame
Electronically and the Ignition Terminal is
de-energized.

iv. Terminals MV and MV/PV of the

IGNITION MODULE are energized and
supply power to the Main Gas Valve. The
Gas Valve is energized allowing main gas

ow, and ignition of Main Burners.

v. Call for heat ends. Ignition module is de-

energized, de-energizing gas valve, and

extinguishing pilot and main ame. Vent

Damper (if used) closes.

b. Safety Shutdown

i. Limit: Automatically interrupts power

to the Ignition Module and Gas Valve(s),

extinguishing pilot and main ame, when

water temperature exceeds set point.
Maximum allowable temperature is 250°F.
Circulator continues to operate with call for
heat, Vent Damper (if used) closes. Normal
operation resumes when water temperature
falls below set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate and Vent
Damper (if used) remains open with call
for heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.

iii. Flame Roll-out switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate,
Vent Damper (if used) remains open with
call for heat. Control is single use device.

If ame roll-out switch is activated, do not

attempt to place boiler in operation. Correct

cause of spillage and replace ame roll-out

switch.
iv. Pilot
– Pilot failure can occur during the start-up or

the operating cycle of the boiler. Any pilot

failure of the Q348 Electronic Pilot, after

ignition of pilot ame will close the main

gas valve in 0.8 seconds.
– For approximately 90 seconds after failure

of the Q348 pilot, the module through the

ignition terminal will try to reestablish

pilot ame. If no pilot ame can be sensed

by the ame rod circuit, terminals PV and

MV/PV are de-energized and the module

will lock out on safety. Five to six minutes

after shutdown, the IGNITION MODULE

restarts the ignition sequence. The ignition

trial, shutdown, and wait sequence continues

until either the pilot lights or the Thermostat

is set below room temperature (to end the

call for heat). The ignition sequence can be

reset by setting down the Thermostat for one

minute.

c. Trouble Shooting Guide. See Page 66.

42

Figure 33: Wiring Diagram, Honeywell EI, USA, Continuous Circulation

43

Figure 34: Wiring Diagram, Honeywell EI, USA, Intermittent Circulation

44

Figure 35: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation

45

Figure 36: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation

46

6. Electronically Supervised Intermittent Ignition
(EP/EP-CSD-1) Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat.

ii. Terminal #6 of RM7890A Burner Control

is energized, initiating a microcomputer
monitored circuit test.

iii. The pilot valve (terminal 8) and ignition

transformer (terminal 10) are energized.
The pilot valve opens and the ignition
electrode sparks, igniting the pilot.

iv. After the pilot ame is proven, the ignition

terminal (10) is de-energized and the main
valve terminal (9) is energized, allowing

main gas ow and ignition of main burners.

“Main” gas light will be illuminated.

v. When the call for heat ends, terminal #6

is de-energized, extinguishing the pilot

and main ames. “Main” gas light is de-

energized.

b. Safety Shutdown

i. Limit: Automatically interrupts main burner

operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat. Normal operation
resumes when water temperature falls below
set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate with call for
heat. If blocked vent switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.

iii. Flame Roll-out Switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate
with call for heat. Control is single use

device. If ame roll-out switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and replace ame

roll-out switch.

iv. RM7890A Burner Control: Automatically

interrupts main burner operation if a pilot

ame is not detected during the four or ten
second pilot ame establishing period. The

RM7890A will lockout or recycle based
on jumper settings. “Alarm” light will be
illuminated. Refer to instructions supplied
with RM7890A for additional control
information.

47

Figure 37: Wiring Diagram, EP/EP-CSD-1 Ignition System, USA, Continuous Circulation

48

Figure 38: Wiring Diagram, EP/EP-CSD-1 Ignition System, USA, Intermittent Circulation

49

Figure 39: McDonnell & Miller 750P-MT (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits

Figure 40: McDonnell & Miller 750P-MT (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits (OP & EP)

50

Figure 41: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits

Figure 42: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits

51

VIII. System Start-Up

WARNING

Completely read, understand and follow all
instructions in this manual before attempting
start-up.

A. Safe operation and other performance criteria were met

with the gas manifold and control assembly provided

on boiler when boiler underwent tests specied in

American National Standard for Gas-Fired Low­Pressure Steam and Hot Water Boilers, ANSI Z21.13.

B. Check Main Burners. Main burners must be properly

located on support bracket in Base Rear Panel, seated

on Main Burner Orices, and secured with hitch pin

clips.

C. Verify that the venting, water piping, gas piping

and electrical system are installed properly. Refer to

installation instructions contained in this manual.

D. Conrm all electrical, water and gas supplies

are turned off at the source and that vent is clear of
obstructions.

E. FILL ENTIRE HEATING SYSTEM WITH WATER

and vent air from system. Use following procedure on
a Series Loop or multi-zoned system installed as per

Figure 23 to remove air from system when lling.

WARNING

The maximum operating pressure of this boiler is
50 psig. Never exceed this pressure. Do not plug
or modify pressure relief valve.

1. Close full port ball valve in boiler supply piping.

2. Isolate all zones by closing zone valves or shut-off
valves in supply and return of each zone(s).

3. Attach a hose to the vertical purge valve located
prior to the full port ball valve in the system supply

piping. (Note - Terminate hose in ve gallon bucket
at a suitable oor drain or outdoor area).

4. Starting with one circuit at a time, open zone valve
or shut-off valve in system supply and return piping.

5. Open purge valve.

6. Open ll valve (Make-up water line should be

located directly after full port ball valve in system
supply piping between air scoop and expansion
tank).

7. Allow water to overow from bucket until discharge

from hose is bubble free for 30 seconds.

8. Close the open zone valve or shut-off valve for the
zone being purged of air, then open the zone valve
or shut-off valve for the next zone to be purged.
Repeat this step until all zones have been purged. At

52

completion, open all zone valves or shut-off valves.

9. Close purge valve, continue lling the system
until the pressure gauge reads the desired cold ll
pressure. Close ll valve.

(Note - If make-up water line is equipped with

pressure reducing valve, adjust pressure reducing

valve to desired cold ll pressure. Follow ll valve

manufacturer’s instructions).

