Burnham 8B Series, 805B, 806B, 810B, 807B Installation, Operating And Servicing Instructions

SEIRESB8

RELIOBDERIF-SAG

DNAGNITAREPO,NOITALLATSNI

ROFSNOITCURTSNIECIVRES

,reliobnonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF

.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorp

rebmuNledoMrelioBrebmuNlaireSrelioBetaDnoitallatsnI

____-_____8________6

rotcartnoCgnitaeH rebmuNenohP

sserddA

8141602R13-7/03

1

Price - $5.00

IMPORTANT INFORMATION - PLEASE READ THIS PAGE CAREFULLY

NOTE: The equipment shall 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.

This Series 8B Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters:
Approval No. G1-0202-11A.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.

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.

REGNAD

noitautissuodrazahyltnenimminasetacidnI

,htaednitluserlliw,dediovatonfi,hcihw

ytreporplaitnatsbusroyrujnisuoires

.egamad

.egamad

GNINRAW

noitautissuodrazahyllaitnetopasetacidnI

,htaednitluserdluoc,dediovatonfi,hcihw

ytreporplaitnatsbusroyrujnisuoires

.egamad

NOITUAC

noitautissuodrazahyllaitnetopasetacidnI

nitluseryam,dediovatonfi,hcihw

ytreporproyrujnironimroetaredom

ECITON

nosnoitcurtsnilaicepssetacidnI

ecnanetniamro,noitarepo,noitallatsni

otdetalertontubtnatropmierahcihw

.sdrazahyrujnilanosrep

REGNAD

rosihtfoytinicivehtnisdiuqilrosropavelbammalfrehtoroenilosagesuroerotsTONOD

.ecnailpparehtoyna

lacirtceleynahcuotTONOD-ecnailppaynaetarepootyrtTONOD,sropavsagllemsuoyfI

yletomeramorfreilppussagehtllac,yletaidemmI.gnidliubehtnienohpynaesurohctiws

,elbaliavanusireilppusehtfirosnoitcurtsnis'reilppussagehtwolloF.enohpdetacol

.tnemtrapederifehttcatnoc

elbitsubmocrevoetercnoc,teprac,gniroolfelbitsubmocnoreliobsihtllatsniTONOD

rognipipcitsalpsahcuslairetamdetceffataehynarevoetercnocnoron,doowrogniroolf

.dleihsroolfelbitsubmocdellatsniylreporpatuohtiwgniriw

2

GNINRAW

ehtwolloF.ylefasetarepootecivresdnaecnanetniamralugerseriuqerreliobsihT

.launamsihtnideniatnocsnoitcurtsni

ytreporpesuacnacecnanetniamroecivres,noitaretla,tnemtsujda,noitallatsnireporpmI

erofeblaunameritneehtdnatsrednudnadaeR.efilfossolroyrujnilanosrep,egamad

ebtsumecivresdnanoitallatsnI.ecivresro,noitarepopu-trats,noitallatsnignitpmetta

.ycnegaecivresrorellatsnidelliksdna,decneirepxe,elbaegdelwonkaybylnodemrofrep

.detnevylreporpebtsumreliobsihT

snoisivorperaerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenreliobsihT

.rianoitalitnevdnanoitsubmocetauqedarof

ehtfotratsehterofebdenaelcdnadetcepsniebtsummetsysgnitnevehtforoiretniehT
rofnosaesgnitaehehttuohguorhtyllacidoirepdetcepsniebdluohsdnanosaesgnitaeh

suoixonwollaotyrassecensimetsystnevdetcurtsbonudnanaelcA.snoitcurtsboyna

drawotetubirtnoclliwdnaylefastnevotefilfossolroyrujniesuacdluoctahtsemuf

.ycneiciffes'reliobehtgniniatniam

gnippatehtotnidellatsnisievlavfeilererusserpasselnuetelpmoctonsinoitallatsnI

roflaunamsihtfonoitceSmirTdnagnipiPretaWehteeS-reliobfopotehtnodetacol

.sliated

dnanwodtuhsotreliobehtesuacyamhcihwsecivedytefashtiwdeilppussireliobsihT

gnitaeheht,ytilibissopasisepipnezorfoteudegamadfI.ecivrestuohtiwtrats-erton

dnasdraugefasetairporpparo;rehtaewdlocnidednettanutfelebtondluohsmetsys

sireliobehtfiegamadtneverpotmetsysgnitaehehtnodellatsniebdluohssmrala

.evitareponi

sgnittifepipynawercsnutonoD.erusserphgihrednuretawtohyrevsniatnocreliobsihT

ehtgnirussaylevitisoptuohtiwreliobsihtfostnenopmocynatcennocsidottpmettaron

nehwtnempiuqednagnihtolcevitcetorpraewsyawlA.erusserponsahdnaloocsiretaw

ehtnoylertonoD.seirujnidlacstneverpotreliobsihtgnicivresropugnitrats,gnillatsni

.reliobehtfoerusserpdnaerutarepmetehtenimretedotseguagerutarepmetdnaerusserp

oD.gnitareposireliobehtnehwtohyrevemocebhcihwstnenopmocsniatnocreliobsihT

.loocerayehtsselnustnenopmocynahcuotton

,animulaniatnocleufehtdnanoitsubmocfostcudorp,noitcurtsnocfoslairetamrelioB

rocixotrehtoro/dnasedyhedla,sedixonegortin,edixonomnobrac,slatemyvaeh,acilis

ehtotnwonkerahcihwdnayrujnisuoiresrohtaedesuacnachcihwsecnatsbuslufmrah

esusyawlA.mrahevitcudorperrehtodnastcefedhtrib,recnacesuacotainrofilaCfoetats

ehtybraengnikrowrognicivresnehwtnempiuqednasrotaripser,gnihtolcytefasreporp

.ecnailppa

.htaedroyrujnilanosrepesuacnacredroreporpehtnisnoitcurtsnillawollofoteruliaF

slaunamsrerutcafunamtnenopmocnideniatnocesohtllagnidulcni,snoitcurtsnilladaeR

rogniniatniam,gnitarepo,pugnitrats,gnillatsnierofebreliobehthtiwdedivorperahcihw

.gnicivres

elbammalfrehtodnaenilosag,slairetamelbitsubmocmorfeerfdnaraelcaerareliobpeeK

.sdiuqilrosropav

.retawottcejbusneebsahhcihwlortnochtiwreliobetarepotonoD

.semitllataecalpniebtsumsdraugdnaserusolcne,setalprevocllA

ECITON

.launamsihtfokcabehtnodetnirpsihcihwfoypoca,ytnarrawdetimilasahreliobsihT

yltcerroceraslortnocllatahteesotrotcartnocgnillatsniehtfoytilibisnopserehtsitI

.etelpmocsinoitallatsniehtnehwylreporpgnitarepoeradnadellatsni

evahlevelaesevobateef000,2nahtretaergsedutitlatanoitallatsniroftliubsreliobASU

replevelaesevobateef000,1reptnecrep4etartupnisagecuderotdecifiroyllaicepsneeb

naidanaC.FxidneppAdna2.1.8noitceS,1.322ZISNA/45APFN,edoCsaGleuFlanoitaNeht

.lebalgnitarehtnodetacidnisignizisecifiro'sreliob

3

Table of Contents

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

II. Boiler Assembly ................................................ 8

III. Gas Control System Assembly ....................... 15

(Knockdown Boilers)

IV. Water Trim and Piping .................................... 27

V. Gas Piping ....................................................... 31

VI. Venting ............................................................33

VII. Electrical .......................................................... 36

VIII. System Start-up ............................................... 59

IX. Service ............................................................. 68

X. Repair Parts ..................................................... 75

4

Table 1: Dimensional Data

Figure 1: Dimensional Data

relioB

ledoM

ABC

.oN

B50802017 61/31-4261/31-428/1-618/1-61.tf51x.aid"79.11096
B6084/3-328/7-118 61/31-724/3-528161.tf51x.aid"89.31077
B7082/1-724/3-319 61/31-824/3-528161.tf51x.aid"99.51578
B8084/1-138/5-519 61/31-0361/11-620261.tf51x.aid"99.71089
B908532/1-71012/1-3361/7-622251.tf51x.aid"019.910801
B0184/3-838/3-91012/1-3361/7-622251.tf51x.aid"019.120021

)1(

.)"4/1-73silenap
)2(
)3(
)4(

)sehcnI(snoisnemiD

DE

ASUadanaCASUadanaC

TPN1:ezisnoitcennocsaG

)ylnOretaW(isp05:erusserPgnikroWelbawollAmumixaM

.rellatsniybdeilppussenilneddihninwohssmetI

5

dednemmoceR

eziSyenmihC

)dnuoR(

retaW

tnetnoC

)snollaG(

.xorppA
gnippihS

thgieW

)BL(

pottekcajotroolf(thgiehreliobot"4/3-4sdda;gniroolfelbitsubmocnosnoitallatsnirofderiuqeresablaicepS

I. Pre-Installation

GNINRAW

erofebsnoitcurtsnilladaerylluferaC

llawollofoteruliaF.reliobgnillatsni

esuacnacredroreporpnisnoitcurtsni

.htaedroyrujnilanosrep

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 filed
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/CGA B149 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, 805B-807B: listed for Alcove installation

a. Front: 18"
b. Top: 36"
c. Draft hood, rear, sides and flue connector: 6"

2. USA, 808B-810B: 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 flue connector: 6"

3. Canada, 805B-810B:
a. Top and front: 18" (45.7cm)
b. Flue, rear and sides: 6" (15.2cm)

D. Provide clearance for servicing and proper operation

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

1. Single boiler, 805B-807B, Front/Top: 24" (61cm)

2. Single boiler, 808B-810B, Front/Top: 48" (122cm)

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

E. Install boiler on level floor as close to chimney as

possible. For basement installation provide a solid base
such as concrete or masonry construction if floor is not
level or if water may be encountered on floor around
boiler.

