Burnham 8H, 8HE Installation and Operation Manual
Commercial Boilers
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
SERIES 8H / 8HE
GAS - FIRED BOILER
3050579
This manual must only be used by a qualied heating installer/service technician.
BEFORE installing, read all instructions in this manual and all other information
shipped with the boiler. Post all instructions and manuals near the boiler for
reference by service personnel. Perform steps in the order given. Failure to comply
could result in severe personal injury, death or substantial property damage.
81416023R5 - 4/15
www.burnhamcommercial.com
Price - $5.00
1
IMPORTANT INFORMATION -
READ AND sAvE ThEsE INsTRucTIONs FOR REFERENcE
All boilers must be installed in accordance with National, State and Local Plumbing, Heating
and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations
may differ from this instruction manual. Authorities having jurisdiction should be consulted
before installations are made.
In all cases, reference should be made to the following Standards:
USA BOILERS
A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil
Burning Equipment”, for recommended installation practices.
B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and
Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls
and safety devices.
E. All wiring on boilers installed in the USA shall be made in accordance with the National
Electrical Code and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil
Burning Equipment", for recommended Installation Practices.
B. The equipment shall be installed in accordance with the current Installation Code for Gas
Burning Appliances and Equipment, CSA B149, and applicable Provincial Regulations for
the class; which should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian
Electrical Code and/or Local Regulations.
Hazard Denitions
The following dened terms are used throughout this manual to bring attention to the presence of hazards of
various risk levels or to important information concerning the life of the product.
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
2
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other
appliance.
If you smell gas or fuel oil vapors, do not try to operate the burner/boiler system. Do not touch any
electrical switch or use any phone in the building. Immediately call the gas or oil supplier from a remotely
located phone.
Burner/boiler systems produce steam or hot water in a pressurized vessel by mixing extremely ammable
gaseous, liquid or solid fuels with air to produce combustion and very hot products of combustion.
Explosions, res severe personal injury, death and/or property damage will result from improper, careless
or inadequate installation, operation or maintenance of fuel-burning and boiler equipment.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an knowledgeable, experienced,
and skilled installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efciency.
Installation is not complete unless a pressure relief valve is installed into the specied tapping on the
supply manifold located on top and at rear of appliance - See Section IV, Paragraph C.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler.
This boiler contains components which become very hot when the boiler is operating. Do not touch any
components unless they are cool.
Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions,
including all those contained in component manufacturers manuals which are provided with the boiler
before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.
Do not operate boiler with control which has been subject to water.
All cover plates, enclosures and guards must be in place at all times.
3
This boiler is designed to burn natural and/or LP gas only. Do not use gasoline, crankcase drainings, or
any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel
(i.e. wood, coal). All ammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler
at all times. Keep the boiler area clean and free of re hazards.
Float type low water cutoff devices require annual inspection and maintenance. Refer to instructions in
Section IX, Paragraph B.
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the
responsibility of the installing contractor to see that all controls are correctly installed and are operating
properly when the installation is complete.
USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially
oriced to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orice sizing is indicated on the
rating label.
NOTICE
All Series 8HE cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler
and Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each 8HE
jacket, which indicates the boiler Maximum Allowable working Pressure (MAWP). Each cast iron section is
permanently marked with the MAWP listed on the boiler’s ASME Data Label. The MAWP for all Series 8HE
Boiler is 50 psi (Water Only).
It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler
MAWP. Therefore, in addition to Safety Relief Valves set for 50 psi, Burnham also offers Safety Relief Valves
set for 30 psi (By Special Order Only).