10. Open isolation valve in boiler supply piping.

11. Remove hose from purge valve.

F. Conrm that the boiler and system have no water

leaks.

G. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot)
from gas supplier.

2. Connect manometer to pressure tap on gas valve.
Use 1/8 NPT tapping provided.

3. Temporarily turn off all other gas-red appliances.

4. Turn on gas supply to the boiler gas piping.

5. Conrm that the supply pressure to the gas valve is

14 in. w.c. or less.

6. Open the eld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

7. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method. Check that boiler gas piping, valves, and
all other components are leak free. Eliminate any
leaks.

8. Purge gas line of air.

H. Follow Lighting or Operating Instructions to place

boiler in operation. Refer to label on inside of Front
Removable Panel or appropriate Figure as listed in
Table 11.

DANGER

Do not use matches, candles, open ames or

other ignition source to check for leaks.

Table 11: Lighting and Operating Instructions

Lighting or

Ignition System

Standing Pilot (24) Figure 43 Figure 48

Honeywell EI Figure 44 Figure 49

OP Figure 45 Figure 50

EP Figure 46 Figure 51

OP-CSD-1

EP-CSD-1 Figure 51

Operating

Instructions

Figure 47

Pilot Flame

Illustration

Figure 50

Figure 43: Lighting Instructions (24V Standing Pilot)

53

54

Figure 44: Operating Instructions (EI)

Figure 45: Lighting Instructions (OP)

55

Figure 46: Operating Instructions (EP)

56

BOILER OPERATING INSTRUCTIONS

TO SHUT DOWN:

1. Close manual main shut-off valve(s) and pilot

valve(s).

2. Turn off main electric switch.

TO START UP:

1. Make sure that both the main manual and the pilot

valve(s) have been off for at least ve minutes.

2. Turn room thermostat and all operating controls to
lowest setting.

3. Remove burner access panel(s).

4. Open manual pilot valve(s).

NOTE:

Item (5) applies only to boilers with standing pilot

safety switch(es).

5. Depress button on standing pilot safety switch and
hold lighted match to pilot, holding button in for at
least one minute or until pilot remains lighted after
button is released. Repeat for remaining standing
pilots.

6. Turn on main electric switch.

7. Reset safety switch on ame safeguard relay.

8. Immediately light constant burning rectication pilot(s)

Q179D with a lighted match. If pilot is not lighted
in 15 seconds, Step (7) must be repeated. Electric
pilot valve(s) are automatic, opening after Step (7).
(“OP” System).

8a. Intermittent electric ignition rectication pilot(s)

Q179C light up automatically when thermostat or
operating control calls for heat. (“EP” System).

9. Replace burner access panel(s).

10. Open manual main shut-off valve(s).

11. Adjust room thermostat and operating controls to
desired setting.

Figure 47: Lighting / Operating Instructions (OP/EP-CSD-1)

57

Figure 48: Honeywell Q314 Pilot Flame

(24V Standing Pilot)

Figure 50: Honeywell Q179D Pilot Flame (OP)

Figure 51: Honeywell Q179C Pilot Flame (EP)

Figure 49: Honeywell Q348 Pilot Flame

(24V Electronic Ignition)

I. Check pilot burner ame and main burner ames

through observation port.

1. Check pilot ame. Refer to Table 11 for appropriate

pilot detail.

2. Adjust thermostat to highest setting.

3. Check main burner ames. See Figure 52. Flame
should have clearly dened inner cones with no

yellow tipping. Orange-yellow streaks caused
by dust should not be confused with true yellow
tipping.

Yellow-tipping indicates lack of primary air.

Improper burner alignment on Main Burner Orice

will also affect primary air injection. Adjust primary
air as follows:

58

Figure 52: Main Burner Flame

CAUTION

Avoid operating this boiler in an environment

where saw dust, loose insulation bers, dry wall

dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.

a. Loosen lock screw.

b. Close air adjustment until yellow tips appear on

ames.

c. Slowly open air adjustment until clearly dened

inner cones are visible.

d. Tighten lock screw.

4. Adjust thermostat to normal setting.

J. Check thermostat or operating control operation.

Raise and lower temperature setting to start and stop
boiler operation.

K. Check ignition system shut-off.

1. Standing Pilot (24V): Disconnect thermocouple
lead at Gas Valve. Gas Valve must close and pilot
and main burners extinguish. If not, replace the gas
valve.

2. Honeywell EI: Disconnect ignitor/sensor cable from
ignition module. Gas valve must close and pilot and
main burners extinguish. If not, measure voltage
across gas valve terminals “TH” and “TR”.

a. If voltage is not present, replace gas valve.

b. If voltage is present, replace ignition module.

3. EP and OP: Refer to instructions supplied with the
Honeywell RM7890 Burner Control.

L. Check Limit(s).

1. Adjust thermostat to highest setting.

2. Observe temperature gauge. When temperature
exceeds limit set point main burners should
extinguish.

3. Adjust limit to setting above observed reading. Main
burners should reignite.

4. Adjust thermostat to lowest setting. Adjust limit to
desired setting.

M. Adjust gas input rate to boiler. Natural Gas.

1. Adjust thermostat to highest setting.

2. Check manifold gas pressure. Manifold pressure
is listed on rating label. Adjust gas valve pressure
regulator as necessary (turn adjustment screw
counterclockwise to decrease manifold pressure, or
clockwise to increase manifold pressure). If pressure
can not be attained, check gas valve inlet pressure.
If less than minimum gas supply pressure listed on
rating label, contact gas supplier for assistance.

3. Clock gas meter for at least 30 seconds. Use Table

12 to determine gas ow rate in Cubic Feet per

Hour.

Table 12: Input Rate

Seconds

for One

Revolution

30 60 120 240 600

32 56 113 225 563

34 53 106 212 529

36 50 100 200 500

40 45 90 180 450

38 47 95 189 474

40 45 90 180 450

42 43 86 172 430

44 41 82 164 410

46 39 78 157 391

48 37 75 150 375

50 36 72 144 360

52 35 69 138 346

54 33 67 133 333

56 32 64 129 321

58 31 62 124 310

60 30 60 120 300

62 29 58 116 290

64 29 56 112 281

66 29 54 109 273

68 28 53 106 265

70 26 51 103 257

72 25 50 100 250

74 24 48 97 243

76 24 47 95 237

78 23 46 92 231

80 22 45 90 225

One-Half

Cu. Ft.