F. Protect gas ignition system components from water

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

GNINRAW

noitallatsnirofdeifitrecngisedsiecnailppA

roF.ylnogniroolfelbitsubmocnonno

ylnogniroolfelbitsubmocnonoitallatsni

elbaTnidetsilesablaicepsnodellatsninehw
.gnitepracnodellatsniebtontsumrelioB.2
sihcihwetercnocnodellatsnisireliobnehW

gnitlemottcejbussitahtlairetamarevo

laicepseht,).cte,gnibuttnaidarXEP,CVP(

tonsidapetercnocA.desuebtsumesab

.gniroolfelbitsubmoctcetorpottneiciffus

Table 2: Special Base Required for Installation on

Combustible Flooring

.oNledoMrelioBrebmuNtraPesaBlaicepS

B50855061816
B60856061816
B70857061816
B80858061816
B90859061816
B01850161816

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, Section 5.3, Air for Combustion and
Ventilation; or CAN/CGA B149 Installation Codes,
Part 5, Venting Systems and Air Supply for
Appliances.

GNINRAW

rianoitalitnevdnanoitsubmocetauqedA

reporperussaotdedivorpebtsum

.noitsubmoc

The following guideline is based on the National Fuel
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.

6

a. If result is greater than or equal to 50 ft³ per 1,000

Btuh, space is considered an unconfined space.

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

considered a confined 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 floors, between wall-ceiling joints, between
wall panels, at plumbing and electrical
penetrations, and at other openings.

5. For boiler located in an unconfined space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air infiltration through cracks
around windows and doors.

6. For boiler located in an unconfined space in a

building of unusually tight construction or in a
confined 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" (7.6cm).

a. Two permanent openings: Locate one opening

within 12 " (30.5cm) of top of space. Locate
remaining opening within 12" (30.5cm) of bottom
of space. Size each 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
confined space.

Alternate method for boiler located within confined
space. Use indoor air if two permanent openings

communicate directly with additional space(s) of
sufficient volume such that combined volume of all
spaces meet criteria for unconfined 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
fixed 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 flue
gases.

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" (2.5cm)
from the sides and rear and 6" (15.2cm) from the
front. Locate the opening within 12 " (30.5cm) of
top of space. Size opening per following:

GNINRAW

rehtoroenilosagerehwreliobllatsnitonoD

fosecruosro,sdiuqilrosropavelbammalf

,srenaelc,sehcaelb.e.i(snobracordyh

cirbaf,srevomertniap,syarps,slacimehc

.derotsrodesuera).cte,srenetfos

ECITON

ehtotdragerhtiwreliobehtfognizis-siM

evissecxenitluserlliwdaolmetsysgnitaeh

tnenopmocdetareleccadnagnilcycreliob

tnarrawTONSEODmahnruB.eruliaf

reliobdezis-simybdesuacseruliaf

otreliobehtezisrevoTONOD.snoitacilppa

yltaergsreliobelpitlum/raludoM.metsyseht

.gnizisrevoreliobfodoohilekilehtecuder

7

II. Boiler Assembly

A. Remove Crate (Semi-Pak and Packaged Only)

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
floor behind skid.

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

Figure 2: Skid Removal

Table 3: Purpose of Tappings

gnippaTeziSesopruP

A"2ylppuS
B"2nruteR
C"¾evlaVfeileR
D"¾timiL
E"¾timiLyrailixuA
F"¾tuohsaW
G"¾niarD

Figure 3: Tapping Locations

8

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.

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 fill valve and piping to Drain Tapping G.

GNINRAW

.reliobtsetkaelotriaesutonoD

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 fill valve and piping, purge
valve and piping, and pressure gauge.

E. Install special base if installation is on combustible

flooring. See Figure 4. Floor shield adds 4¾" to boiler
height.

1. Place special base on combustible floor 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 805B - 807B may be enclosed

Figure 4: Installation of Special Base for Combustible Flooring

9

Figure 5: General Assembly (Knockdown Boilers)

on three sides (alcove) while maintaining
clearances shown in Figure 4.

F. Move boiler to permanent location by sliding or

walking. DO NOT DROP.

For Packaged Boiler proceed to Section IV: Trim and
Piping.

G. 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.

H. Inspect joints between sections. They were factory

sealed. If any openings resulted during shipment or
handling, reseal with furnace cement. Confirm tie rods
are only hand tight to allow for thermal expansion.

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

hardware located in Combination Boiler Parts and
Control Carton.

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

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

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

J. 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 Orifice, and secured with hitch pin clip.

K. 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.

10

Figure 6: Flame Roll-out Switch Installation

Figure 7: Burner/Burner Access Panel Installation

11

1. Cut insulation from semicircular notch at right end of
the burner access panel. Models 808B - 810B 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.

L. 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 6.

M. 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.

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

O. 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).

P. 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.

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

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

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

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

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

Gas Control System Assembly (Knockdown Boilers).

S. 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. EP Only: 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 Amplifier.

5. Install heat shield.

12

Figure 8: Jacket Assembly

13

Figure 9: EP/OP Control Installation

14

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 liquefied 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 liquefied petroleum gas.

2. Install pilot burner piping and controls.

a. Honeywell EI

i. USA - See Figure 12.

ii. Canada - See Figure 13.

b. Johnson EI

i. USA - See Figure 14.

ii. Canada - See Figure 15.

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 Johnson Ignition Module to Mounting

Bracket using two (2) #6 x ¾" sheet metal screws
or 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 16. Use thread (joint) compound (pipe dope)
resistant to action of liquefied petroleum gas.

2. Install pilot burner piping and controls. See Figure

16.

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 17. Use thread (joint) compound (pipe dope)
resistant to action of liquefied petroleum gas.

2. Mount pilot switch.

3. Install pilot burner piping and controls. See Figure

17.

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 18.

2. Install pilot burner piping and controls. See Figure

18.

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.

15

b. Attach transformer/control center to junction

box.

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

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 19.

2. Install pilot burner piping and controls. See Figure

19.

3. Install Ignition Transformer.

a. Attach Ignition Transformer to Jacket Vestibule

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, 806B & 807B

17

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

18

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

19

Figure 13: Schematic Pilot Piping (Honeywell EI)

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

20

Figure 14: Schematic Pilot Piping (Johnson EI), USA

21

Figure 15: Schematic Pilot Piping (Johnson EI)

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

22

Figure 16: Schematic Gas Piping, OP Control System, 806B - 810B

23

Figure 17: Schematic Gas Piping, OP-CSD-1 Control System, 808B - 810B

24

Figure 18: Schematic Gas Piping, EP Control System (Natural Gas Only), 806B - 810B

25

Figure 19: Schematic Gas Piping, EP-CSD-1 Control System, 808B - 810B

26

IV. Water Trim and Piping

.erutcurts

.retawfonoitidda

GNINRAW

roreliobotegamaddnanoitareporeporpminitluseryamreliobepipylreporpoteruliaF

reliobleetsdnanorifonoisorrocesuaclliwretawreliobfonoitanimatnocnegyxO

smelborprevoctonseodytnarraWs'mahnruB.eruliafreliobotdaelnacdna,stnenopmoc

tneuqerfybdesuacpu-dliub)emil(elacsroretawreliobfonoitanimatnocnegyxoybdesuac

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 fittings.

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 fittings 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 system to obtain a 20°F temperature rise through

the boiler (see Table 4). If a temperature rise greater
than 40°F is desired, consult Burnham.

C. Install Safety Relief Valve. See Figure 20. 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.

GNINRAW

.tnemegnarragnipip

Table 4: Flow Rate, Temperature Rise, and

Pressure Drop

RELIOB

EZIS

B508

B608

B708

B808

B908

B018

WOLF

ETAR

)MPG(

12
41
01

62
71
31

13
12
51

73
42
81

24
82
12

74
13
32

.PMET

ESIR

URHT

RELIOB

F°02
F°03
F°04

F°02
F°03
F°04

F°02
F°03
F°04

F°02
F°03
F°04

F°02
F°03
F°04

F°02
F°03
F°04

.NIM

RELIOB

GNIPIP

)TPN(

"½1
"¼1
"¼1

"½1
"½1
"¼1

"2

"½1
"¼1

"2

"½1
"½1

"2
"2

"½1

"2
"2

"½1

tsumgnipipegrahcsidevlavfeilererusserP

erevesfolaitnetopehttahthcusdepipeb

ynaniepipTONOD.detanimilesisnrub

TONOD.ruccodluocgnizeerferehwaera

.spacrosgulp,sevlavffotuhsynallatsni

egrahcsidreporprofsedoClacoLtlusnoC

RELIOB

ERUSSERP

PORD

'3
'2
'1

'3
'2
'1

'3
'2
'1

'3
'2
'1

'3
'2
'1

'3
'2
'1

27

Figure 20: Safety Relief Valve Installation

Figure 21: Drain Piping Installation

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 23.

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

"A". See Figure 3.

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 25. 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 24. Also consult I=B=R
Installation and Piping Guides.

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
flow control valves to prevent gravity circulation of
boiler water during cooling system operation.

3. Use boiler bypass if boiler is operated in system
which has a large volume or excessive radiation
where low boiler water temperatures may be
encountered (i.e. converted gravity circulation
system, etc.). See Figure 25.