4
Important Product Safety Information
Refractory Ceramic Fiber Product
The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures above 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
• If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
5
Table of Contents
I. Pre-Installation .............................................................8
II. Boiler Assembly .........................................................10
III. Gas Control System Assembly ..................................17
(Knockdown Boilers)
IV. Water Trim and Piping ...............................................24
V. Gas Piping ..................................................................28
VI. Venting .......................................................................30
VII. Electrical ....................................................................33
VIII. System Start-up ..........................................................49
IX. Service .......................................................................57
X. Repair Parts ................................................................62
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Table 1: Dimensional Data
Figure 1: Dimensional Data
Boiler
Model
805H 252 20 10 7 24-13/16 16-1/8 7” dia. x 15 ft. 11.9 600 610
806H 315 23-3/4 11-7/8 8 27-13/16 18 8” dia. x 15 ft. 13.9 690 700
807HE 340 27-1/2 13-3/4 8 27-13/16 18 8” dia. x 15 ft. 15.9 785 870
808HE 410 31-1/4 15-5/8 9 30-13/16 20 8” dia. x 15 ft. 17.9 895 955
809HE 460 35 17-1/2 10 33-1/2 22 10” dia. x 15 ft. 19.9 985 1050
810HE 505 38-3/4 19-3/8 10 33-1/2 22 10” dia. x 15 ft. 21.9 1075 1150
Input
(MBH)
A B C D E Packaged Knockdown
Dimensions (Inches)
Recommended
Chimney Size
(Round)
Water
Content
(Gallons)
Approx. Shipping Weight
(LB.)
7
I. Pre-Installation
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
A. Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of boiler to carrier in good condition. Any claim
for damage or shortage in shipment must be led
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
B. Installation must conform to the requirements of
the authority having jurisdiction. In the absence of
such requirements, installation must conform to the
National Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or
CAN/CSA B149.1 Installation Codes. Where required
by the authority having jurisdiction, the installation
must conform to the Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
No CSD-1.
C. Provide clearance between combustible material and
boiler jacket (following clearances are minimums):
1. USA, 805H-807HE: listed for Alcove installation
a. Front: 18”
b. Top: 36”
c. Draft hood, rear, sides and ue connector: 6”
Appliance is design certied for installation on
noncombustible ooring only. For installation
on combustible ooring only when installed on
special base listed in Table 2. Boiler must not be
installed on carpeting. When boiler is installed on
concrete which is over a material that is subject
to melting (PVC, PEX radiant tubing, etc.), the
special base must be used. A concrete pad is not
sufcient to protect combustible ooring.
Table 2: Special Base Required for Installation on
Combustible Flooring
Boiler Model Special Base Part Number
805H 61816055
806H 61816065
807HE 61816075
808HE 61816085
809HE 61816095
810HE 61816105
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2. USA, 808HE-810HE: for installation in room
which is large in comparison with size of boiler.
a. Front: 18”
b. Top: 51½”
c. Draft hood, rear, sides, and ue connector: 6”
3. Canada, 805H-810HE:
a. Top and front: 18” (45.7 cm)
b. Flue, rear and sides: 6” (15.2 cm)
D. Provide clearance for servicing and proper operation
(following clearances are recommended and may be
reduced to minimum clearances shown above):
1. Single boiler, 805H-807HE, Front/Top: 24” (61.0
cm)
2. Single boiler, 808HE-810HE, Front/Top: 48”
(122.0 cm)
3. Multiple/modular boiler, USA /Canada, Sides: 1”
(2.5 cm)
E. Install boiler on level oor as close to chimney as
possible. For basement installation provide a solid base
such as concrete or masonry construction if oor is not
level or if water may be encountered on oor around
boiler.
F. Protect gas ignition system components from
water (dripping, spraying, rain, etc.) during boiler
operation and service (circulator replacement, control
replacement, etc.).
G. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or the National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation; or CAN/
CSA B149.1, Venting Systems and Air Supply for
Appliances.
Adequate combustion and ventilation air must be
provided to assure proper combustion.
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.
3
a. If result is greater than or equal to 50 ft
1,000 Btuh, space is considered an unconned
space.
per
b. If result is less than 50 ft3 per 1,000 Btuh, space
is considered a conned space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and
b. Weather-stripping has been added on openable
windows and doors, and
c. Caulking or sealants applied in joints around
window and door frames, between sole
plates and oors, between wall-ceiling joints,
between wall panels, at plumbing and electrical
penetrations, and at other openings.
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.