Size of Gas Meter Dial

One

Cu. Ft.

Two

Cu. Ft.

Five

Cu. Ft.

4. Determine Input Rate. Multiply gas ow rate by gas

heating value.

Warning

Failure to properly adjust gas input rate will result

in over ring or under ring of the appliance.

Improper and unsafe boiler operation may result.

5. Compare measured input rate to input rate stated on
rating label.

a. Boiler must not be overred. Reduce input rate

by decreasing manifold pressure. Do not reduce

more than 0.3 inch w.c. If boiler is still overred,

contact your Burnham distributor or Regional

Ofce for replacement Gas Orices.

59

b. Increase input rate if less than 98% of rating

plate input. Increase manifold gas pressure no
more than 0.3 inch w.c. If measured input rate is
still less than 98% of rated input:

i. Remove Main Burners per procedure in

Section IX: Service.

ii. Remove gas orices. Drill one (1) drill size

larger (drill size is stamped on orice, or see

Key No. 4E).

iii. Reinstall gas orices and main burners.

Measure input rate.

6. Recheck Main Burner Flame.

7. Return other gas-red appliances to previous

conditions of use.

N. Adjust gas input rate to boiler. LP/Propane.

1. Set thermostat to highest setting.

2. Adjust tank regulator for gas valve inlet pressure of

13.5 inches w.c. or less.

3. Gas valve has step opening regulator which initially
opens to 1.4 or 2.5 inch w.c. and steps to full
pressure after approximately 30 seconds. Check
manifold pressure after step has occurred. Adjust gas
valve pressure regulator as necessary for 10.0 inches
w.c. (turn adjustment screw counterclockwise to
decrease manifold pressure, or clockwise to increase
manifold pressure). If 10.0 inches w.c. can not be
attained, check gas valve inlet pressure. If less than

11.0 inches w.c., contact gas supplier for assistance.

O. Clean Heating System

Oil, grease, and other foreign materials which

accumulate in new hot water boilers and a new or

reworked system should be boiled out, and then

thoroughly ushed. A qualied water treatment

chemical specialist should be consulted for
recommendations regarding appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.

P. Check Damper Operation - If boiler is equipped with

vent damper, vent damper must be in open position
when boiler main burners are operating. Start boiler,
refer to instructions on damper to determine if damper
is in full open position.

Q. Install Front Removable Panel.

1. Engage top ange (longer of 2 anges) behind

Upper Front Panel.

2. Swing lower portion of door toward boiler.

3. Lower door to engage bottom ange behind Lower

Front Tie Bar.

R. Combustion Chamber Burn-Off

1. The mineral wool combustion chamber panels
contain a cornstarch based binder that must be
burned out at installation to prevent odors during
subsequent boiler operation.

2. Ventilate the boiler room, set the high limit to its
maximum setting, set the thermostat to call for heat.

3. Allow the boiler to re for at least an hour or until

the odor from the cornstarch has dissipated.

4. Return the high limit and thermostat to their desired
settings.

S. Review User’s Information Manual and system

operation with owner or operator.

60

IX. Service

WARNING

Service on this boiler should be undertaken only by trained and skilled personnel from a qualied service
agency. Inspections should be performed at intervals specied in this manual. Maintain manual in a

legible condition.

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

Do not place any obstructions in boiler room that will hinder ow of combustion and ventilation air.

The service instructions contained in this manual are in addition to the instructions provided by the
manufacturer of the boiler components. Follow component manufacturer’s instructions. Component
manufacturer’s instructions were provided with the boiler. Contact component manufacturer for replace­ment if instructions are missing. Do not install, start up, operate, maintain or service this boiler without
reading and understanding all of the component instructions. Do not allow the boiler to operate with
altered, disconnected or jumpered components. Only use replacement components identical to those
originally supplied by Burnham Commercial.

A. General. Inspection and service must be conducted

annually. Turn off electrical power and gas supply while
conducting service or maintenance. Follow instructions
TO TURN OFF GAS TO APPLIANCE. See Lighting/
Operating Instructions on inside of Front Removable
Door.

WARNING

Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.

B. Maintenance of Low Water Cut-off (if used). Follow

instructions provided with low water cut-off.

C. Vent System. Check for:

1. obstructions

2. accumulations of soot

3. deterioration of vent pipe or vent accessories due to
condensation or other reasons

4. proper support—no sags, particularly in horizontal
runs

5. tightness of joints. Remove all accumulations of
soot with wire brush and vacuum

Remove all obstructions. Replace all deteriorated parts

and support properly. Seal all joints.

D. Remove Main Burners for cleaning, changing orice

plugs, or repairs.

1. Shut down gas boiler in accordance with Lighting/
Operating Instructions on inside of Front Removable
Door. Close Manual Shut-off Valve.

2. Remove Front Removable Door. Raise Lower Front
Tie Bar.

3. Disconnect ignition system.

4. Remove burner access panel(s).

5. Mark location of Main Burner with Pilot Bracket on
manifold.

6. Remove hitch pin clips from Main Burner Orices.

7. Hold Main Burner on throat. Lift slightly to raise
rear of burner. Push to rear of boiler until burner

clears Main Burner Orice. Lift burners out.

8. Check burners to be sure they do not contain foreign
matter or restrictions. Clean burners with a soft
bristle brush, blow any dirt out with compressed air
or use a vacuum cleaner. See Figure 53.

E. Clean Boiler Flueways. See Figure 53.

1. Shut down gas boiler in accordance with Lighting/
Operating Instructions on inside of Front Removable
Door. Close Manual Shut-off Valve.

2. Disconnect vent system. Remove Draft Hood.

3. Remove Jacket Top Panel.

4. Remove Canopy from top of boiler.

5. Lift Flue Bafes out of ueways. Remove any

accumulated scale or soot.