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

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

"G". See Figure 21. 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 22.

a. Install 2" NPT x 10" lg. nipple with gauge tapping

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

5. A start-up strainer is recommended for practically all
modular 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 Water Heater (if used). Refer to Alliance

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

28

Figure 22: Temperature-Pressure Gauge

Installation

Figure 23: Alternate Temperature-Pressure

Gauge Installation

Figure 24: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

29

Figure 25: Recommended Boiler Piping for Circulator Zoned Heating Systems

30

V. Gas Piping

GNINRAW

.daoldetcennoc

.reilppussagtlusnoC.dedeeneb

Size gas Piping. Design system to provide adequate

A.

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 fittings. Refer to
Table 6 for maximum capacity of Schedule 40 pipe.
Table 7 lists equivalent length for standard fittings.

4. Specific gravity of gas. Gas piping systems for gas
with a specific gravity of 0.70 or less can be sized

otylppussagepipylreporpoteruliaF

dnanoitareporeporpminitluseryamreliob

syawlA.erutcurtsroreliobehtotegamad

eerfkaelyletulosbasignipipsagerussa

ehtrofepytdnaezisreporpehtfodna

yamrotalugererusserpsaglanoitiddanA

directly from Table 6, unless authority having
jurisdiction specifies a gravity factor be applied. For
specific gravity greater than 0.70, apply gravity
factor from Table 8. If exact specific 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/CGA B149 Installation
Codes, or size system using standard engineering
methods acceptable to authority having jurisdiction.

B. Connect boiler gas valve to gas supply system.

GNINRAW

nosdnuopmocdaerhtreporpesuoteruliaF

foskaelnitluseryamsrotcennocsaglla

.sagelbammalf

GNINRAW

ebtsummetsysdnareliobotylppussaG

rognillatsniotroirpffotuhsyletulosba

.gnipipsagreliobgnicivres

Table 5: Rated Input

relioB

ledoM

rebmuN

B5084625.5011
B6080332311
B7086935.8511
B80826457.4811
B90882552.1121
B0184955.7321

larutaNenaporP/PL

1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow the National

yticapaCdetaR

]ruohrepteefcibuc[

saG

noitcennoC

eziS

Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or CAN/
CGA B149 Installation Codes.

2. Use thread (joint) compound (pipe dope) resistant to
action of liquefied petroleum gas.

3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas valve and
outside jacket. See Figure 26.

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.

ECITON

neebevahlevelaesevobateef000,2nahtretaergsedutitlatanoitallatsniroftliubsreliobASU

ehtreplevelaesevobateef000,1reptnecrep4etartupnisagecuderotdecifiroyllaiceps

'sreliobnaidanaC.FxidneppAdna2.1.8noitceS,1.322ZISNA/45APFN,edoCsaGleuFlanoitaN

ehtybelbaifitnedierasledomreliobedutitlahgiH.lebalgnitarehtnodetacidnisignizisecifiro

)'0005-'0002=5,'0054-'0002=4(.lebalgnitarehtnotigidhtnins'rebmunledom

31

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

htgneL

]teeF[

01231872025050,1571063086004,1
0229091053037021052564059
033725158209579002573077
043603154200528071023066
056551151204437151582085
060550159100466831062035
07646908107316521042094
08340907105375811022064
09044806102335011502034

001839705150305301591004

Table 7: Equivalent Lengths of Standard Pipe Fittings & Valves

½¾ 1 ¼1½¾1¼1

porDerusserP.c.whcni3.0porDerusserP.c.whcni5.0

)nepOylluF(sevlaVsgnittiFdedaerhT

epiP

eziS

.D.I

sehcnIetaGebolGelgnA

gniwS

kcehC

°09

woblE

°54

woblE

wolF,eeT°09

nuRhguorhT

wolF,eeT°09

hcnarBhguorhT

"½226.053.06.813.93.46.187.00.11.3
"¾428.044.01.325.113.51.279.04.11.4
"1940.165.04.927.418.66.232.18.13.5

"¼1083.147.06.833.919.85.36.13.29.6

Table 8: Specific Gravity Correction Factors

cificepS

ytivarG

05.001.103.170.1

55.040.104.140.1

06.000.105.100.1

56.069.006.179.0

07.039.007.149.0

57.009.0

08.078.0

noitcerroC

rotcaF

cificepS

ytivarG

noitcerroC

rotcaF

.ecruosnoitingirehtoro

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 nonflammable
solution.

Figure 26: Recommended Gas Piping

32

GNINRAW

,semalfnepo,seldnac,sehctamesutonoD

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/CGA B149
Installation Codes, Part 5, Venting Systems and Air
Supply for Appliances. Install any of the following for
this Series 8B 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
flue 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 efficiency.

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 fireplaces.

top of boiler. On Knocked Down boilers, the assembly is
located in Combination Boiler Parts and Control Carton.

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 27.

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 27.

GNINRAW

tneVdekcolBtuohtiwreliobetarepotonoD

.dellatsniylreporphctiwS

REGNAD

gnillatsnierofebyenmihcgnitsixetcepsnI

detarofrepecalperronaelcoteruliaF.reliob

.htaed

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.

GNINRAW

ynaecalprodoohtfardreliobretlatonoD

ehtnirepmaddevorppa-nonronoitcurtsbo

egallipssageulF.metsystnevrognihceerb

lliwnoitareporeliobefasnU.rucconac

.rucco

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

royrujnierevesesuaclliwgninilelitroepip

Figure 27: Blocked Vent Switch Installation

33

E. Boiler Equipped With Vent Damper. See Figure 28.

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

NOITUAC

owtlortnocotrepmadtnevenoesutonoD

.secnailppagnitaeheromro

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
modification to either (Refer to instructions packed
with vent damper for specific instructions). Vent
damper position indicator to be visible to users.

NOITUAC

-gnicivresrofecnaraelcetauqedaedivorP
neewtebecnaraelcmuminim"6edivorp
.noitcurtsnocelbitsubmocdnarepmad

F. Install Vent Connector from draft hood or vent damper

to chimney. See Figure 29. For modular or multiple
boiler installations, review "Multiple-Modular Manual
for Series 8B Gas Boilers", P/N 8141615.

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

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 flush with inside of
flue 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.

Figure 28: Vent Damper Installation

34

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.

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

GNINRAW

nommoceht,metsysgnitnevnommoc

.tiotdetcennoc

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
deficiencies 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
fireplace 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

amorfdevomersireliobgnitsixenanehW

rofegralootebotylekilsimetsysgnitnev

gniniamersecnailppaehtfognitnevreporp

5 minutes of main burner operation. Use the flame 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, fireplace
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 29: Typical Vent System

35

VII. Electrical

.mrah

REGNAD

ecivresronoitallatsnignitpmettaerofebderewopnuerasnoitcennoclacirtcelellaerussaylevitisoP
sexoblacirtcelellatuokcoL.gnidliubroreliobehtfosnoitcennocrostnenopmoclacirtcelefo

.ffodenrutsirewopecnokcoldaphtiw

GNINRAW

lacisyhpsuoiresnitluseryamreliobehtotsnoitcennoclacirtceleeriwylreporpoteruliaF

erofebffosirewopllaerusekaM.ecruosenonahterommorfebyamrewoplacirtcelE

.krowlacirtceleynagnitpmetta

.tcennocsiddesufdezisylreporpahtiwdetcetorpebtsumreliobhcaE

.slortnocgnitareporoytefasynaevitareponiekamrotuopmujreveN

reliobhcaE.ylnosesoprupecnereferroferalaunamsihtnideniatnocsmargaidgniriwehT

ehtdnamargaidsihtotrefeR.roodtnorfehtotdehcattamargaidgniriwahtiwdeppihssi

gniriwllawollofdnadnatsrednu,daeR.reliobehthtiwdesuslortnocynafomargaidgniriw

.slortnocehthtiwdeilppussnoitcurtsni

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 805, optional

on 806-810). See Figure 28.

1. Attach Vent Damper Harness to mounting hole in
Jacket Left Side Panel. Install Cable Clamp around
flexible 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 28.

C. Install thermostat. Locate on inside wall approximately

4 feet above floor. Do not install on outside wall, near
fireplace, or where influenced by drafts or restricted air
flow, hot or cold pipes, lighting fixtures, 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 30: Vent Damper Schematic Wiring Diagram

36

E. Alliance Water Heater (if used). May be used with

Intermittent Circulation only.

Refer to Alliance Installation, Operating and
Service Instructions for wiring, piping and
additional information.

F. Vent Damper Sequence of Operation. See Figure 30 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 satisfied.

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 satisfied, 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

metsySlortnoC

toliPgnidnatSV421.13.0

)IE(noitingIcinortcelEV42

* ybgnittesrotapicitnataehecuder,gnitteserutarepmettatsomrehtevobadetaehsimoorfI

gnitteSrotapicitnAtaeH *

noitalucriCsuounitnoCnoitalucriCtnettimretnI

9.0:ASU

3.0

2.1:adanaC

esaercni,erutarepmetderisedgnihcaermoortuohtiwseclyctrohsreliobfI.spma2.0ro1.0

.spma2.0ro1.0ybgnittesrotapicitnataeh

37

Table 10: Sequence of Operation and Wiring Diagrams

metsySnoitingIyrtnuoCleuFseziSrelioB

)V42(toliPgnidnatS

toliPgnidnatS

)V021--PO(

toliPgnidnatS

)V021--1-DSC-PO(

noitingItnettimretnI

)V42--IEllewyenoH(

noitingItnettimretnI
)V42--IEnosnhoJ(

noitingItnettimretnI

)V021--PE(

&ASU

adanaC

&ASU

adanaC

ASUsaGPL.tceS01-833erugiF43erugiF14egaP

ASU

adanaC

ASU

adanaC

&ASU

adanaC

saGlarutaN

saGPL

saGlarutaN

saGPL

saGlarutaN

saGPL

saGlarutaN.tceS01-5

saGPL.tceS7-5

saGlarutaN

saGPL

saGlarutaN.tceS01-5

saGPL.tceS7-5

saGlarutaN.tceS01-634erugiF44erugiF45egaP

saGPLelbaliavAtoN

erugiFmargaiDgniriW

suounitnoCtnettimretnI

.tceS7&613erugiF23erugiF83egaP

.tceS01-633erugiF43erugiF14egaP

.tceS01-553erugiF63erugiF

73erugiF83erugiF

.tceS01-593erugiF04erugiF

14erugiF24erugiF

foecneuqeS

noitarepO

44egaP

94egaP

noitingItnettimretnI

)V021--1-DSC-PE(

ASUsaGlarutaN.tceS01-834erugiF44erugiF45egaP

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

flow and ignition of main burners.