6. For boiler located in an unconned space in a
building of unusually tight construction or in
a conned space, provide outdoor air through
permanent opening(s) which communicate directly
or by duct with the outdoors or spaces (crawl or
attic) freely communicating with the outdoors.
Minimum dimension of air opening(s) is 3” (7.6
cm).
a. Two permanent openings: Locate one opening
within 12 inches (30.5 cm) of top of space.
Locate remaining opening within 12 inches
(30.5 cm) of bottom of space. Size each opening
per following:
i. Direct communication with outdoors.
Minimum free area of each opening must be
1 square inch per 4,000 Btu per hour input
of all equipment in space.
ii. Vertical ducts. Minimum free area of each
opening must be 1 square inch per 4,000
Btu per hour input of all equipment in space.
Duct cross-sectional area shall be same as
opening free area.
iii. Horizontal ducts. Minimum free area of each
opening must be 1 square inch per 2,000
Btu per hour input of all equipment in space.
Duct cross-sectional area shall be same as
opening free area.
b. One permanent opening shall be permitted where
the boiler has clearances of at least 1” (2.5 cm)
from the sides and rear and 6” (15.2 cm) from
the front. Locate the opening within 12 inches
(30.5 cm) of top of space. Size opening per
following:
i. Minimum free area of 1 square inch per
3,000 Btu per hour input of all equipment in
space.
ii. Free area shall not be less than the sum
of the areas of all vent connectors in the
conned space.
Alternate method for boiler located within conned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcient volume such that combined volume of all
spaces meet criteria for unconned space. Size each
opening for minimum free area of 1 square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be xed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
8. For Specially Engineered Installations. The above
requirements shall be permitted to be waived
where special engineering, consistent with good
engineering practice and approved by the authority
having jurisdiction, provides an adequate supply of
air for combustion, ventilation, and dilution of ue
gases.
Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
Mis-sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler
to the system. Modular/multiple boilers greatly
reduce the likelihood of boiler oversizing.
9
II. Boiler Assembly
A. Remove Crate
1. Remove all fasteners at crate skid.
2. Lift outside container and remove with all other
inside protective spacers and bracing.
B. Remove boiler from skid. See Figure 2. Exercise care
to avoid dropping boiler.
1. Place boiler in approximate location. Refer to
Section I: Pre-Installation. Remove base hold down
bolts.
2. Using pry bar under rear corner of Base End Panel,
raise boiler and install 1½” wood blocks under rear
corners. Install ¾” pipe roller between Base and
skid.
3. Remove 1½” wood blocks. Place 3” pipe roller on
oor behind skid.
4. Roll boiler off skid. Move skid out of way.
5. Roll boiler until 3” roller is located as shown. Use
pry bar to install wood blocks under front corners of
base. Remove 3” roller.
Figure 2: Skid Removal
10
Figure 3: Tapping Locations
Table 3: Purpose of Tappings
Tapping Size Purpose
A 2” Supply
B 2” Return
C 3/4” Relief Valve
D 3/4” Limit
E 3/4” Auxiliary Limit
F 3/4” Washout
G 3/4” Drain
6. Lift boiler with pry bar. Remove wood blocks.
Lower boiler.
C. For Packaged Boiler only, proceed to Paragraph E.
D. Test Section Assembly for leaks before connecting to
system and installing controls, trim and jacket. Refer to
Figure 3 and Table 3.
1. Plug Tappings C & E (¾ NPT) and Return Tapping
B (2 NPT).
2. Insert ¾” NPT x ¼” NPT bushing in Tapping D.
Install pressure gauge capable of indicating 50 psi.
3. Insert 2” NPT x ¾” NPT bushing in Supply Tapping
A. Install purge valve with a hose that runs to a
drain.
4. Connect ll valve and piping to Drain Tapping G.
Do not use air to leak test boiler.
5. Fill boiler completely with water by venting air
through purge valve. Close purge valve and apply
water pressure of at least 10 psi but less than 50 psi
gauge pressure.
6. Examine boiler for leaks or damage due to shipment
or handling.