6. Thoroughly clean ueways with ue brush,

removing all scale and soot. See Figure 53.

7. Clean boiler heating surface accessible from
combustion chamber with straight handle wire
brush.

8. Reinsert Blue Bafes into ueways. See Figure 53
for correct bafe orientation. Tabs at top of each
bafe should rest o top of Flue Pins.

9. Install Canopy. See Section II: Boiler Assembly,
Paragraph G.

10. Install Jacket Top Panel, Draft Hood, Vent Damper
(if used) and Vent System.

61

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures about 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.

First Aid Procedures

:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

62

F. Clean Combustion Chamber by vacuuming. Exercise

care to avoid damaging Base Insulation.

G. Install Burners by reversing procedures used to

remove burners. Verify Main Burners are properly
located on support bracket in Base Rear Panel, seated

on Main Burner Orices, and secured with hitch pin

clips. Verify Main Burner with Pilot Bracket is in
proper location. See Table 13.

H. Lubrication. Manufacturers Instruction should be

followed on all parts installed on boiler requiring
lubrication. This includes type of lubricant to be used,
frequency of lubrication, and points to lubricate.

I. Check operation. Refer to Section VIII: System Start-

up.

Figure 53: Boiler Flueway Cleaning

Table 13: Pilot Burner Location

Boiler Model Pilot Located Between Burners*

805H 4 & 5

806H 5 & 6

807H 6 & 7

808H 6 & 7

809H 7 & 8

810H 8 & 9

* Burners numbered left to right as viewed from front of boiler.

63

Honeywell EI Ignition Module Yellow LED Flame Codes

Yellow LED

Flash Code

a

Indicates Recommended Service Action

Heartbeat Normal Flame Signal N/A

Weak Flame Signal -

System will operate reliably but ame signal is less than

2

desired.

Note: This indication may ash temporarily during or

Perform routine maintenance to

assure optimum ame signal.

shortly after lightoff on some applications.

Marginal Flame Signal (less than 1.1 µA) -

System may not operate reliably over time. Service call

1

recommended.

Note: This indication may ash temporarily during or

Check gas supply, pilot burner, ame
sense wiring, contamination of ame rod,

burner ground connection.

shortly after lightoff on some applications.

OFF

a

Flash Code Descriptions

below minimum threshold for system operation.

No Flame or Flame Signal -

N/A

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- The ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then repeats

sequence.

64

Honeywell EI Ignition Module Green LED Status Codes

Green LED

Flash Code

(X + Y)

a

Indicates Next System Action Recommended Service Action

OFF No “Call for Heat” N/A None

Flash Fast

Startup - Flame sense
calibration

N/A None

Heartbeat Normal operation N/A None

If system fails to light on next trial for

5 minute Retry Delay-

2

Pilot ame not detected

during trial for ignition

Initiate new trial for ignition after
retry delay completed.

ignition check gas supply, pilot burner,

spark and ame sense wiring, ame rod

contamination or out of position, burner
ground connection.

3

Recycle- Flame failed
during run

Initiate new trial for ignition. Flash
code will remain through the ignition

trial until ame is proved.

If system fails to light on next trial
for ignition check gas supply, pilot

burner, ame sense wiring, ame rod

contamination, burner ground connection.

If situation self corrects within 10
seconds, control returns to normal

4

Flame sensed out of
sequence

sequence. If ame out of sequence

remains longer than 10 seconds,

control goes to Flash code 6+4 (see

Check for pilot ame. Replace gas valve
if pilot ame present. If no pilot ame,

cycle “Call for Heat.” If error repeats,
replace control.

below)

7

8

Flame sense leakage to
ground

Low secondary voltage
supply- (below 15.5 Vac)

5 minute Retry Delay-

6 + 2

On every third retry on
same “Call for Heat”

On every 6th ame

6 + 3

failure during run on the
same “Call for Heat”

Flame sensed out of

6 + 4

sequence- longer than
10 seconds

Soft lockout due to error

ON

detected during self
check sequences

a

Flash Code Descriptions:

Control remains in wait mode.
When the fault corrects, control
resumes normal operation after a
one minute delay.

Control remains in wait mode.
When the fault corrects, control
resumes normal operation after one
minute delay.

Initiate new trial for ignition after
retry delay completed.

5 minute retry delay, then initiate
new trial for ignition.

Control waits until ame is no

longer sensed and then goes to
soft lockout. Flash code continues.
Control auto resets from soft
lockout after one hour.

Control auto resets from soft
lockout after one hour.

Check ame sense lead wire for damage
or shorting. Check that ame rod is in
proper position. Check ame rod ceramic

for cracks, damage or tracking.

Check transformer and AC line for proper
input voltage to the control. Check with
full system load on the transformer.

Check gas supply, pilot burner, spark

and ame sense wiring, ame rod

contamination or out of position, burner
ground connection.

Check gas supply, pilot burner, ame
sense wiring, contamination of ame rod,

burner ground connection.

Check for pilot ame. Replace gas valve
if pilot ame present. If no pilot ame,

cycle “Call for Heat.” If error repeats,
replace control.

Reset by cycling “Call for Heat.” If error
repeats, replace the control

- Flash Fast: rapid blinking

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then

repeats the sequence.

- X + Y ash codes signify that the LED ashes X times at 2Hz, remains off for two seconds, ashes Y times at

2 Hz, remains off for three seconds, and then repeats the sequence.

65

Honeywell EI Trouble Shooting Guide

66

X. Repair Parts

All Series 8H Repair Parts may be obtained through your local Burnham Wholesale distributor. Should
you require assistance in locating a Burnham Distributor in your area, or have questions regarding the
availability of Burnham products or repair parts, please contact Burnham Customer Service at:
[phone] or Fax [phone].

67

Item No. Description Part No.