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

energized, extinguishing main flame. 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 flue 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
flames 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
flame roll-out switch is activated, do not
attempt to place boiler in operation. Correct
cause of spillage and replace flame roll-out
switch.

iv. Thermocouple: Senses pilot flame and

causes gas valves to turn off main burner
and pilot burner gas flow should pilot burner
flame extinguish. Circulator continues to
operate and Vent Damper (if used) remains
open with call for heat.

38

Figure 31: Wiring Diagram, Standing Pilot (24), USA and Canada, Continuous Circulation

39

Figure 32: Wiring Diagram, Standing Pilot (24V), USA and Canada, Intermittent Circulation

40

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 flame is proven, terminal #9 of

RM7890C is energized, allowing main gas
flow 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 de-energizing gas
valves and extinguishing main flame.
"Main" gas light is de-energized.

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 flame is proven, terminal #9 of

RM7890C is energized, allowing main gas
flow 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 de-energizing gas
valves and extinguishing main flame.
"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 flue 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
flames or excessive heat are present in
vestibule. Circulator continues to operate
with call for heat. Control is single use
device. If flame roll-out switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and replace flame
roll-out switch.

iv. RM7890C Burner Control: Automatically

interrupts main burner operation if a pilot
flame is not detected during the four or ten
second pilot flame 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.

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 flue 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
flames or excessive heat are present in
vestibule. Circulator continues to operate
with call for heat. Control is single use
device. If flame roll-out switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and replace flame
roll-out switch.

iv. RM7890C Burner Control: Automatically

interrupts main burner operation if a pilot
flame is not detected during the four or ten
second pilot flame 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 flame is not detected at
any time.

41

Figure 33: Wiring Diagram, OP/OP-CSD-1 Ignition System, Continuous Circulation

42

Figure 34: Wiring Diagram, OP/OP-CSD-1 Ignition System, Intermittent Circulation

43

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
flow, and ignition of Main Burners.

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

energized, de-energizing gas valve, and
extinguishing pilot and main flame. 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 flame, 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 flue 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
flames 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 flame roll-out switch is activated, do not
attempt to place boiler in operation.
Correct cause of spillage and replace flame
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 flame 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
flame. If no pilot flame can be sensed by
the flame 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 71.

44

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

45

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

46

Figure 37: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation

47

Figure 38: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation

48

5. Johnson EI Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat. Vent Damper (if used) opens.

ii. Ignition Module Terminals 1, GND and the

Ignition Terminal are energized. Terminals 1
and GND power the Pilot Valve in the Gas
Valve supplying as 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 J991 Pilot

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

iv. Terminals 3 and GND of the IGNITION

MODULE are energized and supply power to
the Main Gas Valve. The Gas Valve is
energized allowing main gas flow, and
ignition of Main Burners.

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

energized, de-energizing gas valve, and
extinguishing pilot and main flame. 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 flame, 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 flue gas spillage occurs. Circulator
continues to operate, 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
flames 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
flame roll-out switch is activated, do not
attempt to place boiler in operation. Correct
cause of spillage and replace flame 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 J991 Electronic Pilot, after
ignition of pilot flame will close the main gas
valve.

– For approximately 90 seconds after failure
of the J991 pilot, the module through the
ignition terminal will try to reestablish pilot
flame. If no pilot flame can be sensed by the
flame rod circuit, terminals 1 and GND are de­energized 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 Pages 72 and 73.

49

Figure 39: Wiring Diagram, Johnson EI, USA, Continuous Circulation

50

Figure 40: Wiring Diagram, Johnson EI, USA, Intermittent Circulation

51

Figure 41: Wiring diagram, Johnson EI, Canada, Continuous Circulation

52

Figure 42: Wiring Diagram, Johnson EI, Canada, Intermittent Circulation

53

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 flame is proven, the ignition

terminal (10) is de-energized and the main
valve terminal (9) is energized, allowing main
gas flow 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 flames. "Main" gas light is de­energized.

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 flue 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 flames
or excessive heat are present in vestibule.
Circulator continues to operate with call for
heat. Control is single use device. If flame
roll-out switch is activated, do not attempt to
place boiler in operation. Correct cause of
spillage and replace flame roll-out switch.

iv. RM7890A Burner Control: Automatically

interrupts main burner operation if a pilot
flame is not detected during the four or ten
second pilot flame 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.

54

Figure 43: Wiring Diagram, EP/EP-CSD-1 Ignition System, USA, Continuous Circulation

55

Figure 44: Wiring Diagram, EP/EP-CSD-1 Ignition System, USA, Intermittent Circulation

56

Figure 45: McDonnell & Miller PS-851 (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits

Figure 46: McDonnell & Miller PS-851 (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits (OP & EP)

57

Figure 47: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits

Figure 48: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits

58

VIII. System Start-up

GNINRAW

llawollofdnadnatsrednu,daeryletelpmoC

erofeblaunamsihtnisnoitcurtsni

.putratsgnitpmetta

A. Safe operation and other performance criteria were met

with the gas manifold and control assembly provided
on boiler when boiler underwent tests specified 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 Orifices, 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. Confirm 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 25 to remove air from system when filling.

GNINRAW

sihtfoerusserpgnitarepomumixamehT

.erusserpsihtdeecxereveN.gisp05sireliob

.evlavfeilererusserpyfidomrogulptonoD

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

9. Close purge valve, continue filling the system until
the pressure gauge reads the desired cold fill
pressure. Close fill valve.

(Note - If make-up water line is equipped with
pressure reducing valve, adjust pressure reducing
valve to desired cold fill pressure. Follow fill valve
manufacturer’s instructions).

10. Open isolation valve in boiler supply piping.

11. Remove hose from purge valve.

F. Confirm 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-fired appliances.

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

5. Confirm that the supply pressure to the gas valve is
14 in. w.c. or less.

6. Open the field 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.

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 five gallon
bucket at a suitable floor 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 fill 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 overflow 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.

REGNAD

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.

Table 11: Lighting and Operating Instructions

rognithgiL

metsySnoitingI

toliPgnidnatS

)V42(

IEllewyenoH

IEnosnhoJ65erugiF
PO15erugiF75erugiF
PE25erugiF85erugiF

1-DSC-PO
1-DSC-PE85erugiF

59

gnitarepO

snoitcurtsnI

94erugiF45erugiF

05erugiF

35erugiF

rosemalfnepo,seldnac,sehctamesutonoD

.skaelrofkcehcotecruosnoitingirehto

emalFtoliP

noitartsullI

55erugiF

75erugiF

Figure 49: Lighting Instructions (24V Standing Pilot)

60

Figure 50: Operating Instructions (EI)

61

Figure 51: Lighting Instructions (OP)

62

Figure 52: Operating Instructions (EP)

63

.1tolipdna)s(evlavffo-tuhsniamlaunamesolC

.2.hctiwscirtceleniamffonruT

.1tolipehtdnalaunamniamehthtobtahterusekaM

.2otslortnocgnitarepolladnatatsomrehtmoornruT

.3.)s(lenapsseccarenrubevomeR

SNOITCURTSNIGNITAREPORELIOB

:NWODTUHSOT

.)s(evlav

:PUTRATSOT

.setunimeviftsaeltarofffoneebevah)s(evlav

.gnittestsewol

.4

:ETON

.5dnahctiwsytefastolipgnidnatsnonottubsserpeD

.6.hctiwscirtceleniamnonruT
.7.yalerdraugefasemalfnohctiwsytefasteseR
.8noitacifitcergninrubtnatsnocthgilyletaidemmI

.a8)s(tolipnoitacifitcernoitingicirtceletnettimretnI

.9.)s(lenapsseccarenrubecalpeR

.)s(evlavtoliplaunamnepO

tolpgnidnatshtiwsreliobotylnoseilppa)5(metI

.)se(hctiwsytefas

tarofninottubgnidloh,tolipothctamdethgildloh

retfadethgilsniamertoliplitnuroetunimenotsael

gnidnatsgniniamerroftaepeR.desaelersinottub

.stolip

tonsitolipfI.hctamdethgilahtiwD971Q)s(tolip
.detaeperebtsum)7(petS,sdnoces51nidethgil
retfagninepo,citamotuaera)s(evlavtolipcirtcelE

.)metsyS"PO"(.)7(petS

rotatsomrehtnehwyllacitamotuaputhgilC971Q

.)metsyS"PE"(.taehrofsllaclortnocgnitarepo

.01.)s(evlavff-tuhsniamlaunamnepO

.11otslortnocgnitarepodnatatsomrehtmoortsujdA

Figure 53: Lighting / Operating Instructions (OP/EP-CSD-1)

.gnittesderised

64

Figure 54: Honeywell Q314 Pilot Flame

(24V Standing Pilot)

Figure 57: Honeywell Q179D Pilot Flame (OP)

Figure 55: Honeywell Q348 Pilot Flame

(24V Electronic Ignition)

Figure 56: Johnson J991 Pilot Flame

(24V Electronic Ignition)

Figure 58: Honeywell Q179C Pilot Flame (EP)

I. Check pilot burner flame and main burner flames

through observation port.