7. Remove plugs from Return Tapping B, Tapping C,
and Tapping E (if second limit or operating control
is used). Also remove ll valve and piping, purge
valve and piping, and pressure gauge.
E. Install special base if installation is on combustible
ooring. See Figure 4. Floor shield adds 4¾” to boiler
height.
1. Place special base on combustible oor with surface
marked “FRONT” in upward position.
2. Locate special base with spacing to combustible
materials as shown in Figure 4.
3. Place boiler on special base. Boiler must rest inside
locating brackets. Boiler jacket panels will overhang
special base.
4. Do not enclose boiler (including special base) on all
four sides. Models 807HE may be enclosed on three
sides (alcove) while maintaining clearances shown
in Figure 4.
Figure 4: Installation of Special Base for Combustible Flooring
11
Figure 5: General Assembly (Knockdown Boilers)
F.
Move boiler to permanent location by sliding or
walking. Do not drop.
For Packaged Boiler, proceed to Paragraph L.
G. Conrm that one (1) Flue Bafe is properly
positioned in each Boiler Flueway. Tabs at the top
of each Flue Bafe should be resting on top row of Flue
Pins on each adjoining section.
H. Install Canopy on section assembly. See Figure 5.
Canopy and hardware are located in Combination
Boiler Parts and Control Carton.
1. Position Canopy on top of Section Assembly. Locate
between end sections and sealing ledge on front and
back of each section.
2. Fasten each end with ¼” - 20 x 1” carriage bolts,
washers and nuts.
3. Seal between Canopy and Section Assembly with
furnace cement.
I. Inspect joints between sections. They were factory
sealed. If any openings resulted during shipment or
handling, reseal with furnace cement. Conrm tie rods
are only hand tight to allow for thermal expansion.
J. Install Base Front Panel. See Figure 5. Panel and
hardware located in Combination Boiler Parts and
Control Carton.
12
1. Attach Base Front Panel to Section Assembly using
¼” - 20 x 1¼” carriage bolts, washers and nuts.
2. Seal between top of Base Front Panel and Section
Assembly with furnace cement (shipped in
Combination Boiler Parts and Control Carton).
3. Seal between top of Base Rear Panel and Section
Assembly with furnace cement.
K. Install Pilot/Main Burner Assembly. See Figure 7.
Assembly is located in Combination Boiler Parts and
Control Carton. Verify assembly is properly located
on support bracket in Base Rear Panel, seated on Main
Burner Orice, and secured with hitch pin clip.
L. Adjust Burner Air Shutters on all Burners. See
Figure 7. (On Packaged Boilers, Front Door and
Burner Access Panel(s) must be removed to make
adjustments.) Distance between front edge of Burner
Air Shutter and burner mounting ring should be
approximately 11/16”. To adjust this distance, loosen
screw at top of air shutter and slide into correct
position. Then tighten screw. (Replace Burner Access
Panel(s) and Front Door on Packaged Boilers.)
For Packaged Boiler, proceed to Section IV: Water Trim
and Piping.
Figure 6: Flame Roll-out Switch Installation
Figure 7: Burner/Burner Access Panel Installation
13
Attach Flame Roll-out Switch to Burner Access Panel.
M.
See Figure 6. Flame Roll-out Switch and hardware
are located in Combination Boiler Parts and Control
Carton. Flame Roll-out Switch is a single use device
- do not test with heat - switch cannot be reset.
1. Cut insulation from semicircular notch at right
end of the burner access panel. Models 808HE 810HE have two (2) burner access panels. Remove
insulation from notch of right side burner access
panel only.
2. Attach Flame Roll-out Switch Mounting Bracket to
burner access panel with (1) #8 x ½” lg. sheet metal
screw.
3. Attach Flame Roll-out Switch to mounting bracket
with (1) #8 x ¾” lg. sheet metal screw.
N. Install Burner Access Panel(s). Locate Burner Access
Panel(s) in Combination Boiler Parts and Control
Carton. Engage Burner Access Panel holes with
projections on Base Front Panel. See Figure 5.
O. Install Immersion Well(s).
1. Remove Immersion Well(s) from Combination
Boiler Parts and Control Carton..