805H 806H 807H 808H 809H 810H

Quantity

1. Heat Exchanger Assembly

6171605 1 --- --- --- --- ---

6171606 --- 1 --- --- --- ---

1 Complete (Less Flue Bafes)

1A Left End Section 7171601 1 1 1 1 1 1

1B Intermediate Section 7171603 3 4 5 6 7 8

1C Right End Section 7171602 1 1 1 1 1 1

1D Tie Rod

1E Washer 80860600 4 4 4 4 4 4

1F Nut 80860400 4 4 4 4 4 4

1G Slip Nipple, 3” 7066002 8 10 12 14 16 18

1H Flue Bafe 7111622 4 5 6 7 8 9

6171607 --- --- 1 --- --- ---

6171608 --- --- --- 1 --- ---

6171609 --- --- --- --- 1 ---

6171610 --- --- --- --- --- 1

80861032 1 --- --- --- --- ---

80861033 --- 1 --- --- --- ---

80861013 --- --- 1 --- --- ---

80861034 --- --- --- 1 --- ---

80861035 --- --- --- --- 1 ---

80861036 --- --- --- --- --- 1

68

Item No. Description Part No.

2. Canopy

2A Canopy

2B Bolt, Carriage, ¼ - 20 x 1” 80860115 2 2 2 2 2 2

2C Washer, ¼” Flat 80860603 2 2 2 2 2 2

2D Nut, ¼” - 20 80860407 2 2 2 2 2 2

Quantity

805H 806H 807H 808H 809H 810H

6111605 1 --- --- --- --- ---

6111606 --- 1 --- --- --- ---

6111607 --- --- 1 --- --- ---

6111608 --- --- --- 1 --- ---

6111609 --- --- --- --- 1 ---

6111610 --- --- --- --- --- 1

69

Item

No.

Description Part No.

805H 806H 807H 808H 809H 810H

Quantity

3. Base Assembly

3A Base End Panel 7181601 2 2 2 2 2 2

61816052 2 --- --- --- --- ---

61816062 --- 2 --- --- --- ---

3B Base Channel Assembly

3C Base Rear Panel Assembly

3D Base Front Panel Assembly

3E Burner Access Panel Assembly

3F Jacket Attachment Bracket 7041601 4 4 4 4 4 4

3G Bolt, Carriage, ¼ - 20 x 1¼” 80860106 4 4 4 4 4 4

3H Washer, ¼” Flat 80860603 4 4 4 4 4 4

3J Nut, ¼ - 20 80860407 4 4 4 4 4 4

3K Screw, Self Tapping, ¼ - 20 x ½” 80860700 3 4 4 5 5 6

3L Screw, Cap, Hex Head, 5/16” - 18 x ¾” 80861302 2 2 2 2 2 2

3M Screw, Cap, Hex Head, 5/16 - 18 x 1¼” 80861311 6 6 6 6 6 6

3N Screw, Sheet Metal, #8 x ½” 80860000 8 8 8 8 8 8

3P Washer, 3/8” Flat 80860600 6 6 6 6 6 6

3Q Nut, 5/16” 80860403 6 6 6 6 6 6

3R Screw, Self Tapping, ¼ - 20 x ¾” 80860702 10 10 10 10 10 10

61816072 --- --- 2 --- --- ---

61816082 --- --- --- 2 --- ---

61816092 --- --- --- --- 2 ---

61816102 --- --- --- --- --- 2

61816051 1 --- --- --- --- ---

61816061 --- 1 --- --- --- ---

61816071 --- --- 1 --- --- ---

61816081 --- --- --- 1 --- ---

61816091 --- --- --- --- 1 ---

61816101 --- --- --- --- --- 1

61816053 1 --- --- --- --- ---

61816063 --- 1 --- --- --- ---

61816073 --- --- 1 --- --- ---

61816083 --- --- --- 1 --- ---

61816093 --- --- --- --- 1 ---

61816103 --- --- --- --- --- 1

61816054 1 --- --- --- --- ---

61816064 --- 1 --- --- --- ---

61816074 --- --- 1 --- --- ---

61816084 --- --- --- 2 --- ---

61816094 --- --- --- --- 2 ---

61816104 --- --- --- --- --- 2

70

Item

No.

Description Part No.

805H 806H 807H 808H 809H 810H

Quantity

4. Manifold and Main Burners

4A Main Burner 8231602 8 10 12 15 17 19

Main Burner with Pilot Bracket, Standing Pilot (24V) 8231601 --- 1 1 1 1 1

Main burner with Pilot Bracket, Honeywell EI 8231604 1 1 1 1 1 1

4B

Main Burner with Pilot Bracket, OP

Main burner with Pilot Bracket, EP

4C Manifold

4D Pipe Plug, 1/8 NPT (Included with 4C) --- 1 1 1 1 1 1

Main Burner Orice, #39 (Natural Gas Only * 822603

4E

Main Burner Orice, #53 (LP/Propane Only) * 8226002

4F Hitch Pin Clip 822604 9 11 13 16 18 20

* Main burner orice sizes shown for normal altitude (0-2000 feet). For High Altitude consult factory.

8231603 --- 1 1 1 1 1

82216051 1 --- --- --- --- ---

82216061 --- 1 --- --- --- ---

82216071 --- --- 1 --- --- ---

82216081 --- --- --- 1 --- ---

82216091 --- --- --- --- 1 ---

82216101 --- --- --- --- --- 1

9 11 13 16 18 20

71

Item

No.

Description Part No. Size Quantity

5-1 Gas Train -- Standing Pilot (24V, OP)
24V: USA & Canada, 6 & 7 Section, Natural & LP Gas
OP: USA & Canada, 6 - 10 Section, Natural & LP Gas

Gas Valve, Robertshaw 7000ERHC-S7C, Natural Gas, 1” NPT 81660156

A

Gas Valve, Robertshaw 7000ERHC-LP-S7C, LP Gas, 1” NPT 81660157

Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT 81660235 806H-807H 1

B

Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 808H-810H 1

C Lubricated Manual Shut-Off Valve, Newman-Milliken 200M, 1” NPT 822619

D Hex Bushing, 1” NPT x ¾” NPT 806600501 806H & 807H 1

Nipple, ¾” NPT x 2” Lg. 806600003 806H & 807H USA: 1

E

Nipple, 1” NPT x 2” Lg. 806600004 808H-810H Canada: 2

Street Elbow, 1” NPT x ¾” NPT 806601512 806H - 807H

F

Street Elbow, 1¼” NPT x 1” NPT 806601513 808H - 810H

806H - 810H 1

808H-810H

Canada Only

1

1

72

Item

No.