1. Check pilot flame. Refer to Table 11 for appropriate
pilot detail.

2. Adjust thermostat to highest setting.

3. Check main burner flames. See Figure 59. Flame
should have clearly defined inner cones with no
yellow tipping. Orange-yellow streaks caused by
dust should not be confused with true yellow
tipping.

65

NOITUAC

tnemnorivnenanireliobsihtgnitarepodiovA

yrd,srebifnoitalusniesool,tsudwaserehw

sireliobfI.tneserpera.cte,tsudllaw

renrubeht,snoitidnocesehtrednudetarepo

dnadenaelcebtsumstropdnaroiretni

.noitareporeporperusniotyliaddetcepsni

Yellow-tipping indicates lack of primary air. Improper
burner alignment on Main Burner Orifice will also
affect primary air injection. Adjust primary air as
follows:

a. Loosen lock screw.

b. Close air adjustment until yellow tips appear on

flames.

Figure 59: Main Burner Flame

c. Slowly open air adjustment until clearly defined

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 Terminal (9) of 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. Johnson EI: Disconnect sensor cable from
Terminal 4 (SENSE). Gas valve must close and
pilot and main burner 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.

4. 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 flow rate in Cubic Feet per
Hour.

4. Determine Input Rate. Multiply gas flow rate by gas
heating value.

GNINRAW

lliwetartupnisagtsujdaylreporpoteruliaF

ehtfognirifrednurognirifrevonitluser

reliobefasnudnareporpmI.ecnailppa

.tluseryamnoitarepo

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

a. Boiler must not be overfired. Reduce input rate

by decreasing manifold pressure. Do not reduce
more than 0.3 inch w.c. If boiler is still
overfired, contact your Burnham distributor or
Regional Office for replacement Gas Orifices.

66

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 orifices. Drill one (1) drill size

larger (drill size is stamped on orifice, or
see Key No. 4E).

iii. Reinstall gas orifices and main burners.

Measure input rate.

6. Recheck Main Burner Flame.

7. Return other gas-fired 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 flushed. A qualified 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 flange (longer of 2 flanges) behind
Upper Front Panel.

2. Swing lower portion of door toward boiler.

3. Lower door to engage bottom flange behind Lower
Front Tie Bar.

Table 12: Input Rate

sdnoceS

enOrof

noituloveR

0306021042006
2365311522365
4335601212925
6305001002005
837459981474
045409081054
243468271034
441428461014
649387751193
847357051573
056327441063
255396831643
453376331333
652346921123
851326421013
060306021003
269285611092
469265211182
669245901372
868235601562
076215301752
275205001052
47428479342
67427459732
87326429132
08225409522

flaH-enO

.tF.uC

enO

.tF.uC

owT

.tF.uC

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 fire 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.

laiDreteMsaGfoeziS

eviF

.tF.uC

67

IX. Service

GNINRAW

amorflennosrepdelliksdnadeniartybylnonekatrednuebdluohsreliobsihtnoecivreS

sihtnideificepsslavretnitademrofrepebdluohssnoitcepsnI.ycnegaecivresdeifilauq

.noitidnocelbigelanilaunamniatniaM.launam

elbammalfrehtodnaenilosag,slairetamelbitsubmocfoeerfdnaraelcaerareliobpeeK

.sdiuqildnasropav

dnanoitsubmocfowolfrednihlliwtahtmoorreliobnisnoitcurtsboynaecalptonoD

.rianoitalitnev

snoitcurtsniehtotnoitiddanieralaunamsihtnideniatnocsnoitcurtsniecivresehT

s'rerutcafunamtnenopmocwolloF.stnenopmocreliobehtforerutcafunamehtybdedivorp

.reliobehthtiwdedivorperewsnoitcurtsnis'rerutcafunamtnenopmoC.snoitcurtsni

,llatsnitonoD.gnissimerasnoitcurtsnifitnemecalperrofrerutcafunamtnenopmoctcatnoC

follagnidnatsrednudnagnidaertuohtiwreliobsihtecivresroniatniam,etarepo,putrats

detcennocsid,deretlahtiwetarepootreliobehtwollatonoD.snoitcurtsnitnenopmoceht

yllanigiroesohtotlacitnedistnenopmoctnemecalperesuylnO.stnenopmocderepmujro

.mahnruBybdeilppus

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.

GNINRAW

nehwnoitcennocsidotroirpseriwllalebaL
esuacnacsrorregniriW.slortnocgnicivres

yfireV.noitareposuoregnaddnareporpmi

.gnicivresretfanoitareporeporp

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 orifice

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 Orifices.

7. Hold Main Burner on throat. Lift slightly to raise rear
of burner. Push to rear of boiler until burner clears
Main Burner Orifice. 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 60.

E. Clean Boiler Flueways.

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. Thoroughly clean flueways with flue brush,
removing all scale and soot. See Figure 60.

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

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

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

68

noitamrofnIytefaStcudorPtnatropmI

tcudorPrebiFcimareCyrotcarfeR

Warning:

This product contains refractory ceramic fibers (RCF). RCF has been classified
as a possible human carcinogen. After this product is fired, RCF may, when
exposed to extremely high temperature (>1800F), change into a known human
carcinogen. When disturbed as a result of servicing or repair, RCF becomes
airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace previously fired RCF (combustion chamber insulation,
target walls, canopy gasket, flue cover gasket, etc.) 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 air tight plastic bag.

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.

69

Figure 60: Boiler Flueway Cleaning

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 Orifices, 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.

Table 13: Pilot Burner Location

B5085&4
B6086&5
B7087&6
B8087&6
B9087&6
B0188&7

.reliobfo

70

.oNledoMrelioB

*srenruB

neewteBdetacoLtoliP

tnorfmorfdeweivsathgirottfelderebmunsrenruB*

Honeywell EI Trouble Shooting Guide

71

Johnson EI Trouble Shooting Guide

72

73

SERVICE RECORD

DATE SERVICE PERFORMED

74

SERVICE RECORD

DATE SERVICE PERFORMED

X. Repair Parts

All Series 8B 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].

75

metI

.oN

noitpircseD.oNtraP

B508B608B708B808B908B018

ytitnauQ

ylbmessAregnahcxEtaeH.1

50617161--------------­6061716---1-----------­7061716------1---------

1etelpmoC

8061716---------1-----­9061716------------1---

0161716---------------1
A1noitceSdnEtfeL1061717 111111
B1noitceSetaidemretnI3061717345678
C1noitceSdnEthgiR2061717 111111

doReiT230168081--------------­doReiT33016808---1------------

D1

E1rehsaW00606808 444444
F1tuN00406808 444444
G1"3,elppiNpilS200660780121416181

doReiT31016808------1--------­doReiT43016808---------1-----­doReiT53016808------------1--­doReiT63016808---------------1

76

metI

.oN

noitpircseD.oNtraP

B508B608B708B808B908B018

ytitnauQ

yponaC.2

50611161-------------------­6061116----1----------------

A2yponaC

B2"1x02-¼,egairraC,tloB51106808 222222
C2talF"¼,rehsaW30606808 222222
D202-"¼,tuN70406808 222222

7061116--------1-----------­8061116------------1-------­9061116----------------1---­0161116--------------------1

77

metI

.oN

noitpircseD.oNtraP

B508B608B708B808B908B018

ytitnauQ

.3ylbmessAesaB

A3lenaPdnEesaB1061817222222

250618162--------------­26061816---2------------

B3ylbmessAlennahCesaB

C3ylbmessAlenaPraeResaB

D3ylbmessAlenaPtnorFesaB

E3ylbmessAlenaPsseccArenruB

F3tekcarBtnemhcattAtekcaJ1061407444444
G3"¼1x02-¼,egairraC,tloB60106808444444
H3talF"¼,rehsaW30606808444444

J302-¼,tuN70406808444444

K3"½x02-¼,gnippaTfleS,wercS00706808344556

27061816------2--------­28061816---------2-----­29061816------------2--­20161816---------------2
150618161--------------­16061816---1-----------­17061816------1--------­18061816---------1-----­19061816------------1--­10161816---------------1
350618161--------------­36061816---1-----------­37061816------1--------­38061816---------1-----­39061816------------1--­30161816---------------1
450618161--------------­46061816---1-----------­47061816------1--------­48061816---------2-----­49061816------------2--­40161816---------------2

L3"¾x81-"61/5,daeHxeH,paC,wercS20316808222222

M3"¼1x81-"61/5,daeHxeH,paC,wercS11316808666666

N3"½x8#,lateMteehS,wercS00006808888888
P3talF"8/3,rehsaW00606808666666
Q381-"61/5,tuN30406808666666
R3"¾x02-¼,gnippaTfleS,wercS20706808010101010101