2. Insert Immersion Well in Tapping D. See Figure 3.
3. If second limit or operating control is used, insert
immersion well in Tapping E. If vertical gas
piping is to be installed inside of boiler jacket, it
is recommended that second limit be installed in
system piping.
P. Install Jacket. See Figure 8.
1. Locate four (4) Jacket Attachment Brackets in
Combination Boiler Parts and Control Carton.
Attach to Front Base Panel and Rear Base Panels
with #8 sheet metal screws. See Figure 5.
2. Hang Left Side Panel and Right Side Panel onto
Jacket Attachment Brackets.
3. Attach Lower Rear Panel to Left and Right Side
Panels. Do not tighten sheet metal screws.
4. Attach Upper Rear Panel to Lower Rear Panel. Do
not install three (3) upper screws.
5. Remove Rating Label from envelope marked
“RATING LABEL ENCLOSED”. Remove
Combustible Clearance Label from Combination
Boiler Parts and Controls Carton. Attach to
Vestibule Panel in locations shown.
6. Attach Vestibule Panel to Left Side and Right Side
Panels.
7. Attach Lower Front Tie Bar to Left Side and Right
Side Panels.
8. Engage Upper Front Panel in slots on Left Side
and Right Side Panels. Place Top Panel in position.
Attach Top Panel to Left Side, Right Side and Upper
Rear Panels.
9. Tighten all jacket screws.
10. Afx Lighting/Operating Instructions Label and
Wiring Diagram Label to inside of Front
Removable Door. Labels are located in
Combination Boiler Parts and Control Carton.
Q. Install Junction Box. See Figure 8. Attach junction
box to inside of Left Side Panel with ¼” - 20 x ¼” lg.
machine screw (located in Combination Boiler Parts
and Control Carton).
R. Install Limit Control. Locate limit in Combination
Boiler Parts and Control Carton. Insert limit probe into
left immersion well as far as possible. Tighten set screw
(Model 805 uses Hydrostat 3200 - see Installation and
Operating Manual packed in envelope taped to top of
boiler for packaged boilers and in parts and control
carton for KD boilers for set up).
S. Install Auxiliary Limit or operating control (if used).
Insert control probe into right immersion well as far as
possible. Tighten set screw.
T. Install Gas Control Assembly. Refer to Section III,
Gas Control System Assembly (Knockdown Boilers).
U. EP System: See Figure 9.
1. Install pre-wired EP Control Cabinet Assembly to
right front corner of jacket top panel.
2. Install Honeywell RM7890 Control (located in
RM7890 Control Carton).
3. Remove RM7890’s Dust Cover. With a pair of side
cutters, carefully snip both wire leads to the brown
resistor labelled “JR2” and discard it. Replace Dust
Cover.
4. Install Honeywell R7847 Flame Amplier.
5. Install heat shield.
14
Figure 8: Jacket Assembly
15
16
Figure 9: EP Control Installation
III. Gas Control System Assembly (Knockdown Boilers)
A. 24V Standing Pilot Control System
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
1. Install Gas Control Assembly on Manifold. See
Figure 10. Use thread (joint) compound (pipe dope)
resistant to action of liqueed 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 liqueed petroleum gas.
2. Install pilot burner piping and controls.
a. Honeywell EI
i. USA - See Figure 12.
ii. Canada - See Figure 13.
3. Install Ignition Module.
a. Attach Ignition Control Mounting Bracket to
Jacket Vestibule Panel using two (2) #8 x ½”
sheet metal screws.
b. Attach Honeywell Ignition Module to Mounting
Bracket using two (2) #8 x ½” sheet metal
screws.
c. Connect pilot ground wire and ignitor/sensor
lead(s) to ignition module. Refer to “Section VII:
Electrical” for connection details.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box. See Figure 8.
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
b. Attach transformer/control center to junction
box.
C. 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 14.
2. Install pilot burner piping and controls. See Figure
14.