Description Part No. Quantity

5-2 Gas Train -- Standing Pilot (OP-CSD-1)
OP-CSD-1: USA Only, 8-10 Section, LP Gas Only

A Gas Valve, Robertshaw 7000GVERHC-S7C, LP Gas, 1” NPT 81660271 1

B Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 1

C Lubricated Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT 822615 1

D Leak Test/Shut-off Valve, Conbraco #56-221-01, 1/8” x 1/8” 822679 2

E Pipe Plug, 1/8” 806603594 2

F Hex Bushing, 1/4” x 1/8” 806600520 1

G Nipple, 1” x 2” Long 806600004 2

H Street Elbow, 90° x 1” 806601514 1

J Close Nipple, 1” 806600033 1

K Malleable Coupling, 1-1/4” x 1” 806602502 1

L Wiring Harness, Gas Valve to Solenoid Valve 6136230 1

M Pilot Outlet Plug, Honeywell #394424 8226051 1

73

Item

No.

Description Part No. Size Quantity

5-3 Gas Train -- Intermittent Ignition (EI)
USA: 5 - 10 Section, Natural and LP Gas
Canada: 5 - 10 Section, Natural Gas
5 - 7 Section, LP Gas

Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT 81660151 805H-810H

A

Gas Valve, Robertshaw 7000DERHC-LP, LP Gas, 1” NPT 81660158

B Lubricated Manual Shut-Off Valve, Newman-Milliken 200M, 1” NPT 822619

C Nipple, 1’ NPT x 2” Lg. 806600004

Street Elbow, 1” NPT 806601514 805H-807H

D

Street Elbow, 1¼” NPT x 1” NPT 806601513 808H-810H

USA: 805H-810H

Canada: 805H-807H

808H-810H

Canada Only

1

1

1

74

Item

No.

Description Part No. Size Quantity

5-4 Gas Train -- Intermittent Ignition (EP)
USA & Canada: 6 - 10 Section, Natural Gas Only

A Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 806H-810H 1

Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT 81660235 806H-807H

B

Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 808H-810H

C Lubricated Manual Shut-Off Valve, Newman-Milliken 200M, 1” NPT 822619

D Hex Bushing, 1” NPT x ¾” NPT 806600501 806H & 807H 1

Nipple, ¾” NPT x 2” Lg. 806600003 806H & 807H 1

808H-810H

Canada Only

1

1

E

Nipple, 1” NPT x 2” Lg. 806600004 808H-810H

Street Elbow, 1” NPT x ¾” NPT 806601512 806H & 807H

F

Street Elbow, 1¼” NPT x 1” NPT 806601513 808H-810H

USA: 1

Canada: 2

1

75

Item

No.

Description Part No. Quantity

5-5 Gas Train -- Intermittent Ignition (EP-CSD-1)
USA Only: 8 - 10 Section, Natural Gas Only

A Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 1

B Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 1

C Lubricated Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT 822615 1

D Leak Test/Shut-Off Valve, Conbraco #56-221-01, 1/8” x 1/8” 822679 2

E Pipe Plug, 1/8” 806603594 2

F Hex Bushing, 1/4” x 1/8” 806600520 1

G Nipple, 1” x 2” Long 806600004 2

H Street Elbow, 90° x 1” 806601514 1

J Close Nipple, 1” 806600033 1

K Malleable Coupling, 1-1/4” x 1” 806602502 1

L Wiring Harness, Gas Valve to Solenoid Valve 6136230 1

M Pilot Outlet Plug, Honeywell #394424 8226051 1

76

Item

No.

Description Part No. Size Quantity

5-6 Pilot Assembly and Piping -- Standing Pilot (24V)
USA & Canada: 6 & 7 Section, Natural and LP Gas

Pilot Burner, Honeywell Q314A3687, Natural Gas 8236033

A

B Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead 8236004

C Brass Compression Union, 1/4” OD Tube 8236008 806H & 807H 1

D Regulator, Maxitrol RV12LT, Natural Gas 8226005

E Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630

Canada: 806H & 807H

Natural Gas Only

Canada: 806H & 807H

Natural Gas Only

All 1Pilot Burner, Honeywell Q314A3828, LP Gas 8236034

1

2

77

Item

No.

Description Part No. Size Quantity

5-7 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) USA
5 - 10 Section, Natural and LP Gas

Pilot Burner, Honeywell Q348A1002, Natural Gas 8236072U

A

1Pilot Burner, Honeywell Q348A1010, LP Gas 8236081

B Igniter/Sensor Cable, 36” Lg., Honeywell 394803-2 8236121

C Ground Wire Assembly 6136054 1

D Brass Compression Union, 1/4” OD Tube 8236008 1

805H-810H

78

Item

No.

Description Part No. Size Quantity

5-8 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) Canada
5 - 10 Section, Natural Gas
5 - 7 Section, LP Gas

Pilot Burner, Honeywell Q348A1002, Natural Gas 8236072U 805H-810H

A

Pilot Burner, Honeywell Q348A1010, LP Gas 8236081 805H-807H

B Igniter/Sensor Cable, 36” Lg., Honeywell 394800-36 8236084

C Ground Wire Assembly 6136054

D Brass Compression Union, 1/4” OD Tube 8236008 805H-807H 1

E Shut-Off Valve, Essex P2L 822645

G Pipe Plug, 1/8” NPT, Sq. Head 806603508

805H-807H Natural Gas 2

H Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630

J Solenoid Gas Valve, Johnson H91WG-6 822666

L Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg. 8136019

M Conduit Locknut, 1/2” 8136220 2

N Plastic Insulating Bushing, 1/2” 8136034 1

P Regulator, Maxitrol RV12LT, Natural Gas 8226005

808H-810H Natural Gas 3

805H-807H LP Gas 1

Natural Gas Only

All 1

808H-810H 1F Pipe Tee, 1/8” NPT, Malleable 806601005

All

805H-810H

1

1K Junction Box, 4” Sq. x 1-1/2” Deep 8136259

1

79

Item

No.