78

metI

.oN

noitpircseD.oNtraP

B508B608B708B808B908B018

ytitnauQ

.4srenruBniaMdnadlofinaM

A4renruBniaM206132880121517191

gnidnatS,tekcarBtoliPhtiwrenruBniaM

)V42(toliP

IEllewyenoH,tekcarBtoliPhtiwrenruBniaM

B4

PO,tekcarBtoliPhtiwrenruBniaM

PE,tekcarBtoliPhtiwrenruBniaM

C4dlofinaM

D4)C4htiwdedulcnI(TPN8/1,gulPepiP--- 111111
E4

F4pilCniPhctiH40622891131618102

IEnosnhoJ,tekcarBtoliPhtiwrenruBniaM

*)ylnOsaGlarutaN(73#,ecifirOrenruBniaM106228
*)ylnOenaporP/PL(25#,ecifirOrenruBniaM146228

1061328---11111

4061328 111111

3061328---11111

150612281--------------­16061228---1-----------­17061228------1--------­18061228---------1-----­19061228------------1--­10161228---------------1

91131618102

* .yrotcaftlusnocedutitlAhgiHroF.)teef0002-0(edutitlalamronrofnwohssezisecifirorenrubniaM

79

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)PO,V42(toliPgnidnatS--niarTsaG1-5

saGPL&larutaN,noitceS7&6,adanaC&ASU:V42

saGPL&larutaN,noitceS01-6,adanaC&ASU:PO

A

TPN"¾,4201A5928VllewyenoH,evlaVsaGdioneloS 53206618B708-B608

B

TPN"1,2301A5928VllewyenoH,evlaVsaGdioneloS 63206618B018-B808

C TPN"1,M002nekilliM-namweN,evlaVffO-tuhSlaunaMdetacirbuL 916228

DTPN"¾xTPN"1,gnihsuBxeH 105006608B708&B6081

.gL"2xTPN"¾,elppiN 300006608B708&B6081

E

.gL"2xTPN"1,elppiN 400006608B018-B808

TPN"¾xTPN"1,woblEteertS 215106608B708&B608

F

TPN"1xTPN"¼1,woblEteertS 315106608B018-B808

TPN"1,saGlarutaN,C7S-CHRE0007wahstreboR,evlaVsaG 65106618

TPN"1,saGPL,C7S-PL-CHRE0007wahstreboR,evlaVsaG 75106618

B018-B6081

1

B018-B808

ylnOadanaC

1

1:ASU

2:adanaC

1

80

METI

.ON

NOITPIRCSEDREBMUNTRAPYTITNAUQ

)1-DSC-PO(toliPgnidnatS--niarTsaG2-5

ylnOsaGPL,noitceS01,ylnOASU:1-DSC-PO

ATPN"1,saGPL,C7S-CHREVG0007wahstreboR,evlaVsaG 172066181

BTPN"1,2301A5928VllewyenoH,evlaVsaGdioneloS 632066181
CdetacirbuLffO-tuhSlaunaMevlaVTPN"1,20-304-05#oCarBnoC,5162281
D"8/1x"8/1,10-122-65#oCarBnoC,evlaVffo-tuhS/tseTkaeL 9762282

E"8/1,gulPepiP 4953066082

F"8/1x"4/1,gnihsuBxeH 0250066081
GgnoL"2x"1,elppiN 4000066082

H"1x°09,woblEteertS 4151066081

J"1,elppiNesolC 3300066081

K"1x"4/1-1,gnilpuoCelbaellaM 2052066081

LevlaVdioneloSotevlaVsaG,ssenraHgniriW 03263161
M424493#llewyenoH,gulPteltuOtoliP 15062281

81

METI

.ON

NOITPIRCSED

)IE(noitingItnettimretnI-niarTsaG3-5

saGPLdnalarutaN,noitceS01-5:ASU

saGlarutaN,noitceS01-5:adanaC

saGPL,noitceS7-5

TPN"1,saGlarutaN,CHRED0007wahstreboR,evlaVsaG 15106618B018-B508

A

BacirbuLTPN"1,M002nekilliM-namweN,evlaVffO-tuhSlaunaMdet 916228
C.gL"2xTPN"1,elppiN 400006608

TPN"1,saGPL,PL-CHRED0007wahstreboR,evlaVsaG 85106618

TRAP

REBMUN

EZISYTITNAUQ

B018-B508:ASU

B708-B508:adanaC

B018-B808

ylnOadanaC

1

1

D

TPN"1,woblEteertS 415106608B708-B508

1

TPN"1xTPN"¼1,woblEteertS 315106608B018-B808

82

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)PE(noitingItnettimretnI-niarTsaG4-5

ylnOsaGlarutaN,noitceS01-6:adanaC&ASU

A TPN"1,saGlarutaN,C7S-CHREVG0007wahstreboR,evlaVsaG 86106618B018-B6081

B

C TPN"1,M002nekilliM-namweN,evlaVffO-tuhSlaunaMdetacirbuL 916228

DTPN"¾xTPN"1,gnihsuBxeH 105006608B708&B6081

.gL"2xTPN"¾,elppiN 300006608B708&B6081

E

.gL"2xTPN"1,elppiN 400006608B018-B808

TPN"¾xTPN"1,woblEteertS 215106608B708&B608

F

TPN"1xTPN"¼1,woblEteertS 315106608B018-B808

TPN"¾,4201A5928VllewyenoH,evlaVsaGdioneloS 53206618B708-B608

TPN"1,2301A5928VllewyenoH,evlaVsaGdioneloS 63206618B018-B808

1

B018-B808

ylnOadanaC

1

1:ASU

2:adanaC

1

83

METI

.ON

NOITPIRCSEDREBMUNTRAPYTITNAUQ

)1-DSC-PE(noitingItnettimretnI-niarTsaG5-5

ylnOsaGlarutaN,noitceS01-8,ylnOASU

ATPN"1,saG.taN,C7S-CHREVG0007wahstreboR,evlaVsaG 861066181
BTPN"1,2301A5928VllewyenoH,evlaVsaGdioneloS 632066181
CdetacirbuLffO-tuhSlaunaMevlaVTPN"1,20-304-05#oCarBnoC,5162281
D"8/1x"8/1,10-122-65#oCarBnoC,evlaVffo-tuhS/tseTkaeL 9762282
E"8/1,gulPepiP 4953066082
F"8/1x"4/1,gnihsuBxeH 0250066081
GgnoL"2x"1,elppiN 4000066082
H"1x°09,woblEteertS 4151066081

J"1,elppiNesolC 3300066081

K"1x"4/1-1,gnilpuoCelbaellaM 2052066081

LevlaVdioneloSotevlaVsaG,ssenraHgniriW 03263161

M424493#llewyenoH,gulPteltuOtoliP 15062281

84

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)V42(toliPgnidnatS--gnipiPdnaylbmessAtoliP6-5

saGPLdnalarutaN,noitceS7&6:adanaC&ASU

A

BdaeL.gL"63/w6991A903QllewyenoH,elpuocomrehT4006328

CebuTDO"¼,noinUnoisserpmoCssarB8006328B708&B6081

DsaGlarutaN,TL21VRlortixaM,rotalugeR5006228

ETPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB036228

saGlarutaN,7863A413QllewyenoH,renruBtoliP3306328

llA1saGPL,8283A413QllewyenoH,renruBtoliP4306328

B708&B608:adanaC

ylnOsaGlarutaN

B708&B608:adanaC

ylnOsaGlarutaN

1

2

85

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

ASU)IEllewyenoH(noitingItnettimretnI-gnipiPdnaylbmessAtoliP7-5

saGPLdnalarutaN,noitceS01-5

A

B2-308493llewyenoH,.gL"63,elbaCrosneS/retingI 12163281
CylbmessAeriWdnuorG 45063161
DebuTDO"¼,noinUnoisserpmoCssarB 80063281

saGlarutaN,2001A843QllewyenoH,renruBtoliP U2706328

1

saGPL,0101A843QllewyenoH,renruBtoliP 1806328

B018-B508

86

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

adanaC)IEllewyenoH(noitingItnettimretnI--gnipiPdnaylbmessAtoliP8-5

saGlarutaN,noitceS01-5

saGPL,noitceS7-5

A

B63-008493llewyenoH,.gL"63,elbaCrosneS/retingI4806328
CylbmessAeriWdnuorG4506316
DebuTDO"¼,noinUnoisserpmoCssarB8006328B708-B5081
EL2PxessE,evlaVffo-tuhS546228

GdaeH.qS,TPN"8/1,gulPepiP805306608

HTPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB036228

J6-GW19HnosnhoJ,evlaVsaGdioneloS666228

L.gL"½1xTPN"½,elppiNtiudnoCdigiR9106318

M"½,tunkcoLtiudnoC02263182

N"½,gnihsuBgnitalusnIcitsalP43063181

PsaGlarutaN,TL21VRlortixaM,rotalugeR5006228

saGlarutaN,2001A843QllewyenoH,renruBtoliPU2706328B018-B508

saGPL,0101A843QllewyenoH,renruBtoliP1806328B708-B508

1

llA1

B018-B8081FelbaellaM,TPN"8/1,eeTepiP500106608

saGlarutaNB708-B5082
saGlarutaNB018-B8083

saGPLB708-B5081

1KpeeD"½1x.qS"4,xoBnoitcnuJ9526318

llA

B018-B508

ylnOsaGlarutaN

1

87

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

ASU)IEnosnhoJ(noitingItnettimretnI--gnipiPdnaylbmessAtoliP9-5

saGPLdnalarutaN,noitceS01-5

saGlarutaN,5227WYL199JnosnhoJ,renruBtoliP

)daeLnoitingIsedulcnI(

A

saGPL,D0489WYL199JnosnhoJ,renruBtoliP

)daeLnoitingIsedulcnI(
BC-AA57YnosnhoJ,eborPgnisneS 04063281
C63-HA75YnosnhoJ,daeLrosneS 15063281
DylbmessAeriWdnuorG 45063161
EebuTDO"¼,noinUnoisserpmoCssarB 80063281

0506328

1

6806328

B018-B508

88

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

adanaC)IEnosnhoJ(noitingItnettimretnI--gnipiPdnaylbmessAtoliP01-5

saGlarutaN,noitceS01-5

saGPL,noitceS7-5

A

BC-AA57YnosnhoJ,eborPgnisneS 0406328
C63-HA75YnosnhoJ,daeLrosneS 15063281
DylbmessAeriWdnuorG 45063161

EebuTDO"¼,noinUnoisserpmoCssarB 8006328B708-B5081

FL2PxessE,evlaVffo-tuhS 546228
GelbaellaM,TPN"8/1,eeTepiP 5001066081

HdaeH.qS,TPN"8/1,gulPepiP 8053066081

JTPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB 036228

K6-GW19HnosnhoJ,evlaVsaGdioneloS 666228

LpeeD"½1x.qS"4,xoBnoitcnuJ 95263181
M.gL"½1xTPN"½,elppiNtiudnoCdigiR 91063181

N"½,tunkcoLtiudnoC 02263182

P"½,gnihsuBgnitalusnIcitsalP 43063181

QsaGlarutaN,TL21VRlortixaM,rotalugeR 5006228

)daeLnoitingIsedulcnI(

)daeLnoitingIsedulcnI(

saGlarutaN,5227WYL199JnosnhoJ,renruBtoliP

saGPL,D0489WYL199JnosnhoJ,renruBtoliP

0506328B018-B508

6806328B708-B508

1

1

llA

1

B018-B808

saG

larutaNB708-B508

larutaNB018-B808

saG

saGPLB708-B5081

llA

B018-B508

ylnOsaGlarutaN

2

3

1

1

89

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)PO(toliPgnidnatS--gnipiPdnaylbmessAtoliP11-5

saGPLdnalarutaN,noitceS01-6:adanaC&ASU

saGlarutaN,8001D971QllewyenoH,renruBtoliP5206328

A

saGPL,ecifirO

DK641883/w8001D971QllewyenoH,renruBtoliP

9306326

1

B

C.gL.tf4,0208921RllewyenoH,daeLdoRemalF165263171
D65373llewyenoH,rotcennoChajaR12063281
EylbmessAeriWdnuorG95263161

FebuTDO"¼,noinUnoisserpmoCssarB8006328

GsaGlarutaN,TL21VRlortixaM,rotalugeR5006228

HelbaellaM,TPN"8/1,eeTepiP500106608

JdaeH.qS,TPN"8/1,gulPepiP8053066081

KL2PxessE,evlaVffo-tuhS5462281

LTPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB036228

daeL

.gL"63/w6991A903QllewyenoH,elpuocomrehT

40063281

B018-B608

B018-B608:ASU

B708&B608:adanaC

B018-B608:adanaC

ylnOsaGlarutaN

B018-B808

ylnOadanaC

B708&B608

saGlarutaN

saGlarutaNB018-B8083

saGPLB018-B6081

1

1

1

2

90

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)1-DSC-PO(toliPgnidnatS--gnipiPdnaylbmessAtoliP21-5

ylnOsaGPL,noitceS01-8:ylnOASU

A
BdaeL.gL"63/w6991A903QllewyenoH,elpuocomrehT 40063281
C.gL.tf4,0208921RllewyenoH,daeLdoRemalF 165263171
D65373llewyenoH,rotcennoChajaR 12063281
EylbmessAeriWdnuorG 95263161
FebuTDO"¼,noinUnoisserpmoCssarB 80063281
GsaGPL/.taN,TL21VRlortixaM,rotalugeR 50062281
HC3-BG-26LnosnhoJ,hctiwStoliP 831061081

J"8/1x"8/1,evlaVffO-tuhS/tseTkaeLoCarBnoC 9762281

KTPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB 0362282

saGPL,ecifirODK641883/w8001D971QllewyenoH,renruBtoliP 9306326

1

B018-B808

91

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)PE(noitingItnettimretnI--gnipiPdnaylbmessAtoliP31-5

ylnOsaGlarutaN,noitceS01-6:adanaC&ASU

AsaGlarutaN,9001C971QllewyenoH,renruBtoliP 7106328
B.gL.tf4,0208921RllewyenoH,daeLdoRemalF 165263171
C65373llewyenoH,rotcennoChajaR 12063282
D.gL.tf3,2101601RllewyenoH,daeLnoitingI 74263171
EylbmessAeriWdnuorG 95263161

FebuTDO"¼,gnilpuoCnoisserpmoCssarB 8006328

GL2PxessE,evlaVffo-tuhS 546228
HelbaellaM,TPN"8/1,eeTepiP 5001066081
JdaeH.qS,TPN"8/1,gulPepiP 8053066081

KTPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB 036228

L4-AW19HnosnhoJ,evlaVsaGdioneloS 266228

MpeeD"½1x.qS"4,xoBnoitcnuJ 95263181

N.gL"½1xTPN"½,elppiNtiudnoCdigiR 91063181
P"½,tunkcoLtiudnoC 02263182

B018-B608

B708&B608

adanaC&ASU

B018-B808

ylnOASU

B018-B808

ylnOadanaC

B708&B608
ylnOadanaC

B018-B808

ylnOadanaC

B018-B608

1

1

1

2

3

1

Q"½,gnihsuBgnitalusnIcitsalP 43063181

RsaGlarutaN,TL21VRlortixaM,rotalugeR 5006228

B018-B608

ylnOadanaC

1

92

METI

.ON

NOITPIRCSED

TRAP

REBMUN

EZISYTITNAUQ

)1-DSC-PE(noitingItnettimretnI--gnipiPdnaylbmessAtoliP41-5

ylnOsaGlarutaN,noitceS01:ylnOASU

A,renruBtoliP9001C971QllewyenoHsaGlarutaN,7106328
B.gL.tF4,0208921RllewyenoH,daeLdoRemalF 165263171
C65373llewyenoH,rotcennoChajaR 12063282
D.gL.tF3,2101601RllewyenoH,daeLnoitingI 74263171
EylbmessAeriWdnuorG 95263161

FnoisserpmoCssarBebuTDO"4/1,gnilpuoC80063281

G"8/1x"8/1,kcoCffO-tuhS/tseTkaeLoCarBnoC 9762281

B018-808

HTPN"8/1xebuTDO"¼,retpadAnoisserpmoCssarB 0362282

JsaG4-GW19HnosnhoJ,evlaVdioneloS2662281

KpeeD"½1x.qS"4,xoBnoitcnuJ 95263181

L.gL"½1xTPN"½,elppiNtiudnoCdigiR 91063181

M"½,tunkcoLtiudnoC 02263182

N"½,gnihsuBgnitalusnIcitsalP 43063181
PlarutaN,TL21VRlortixaM,rotalugeRPL/saG50062281

1

93

94

metI

.oN

6etelpmoC

noitpircseD.oNtraP

B508B608B708B808B908B018

ytitnauQ

tekcaJ.6

150614061--------------­16061406---1-----------­17061406------1--------­18061406---------1-----­19061406------------1--­10161406---------------1
350614071--------------­36061407---1------------

A6ylbmessAlenaPpoTtekcaJ

B6lenaPraeRreppUtekcaJ

C6lenaPraeRrewoLtekcaJ

37061407------1--------­38061407---------1-----­39061407------------1--­30161407---------------1

550614061--------------­56061406---1------------

57061406------1--------­58061406---------1-----­59061406------------1--­50161406---------------1

650614061--------------­66061406---1------------

67061406------1--------­68061406---------1-----­69061406------------1--­60161406---------------1

450614061--------------­46061406---1------------

D6lenaPtnorFreppUtekcaJ

E6lenaPelbavomeRtnorFtekcaJ

47061406------1--------­48061406---------1-----­49061406------------1---

40161406---------------1
50614071--------------­6061407---1------------

7061407------1--------­8061407---------1-----­9061407------------1--­0161407---------------1

95

metI

.oN

noitpircseDoNtraP.

B508B608B708B808B908B018

ytitnauQ

deunitnoC(tekcaJ.6)

F6lenaPediStfeLtekcaJ1061406 111111

G6lenaPediSthgiRtekcaJ2061406 111111

350614061-------------------­36061406----1---------------­37061406--------1------------

H6lenaPelubitseVtekcaJ

38061406------------1-------­39061406----------------1---­30161406--------------------1
250614071-------------------­26061407----1----------------

J6raBeiTtnorFrewoLtekcaJ

27061407--------1-----------­28061407------------1-------­29061407----------------1---­20161407--------------------1

96

97

metI

.oN

noitpircseD.oNtraP

B508B608B708B808B908B018

ytitnauQ

slortnoCsuoenallecsiMdnamirT.7

AllewyenoH,F°022-041,timiL

;)toliPgnidnatS&IE(8121D0804L

)PO&PE((2121B0804L

htpeD.lusnI"½1xTPN"¾,lleWnoisremmI 62406108 111111

B3311E6004LllewyenoH,teseRlaunaM,timiL30706108 111111

1BhtpeD.lusnI"3xTPN"¾,lleWnoisremmI 25406108 111111

CeguaGerusserP-erutarepmeTU9616508 111111

1CgnippaTeguaG/w"01xTPN2,elppiN1061608 111111

Disp05,TPN¾,evlaVfeileRytefaS20306618 111111

1D"½3xTPN¾,elppiN830006608 111111

E30-203-53oCarBnoC,TPN4/3,evlaVniarD160306608 111111

1E"½3xTPN¾,elppiN830006608 111111

2ETPN¾,gnilpuoC165206608 111111
FylbmessAtnemecalpeRhctiwStneVdekcolB8506106 111111
GhctiwStuo-lloRemalF44006108 111111