Description Part No. Size Quantity

5-9 Pilot Assembly and Piping -- Standing Pilot (OP)
USA & Canada: 6 - 10 Section, Natural and LP Gas

Pilot Burner, Honeywell Q179D1008, Natural Gas 8236025

A

Pilot Burner, Honeywell Q179D1008 w/388146KD Orice, LP Gas 6236039

B Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead 8236004

C Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561

D Rajah Connector, Honeywell 37356 8236021

E Ground Wire Assembly 6136259

F Brass Compression Union, 1/4” OD Tube 8236008

G Regulator, Maxitrol RV12LT, Natural Gas 8226005

H Pipe Tee, 1/8” NPT, Malleable 806601005

K Shut-Off Valve, Essex P2L 822645

L Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630

806H-810H 1

USA: 806H-810H

Canada: 806H & 807H

Canada: 806H-810H

Natural Gas Only

808H-810H

Canada Only

806H & 807H

Natural Gas

808H-810H Natural Gas 3

806H-810H LP Gas 1

1

1

1J Pipe Plug, 1/8” NPT, Sq. Head 806603508

2

80

Item

No.

Description Part No. Size Quantity

5-10 Pilot Assembly and Piping -- Standing Pilot (OP-CSD-1)
USA Only: 8 - 10 Section, LP Gas Only

A Pilot Burner, Honeywell Q179D1008 w/388146KD Orice, LP Gas 6236039

B Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead 8236004 1

C Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1

D Rajah Connector, Honeywell 37356 8236021 1

E Ground Wire Assembly 6136259 1

F Brass Compression Union, 1/4” OD Tube 8236008 1

G Regulator, Maxitrol RV12LT, Natural / LPGas 8226005 1

H Pilot Switch, Johnson L62-GB-3C 80160138 1

J Conbraco Leak Test / Shut-Off Valve, 1/8” x 1/8” 822679 1

K Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630 2

808H-810H

1

81

Item

No.

Description Part No. Size Quantity

5-11 Pilot Assembly and Piping -- Intermittent Ignition (EP)
USA & Canada: 6 - 10 Section, Natural Gas Only

A Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017

B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1

C Rajah Connector, Honeywell 37356 8236021 2

D Ignition Lead, Honeywell R1061012, 3 Ft. Lg. 7136247 1

E Ground Wire Assembly 6136259 1

F Brass Compression Coupling, 1/4” OD Tube 8236008

G Shut-Off Valve, Essex P2L 822645

J Pipe Plug, 1/8” NPT, Sq. Head 806603508

K Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630

L Solenoid Gas Valve, Johnson H91WA-4 822662

M Junction Box, 4” Sq. x 1-1/2” Deep 8136259 1

N Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg. 8136019 1

P Conduit Locknut, 1/2” 8136220 2

Q Plastic Insulating Bushing, 1/2” 8136034 1

R Regulator, Maxitrol RV12LT, Natural / LP Gas 8226005

806H-810H

806H & 807H

USA & Canada

808H-810H

USA Only

808H-810H

Canada Only

806H & 807H

Canada Only

808H-810H

Canada Only

806H-810H

806H-810H

Canada Only

1

1

1H Pipe Tee, 1/8” NPT, Malleable 806601005

2

3

1

1

82

Item

No.

Description Part No. Size Quantity

5-12 Pilot Assembly and Piping -- Intermittent Ignition (EP-CSD-1)
USA Only: 10 Section, Natural Gas Only

A Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017

B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1

C Rajah Connector, Honeywell 37356 8236021 2

D Ignition Lead, Honeywell R1061012, 3 Ft. Lg. 7136247 1

E Ground Wire Assembly 6136259 1

F Brass Compression Coupling, 1/4” OD Tube 8236008 1

G Conbraco Leak Test / Shut-Off Cock, 1/8” x 1/8” 822679 1

H Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630 2

J Solenoid Gas Valve, Johnson H91WA-4 822662 1

K Junction Box, 4” Sq. x 1-1/2” Deep 8136259 1

L Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg. 8136019 1

M Conduit Locknut, 1/2” 8136220 2

N Plastic Insulating Bushing, 1/2” 8136034 1

P Regulator, Maxitrol RV12LT, Natural / LP Gas 8226005 1

808H-810H

1

83

84

Item

No.

Description Part No.

6. Jacket

6 Complete

6A Jacket Top Panel

6B Jacket Top Panel Insulation

6C Jacket Upper Rear Panel

6D Jacket Upper Rear Panel Insulation

6E Jacket Lower Rear Panel

6F Jacket Upper Front Panel

Quantity

805H 806H 807H 808H 809H 810H

60416111 1 --- --- --- --- ---

60416121 --- 1 --- --- --- ---

60416131 ---- --- 1 --- --- ---

60416141 --- --- --- 1 --- ---

60416151 --- --- --- --- 1 ---

60416161 --- --- --- --- --- 1

70416053 1 --- --- --- --- ---

70416063 --- 1 --- --- --- ---

70416073 --- --- 1 --- --- ---

70416083 --- --- --- 1 --- ---

70416093 --- --- --- --- 1 ---

70416103 --- --- --- --- --- 1

72016058 1 --- --- --- --- ---

72016068 --- 1 --- --- --- ---

72016078 --- --- 1 --- --- ---

72016088 --- --- --- 1 --- ---

72016098 --- --- --- --- 1 ---

72016108 --- --- --- --- --- 1

70416056 1 --- --- --- --- ---

70416066 --- 1 --- --- --- ---

70416076 --- --- 1 --- --- ---

70416086 --- --- --- 1 --- ---

70416096 --- --- --- --- 1 ---

70416106 --- --- --- --- --- 1

72016059 1 --- --- --- --- ---

72016069 --- 1 --- --- --- ---

72016079 --- --- 1 --- --- ---

72016089 --- --- --- 1 --- ---

72016099 --- --- --- --- 1 ---

72016109 --- --- --- --- --- 1

60416056 1 --- --- --- --- ---

60416066 --- 1 --- --- --- ---

60416076 --- --- 1 --- --- ---

60416086 --- --- --- 1 --- ---

60416096 --- --- --- --- 1 ---

60416106 --- --- --- --- --- 1

70416051 1 --- --- --- --- ---

70416061 --- 1 --- --- --- ---

70416071 --- --- 1 --- --- ---

70416081 --- --- --- 1 --- ---

70416091 --- --- --- --- 1 ---

70416101 --- --- --- --- --- 1

85

Item

No.