1GtekcarBgnitnuoMhctiwStuo-lloRemalF2161817 111111

HxoBnoitcnuJ0106318 111111

J

K)sdliubnoitalucriCsuounitnoC(AV05,remrofsnarT94206108 111111

)sdliubnoitalucriCtnettimretnI(

005D5828RllewyenoH,yaleR/remrofsnarT

15206108

111111

47406108

U55106108 111111

L

M

3001M0168SllewyenoH,eludoMnoitingI61106108

1-AGR577GnosnhoJ,eludoMnoitingIetanretlA48106108

repmaDtneVhtiwetelpmoC,ssenraHgniriWelubitseV

)detcipeDtoN()toliPgnidnatSdnaIE(gulPssapyB

111111

01061318111--------­11061318--------- 111

98

metI

.8repmaDtneVcitamotuAdnadooHtfarD

A8dooHtfarD

B8

.oN

noitpircseD.oNtraP

B508B608B708B808B908B018

50611181--------------­4061118---*1-----------­7061118---**1-----------­3061118------*1--------­8061118------**1--------­2061118---------*1-----­8061118---------**1-----­1061118------------*1*1
9061118------------**1**1

"7,repmaDtneVcitamotuA

7-SK-PGVRlakiffE64161181---------------

"8,repmaDtneVcitamotuA

8-SK-PGVRlakiffE7416118---1------------

"9,repmaDtneVcitamotuA

9-SK-PGVRlakiffE8416118------11------

"01,repmaDtneVcitamotuA

01-SK-PGVRlakiffE9416118------------11

ytitnauQ

.ylnOadanaCrof**roylnO.A.S.Urof*htiwdekramsselnu,adanaCdna.A.S.UhtobniesurofstnenopmocllA

99

TT

en Year Limited Warrantyen Year Limited Warranty

T

en Year Limited Warranty

TT

en Year Limited Warrantyen Year Limited Warranty

COMMERCIAL CAST IRON BOILERS — SERIES 5B, 8B, V9 and V11

Burnham Commercial™ hereby warrants to the original owner (“Owner”) of
each Series 5B, 8B, V9, and V11 commercial cast iron boiler ( a “Boiler”)
manufactured by Burnham Commercial, as follows:

First Year - Limited Warranty: Burnham Commercial warrants that each
Boiler will comply, at the time of manufacture, with recognized hydronics
industry regulatory standards and requirements as then in effect and will be
free from defects in material and workmanship under normal usage for a period
of one year from the date of original installation. Subject to all of the terms
and conditions set forth below, if any Boiler, cast iron section, or component
part covered by this warranty is found not to conform with this warranty during
the one year warranty period, Burnham Commercial will, at its option, repair or
replace the non-conforming Boiler, cast iron section, or covered component
part.

Second through 10th Year - Limited Warranty for Cast Iron Sections:
Burnham Commercial warrants that the cast iron sections of each Boiler will be
free from defects in material and workmanship under normal usage for a period
of ten years from the date of original installation. Subject to all of the terms
and conditions set forth below, if any cast iron section covered by this
warranty is found not to conform with this warranty during the warranty period,
Burnham Commercial will, at its option, repair or replace the non-conforming
cast iron section.
The foregoing warranties are subject to the following terms and conditions:

Applicability. These warranties extend only to the original Owner at the

1.

original installation site and may not be assigned or otherwise transferred or
extended to any other person or entity.

Claim Procedure. Owner must contact the original installer and provide

2.

the installer with a detailed description of the claimed defect. If the original
installer is unable to resolve the matter to Owner’s satisfaction, Owner must
notify Burnham Commercial in writing at Burnham Commercial, P.O. 3939,
Lancaster, PA 17605, which notice must be received by Burnham Commercial
prior to the expiration of the applicable warranty period. Owner must make the
Boiler available for inspection by Burnham Commercial and, if requested to do
so by Burnham Commercial, must return the Boiler, cast iron section or
defective component part to Burnham Commercial, at Owner’s expense, for
inspection and/or repair. Owner must cooperate with Burnham Commercial
and take all commercially reasonable efforts to resolve and settle any dispute
arising in connection with a warranty claim before resorting to legal remedies
in court.

Conditions. The foregoing warranties are subject to the following

3.

conditions:

Installation Location. The Boiler must be installed within the

a.)

continental limits of the United States and Canada.

Proper Installation. The Boiler must be installed by a qualified heating

b.)

contractor (whose principal business is the sale, installation and maintenance
of commercial boilers and related equipment) in strict accordance with the
Installation and Operating Instructions Manual furnished with the Boiler and
must not have been damaged prior to or during installation.

Annual Service. The Boiler (including its related burner, controls, and

c.)

other components and accessories) must be serviced annually by a qualified
heating contractor (whose principal business is the sale, installation and
maintenance of commercial boilers and related equipment) and proof of such
service must be provided with each warranty claim. The required annual
service must include all service and maintenance procedures specified in the
Installation and Operating Instructions Manual furnished with the Boiler and all
service and maintenance procedures specified in any instruction manual or
similar document prepared by the manufacturer of the burner, controls and
other components and accessories. Such annual service must also be
performed in accordance with all applicable industry standards and
procedures.

d.)

Proper Operation and Maintenance. The Boiler must be operated and

maintained in strict accordance with the Installation and Operating
Instructions Manual furnished with the Boiler and all applicable industry
standards and procedures.

No Alterations. The Boiler must not have been modified, altered or

e.)

changed in any manner.

f.) Proper Application. The Boiler must be used exclusively for purposes
of commercial space heating or domestic hot water generation through a heat
exchanger (or for a combination of such purposes).

Exclusions. The foregoing warranties do not cover claims arising from or

4.

relating to any of the following:

Component Parts and Accessories. Claims relating to component

a.)

parts and accessories manufactured by others are not covered by these
warranties and will be subject only to the manufacturer’s warranty, if any.

Improper Installation. Claims arising from or relating to improper

b.)

installation are not covered by these warranties.

Natural Disasters. Claims arising from or relating to damage caused

c.)

by natural disasters, including, but not limited to, lightening, fire, earthquake,
hurricane, tornado, or floods are not covered by these warranties.

Alterations. Claims arising from or relating to any alteration or other

d.)

modification not authorized by Burnham Commercial in writing are not covered
by these warranties.

Misuse. The following claims are not covered by these warranties:

e.)

claims arising from or relating to (i) misuse, abuse, mishandling, accident,
neglect or improper service or operation of a Boiler, including, but not limited
to, improper burner adjustment, control setting or maintenance and thermal
shock from low water temperatures; (ii) operation of a Boiler over its rated
capacity; (iii) operation of a Boiler with insufficient water, excessive fresh
make-up water or inadequately deareated water; (iv) freezing of a Boiler or any
part or component thereof; (v) operation with combustion air contaminated
externally by chemical vapors or other contaminants, (vi) use of improper fuel
additives; or (vii) operation of a Boiler with inadequately or improperly treated
water that causes deposit build-up in the cast iron sections or other Boiler
components.

Subsequently Installed Accessories. Claims arising from or relating to

f.)

Boiler accessories (including, but not limited to, circulators, air elimination
devices, deaerators, flow controls and low water cutoffs) which are installed
by Owner after delivery of the Boiler are not covered by these warranties.

Exclusive Remedy. If any Boiler, cast iron section or covered

5.

component part fails to conform to these warranties, Owner’s exclusive
remedy shall be to accept, at the option of Burnham Commercial, repair or
replacement of the non-conforming Boiler, cast iron section or other
component part. These warranties do not cover labor and other costs and
expenses associated with the removal and replacement of a non-conforming
Boiler, cast iron section or other component part, which costs and expenses
shall be the sole responsibility of Owner.

Limitation of Damages. Under no circumstances shall Burnham

6.

Commercial be liable to Owner or to any other person for any indirect,
incidental, special, consequential, or punitive damages of any kind
whatsoever under these warranties or otherwise (including, without limitation,
injury or damage to persons or property, loss of time or labor expense
involved in repairing or replacing a non-conforming Boiler, loss of the use of
the Boiler, and loss of profits, revenues or business, even if Burnham
Commercial has been advised of the possibility of such damages), whether
such damages are sought based upon breach of warranty, breach of contract,
negligence, strict liability or any other legal theory. Burnham’s liability under
these warranties shall under no circumstances exceed the purchase price
paid by the Owner for the Boiler involved.

Exclusivity and Disclaimer. These warranties are given in lieu of all other

7.

express warranties and set forth the entire obligation of Burnham Commercial
with respect to any defective or otherwise non-conforming Boiler and Burnham
Commercial shall have no obligations, responsibilities or liabilities of any kind
whatsoever, except as set forth herein.
EXCEPT AS SET FORTH IN THESE WARRANTIES, BURNHAM MAKES NO
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT
LIMITATION, ANY IMPLIED WARRANTY OF MERCHANTABILITY, ANY
IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND ANY
OTHER IMPLIED WARRANTY ARISING OUT OF A COURSE OF DEALING OR
PERFORMANCE, CUSTOM, USAGE OF TRADE OR OTHERWISE.

No Authority to Expand Warranty. No sales representative, agent or

8.

distributor or has authority to expand or otherwise modify in any way the
scope of these warranties or the obligations of Burnham Commercial
hereunder. No such modification shall be binding unless set forth in a written
document signed by a duly authorized officer of Burnham
Commercial.

Effective Date. This statement of warranties is effective as to all Boilers

9.

sold on or after July 17, 2000 and supersedes all prior warranty statements.

03/03

100