Description Part No.

805H 806H 807H 808H 809H 810H

Quantity

6. Jacket (Continued)

7041605 1 --- --- --- --- ---

7041606 --- 1 --- --- --- ---

6G Jacket Front Removable Panel

6H Jacket Left Side Panel 6041601 1 1 1 1 1 1

6J Jacket Left Side Panel Main Insulation Piece 72016021 1 1 1 1 1 1

6K Jacket Left Side Panel Upper Corner Insulation Piece 72016023 1 1 1 1 1 1

6L Jacket Left Side Panel Lower Corner Insulation Piece 72016022 1 1 1 1 1 1

6M Jacket Right Side Panel 6041602 1 1 1 1 1 1

6N Jacket Right Side Panel Main Insulation Piece 72016011 1 1 1 1 1 1

6P Jacket Right Side Panel Lower Corner Insulation Piece 72016012 1 1 1 1 1 1

6Q Jacket Vestibule Panel

6R Jacket Vestibule Panel Upper Insulation Piece

6S Jacket Vestibule Panel Lower Insulation Piece

6T Jacket Lower Front Tie Bar

7041607 --- --- 1 --- --- ---

7041608 --- --- --- 1 --- ---

7041609 --- --- --- --- 1 ---

7041610 --- --- --- --- --- 1

70416055 1 --- --- --- --- ---

70416065 --- 1 --- --- --- ---

70416075 --- --- 1 --- --- ---

70416085 --- --- --- 1 --- ---

70416095 --- --- --- --- 1 ---

70416105 --- --- --- --- --- 1

72016057 1 --- --- --- --- ---

72016067 --- 1 --- --- --- ---

72016077 --- --- 1 --- --- ---

72016087 --- --- --- 1 --- ---

72016097 --- --- --- --- 1 ---

72016107 --- --- --- --- --- 1

72016056 1 --- --- --- --- ---

72016066 --- 1 --- --- --- ---

72016076 --- --- 1 --- --- ---

72016086 --- --- --- 1 --- ---

72016096 --- --- --- --- 1 ---

72016106 --- --- --- --- --- 1

70416052 1 --- --- --- --- ---

70416062 --- 1 --- --- --- ---

70416072 --- --- 1 --- --- ---

70416082 --- --- --- 1 --- ---

70416092 --- --- --- --- 1 ---

70416102 --- --- --- --- --- 1

86

Item

No.

Description Part No.

805H 806H 807H 808H 809H 810H

Quantity

7. Trim and Miscellaneous Controls

Limit, 140-220°F, Honeywell
L4080D1218 (EI & Standing Pilot);

A

L4080B1212 (EP * OP)

Immersion Well, ¾” NPT x 1½” Insul. Depth 80160426 1 1 1 1 1 1

B Limit, Manual Reset, Honeywell L4006E1133 80160703 1 1 1 1 1 1

B1 Immersion Well, ¾” NPT x 3” Insul. Depth 80160452 1 1 1 1 1 1

C Temperature - Pressure Gauge 100282-01 1 1 1 1 1 1

C1 Nipple, 2 NPT x 10” w/Gauge Tapping 8061601 1 1 1 1 1 1

D Safety Relief Valve, ¾ NPT, 50 psi 81660302 1 1 1 1 1 1

D1 Nipple, ¾ NPT x 3½” 806600038 1 1 1 1 1 1

E Drain Valve, ¾ NPT, Conbraco 35-302-03 806603061 1 1 1 1 1 1

E1 Nipple, ¾ NPT x 3½” 806600038 1 1 1 1 1 1

E2 Coupling, ¾ NPT 806602561 1 1 1 1 1 1

F Blocked Vent Switch Replacement Assembly 6016058 1 1 1 1 1 1

G Flame Roll-out Switch 80160044 1 1 1 1 1 1

G1 Flame Roll-out Switch Mounting Bracket 7181612 1 1 1 1 1 1

H Junction Box 8136010 1 1 1 1 1 1

Control Center, Honeywell R8285D500

J

(Intermittent Circulation builds)

K Transformer, 50VA (Continuous Circulation builds) 80160249 1 1 1 1 1 1

L Ignition Module, Honeywell S8610M3009 100958-01 1 1 1 1 1 1

Vestibule Wiring Harness, Complete with Vent Damper Bypass

M

Plug (EI and Standing Pilot) (Not Depicted)

80160251
80160474

80160155U 1 1 1 1 1 1

81316010 1 1 1 --- --- ---

81316011 --- --- --- 1 1 1

1 1 1 1 1 1

87

Item

No.

Description Part No.

805H 806H 807H 808H 809H 810H

8. Draft Hood and Automatic Vent Damper

8111605 1 --- --- --- --- ---

8111604 --- 1* --- --- --- ---

8111607 --- 1** --- --- --- ---

8111603 --- --- 1* --- --- ---

8A Draft Hood

Automatic Vent Damper, 7”

Efkal RVGP-7 8116324 1 --- --- --- --- ---

Automatic Vent Damper, 8”

Efkal RVGP-8 8116325 --- 1 --- --- --- ---

8B

Automatic Vent Damper, 9”

Efkal RVGP-9 8116326 --- --- 1 1 --- ---

Automatic Vent Damper, 10”

Efkal RVGP-10 8116327 --- --- --- --- 1 1

All components for use in both USA and Canada, unless marked with * for USA Only or ** for Canada Only.

8111608 --- --- 1** --- --- ---

8111602 --- --- --- 1* --- ---

8111608 --- --- --- 1** --- ---

8111601 --- --- --- --- 1* 1*

8111609 --- --- --- --- 1** 1**

Quantity

88

SERVICE RECORD

DATE SERVICE PERFORMED

89

SERVICE RECORD

DATE SERVICE PERFORMED

90

SERVICE RECORD

DATE SERVICE PERFORMED

91

92