3. Install Ignition Transformer.
a. Attach Ignition Transformer to Jacket Vestibule
Panel using four (4) #8 x ½” lg. sheet metal
screws.
b. Connect Ignition Lead from Pilot to Ignition
Transformer.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
b. Attach transformer/control center to junction
box.
D. 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 15.
2. Install pilot burner piping and controls. See Figure
15.
3. Install Ignition Transformer.
a. Attach Ignition Transformer to Jacket Vestibule
Panel using four (4) #8 x ½” lg. sheet metal
screws.
b. Connect Ignition Lead from Pilot to Ignition
Transformer.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
b. Attach transformer/control center to junction
box.
17
18
Figure 10: Schematic Gas Piping, 24V Standing Pilot, 806H - 807HE
Figure 11: Main Gas Piping, Intermittent Ignition (EI)
19
20
Figure 12: Schematic Pilot Piping (Honeywell EI), USA
Figure 13: Schematic Pilot Piping (Honeywell EI)
Canada: Natural Gas, 805H - 810HE; LP Gas, 806H - 807HE
21
22
Figure 14: Schematic Gas Piping, EP Control System (Natural Gas Only), 806H - 810HE
Figure 15: Schematic Gas Piping, EP-CSD-1 Control System, 808HE - 810HE
23
IV. Water Trim and Piping
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can
lead to boiler failure. Burnham’s Warranty does not cover problems caused by oxygen contamination of
boiler water or scale (lime) build-up caused by frequent addition of water.
A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
1. There are many possible causes of oxygen
contamination such as:
a. Addition of excessive make-up water as a result
of system leaks.
b. Absorption through open tanks and ttings.
c. Oxygen permeable materials in the distribution
system.
2. In order to insure long product life, oxygen sources
must be eliminated. This can be accomplished by
taking the following measures:
a. Repairing system leaks to eliminate the need for
addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing ttings which allow
oxygen absorption.
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
f. Use properly designed and operating air
elimination devices in water piping.
B. Design boiler piping and ow rate to obtain proper
temperature rise though the boiler. (See Table 4)
Table 4: Flow Rate, Temperature Rise, and
Pressure Drop
Boiler
Model
805H
806H
807HE
808HE
809HE
810HE
Flow Rate
(GPM)
21
14
10
26
17
13
28
19
14
34
22
17
38
25
19
42
28
21
Temp. Rise
Thru Boiler
20° F
30° F
40° F
20° F
30° F
40° F
20° F
30° F
40° F
20° F
30° F
40° F
20° F
30° F
40° F
20° F
30° F
40° F
Min. Boiler
Piping NPT
1½”
1¼”
1¼”
1½”
1½”
1¼”
2”
1½”
1¼”
2”
1½”
1½”
2”
2”
1½”
2”
2”
1½”
Boiler
Pressure
Drop
3’
2’
1’
3’
2’
1’
3’
2’
1’
3’
2’
1’
3’
2’
1’
3’
2’
1’
Pressure relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut off
valves, plugs or caps. Consult Local Codes for
proper discharge piping arrangement.
C. Install Safety Relief Valve. See Figure 16.
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.
24
Figure 16: Safety Relief Valve Installation
Figure 17: Drain Piping Installation
D.
Install Drain Valve in rear of Left End Section,
Tapping “G”. See Figure 17. 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 18.
Figure 19: Alternate Temperature-Pressure Gauge
Installation
b. Install 2 NPT x ¾ NPT x 2 NPT Tee (provided)
or 2 NPT x 2 NPT x ¾ NPT Tee (installer
furnished). ¾ NPT leg should face forward.
c. Install ¾ NPT x ¼ NPT Bushing.
d. Insert Temperature-Pressure Gauge. Tighten
by applying pressure to square shank on back
of gauge. DO NOT APPLY PRESSURE ON
GAUGE CASE since this may ruin gauge
calibration.
F. Connect system supply and return piping to boiler.
See Figure 21. Also, consult I=B=R Installation
and Piping Guide No. 250. 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
Figure 18: Temperature-Pressure Gauge
Installation
a. Install 2” NPT x 10” lg. nipple with gauge
tapping into Supply Tapping “A”. See Figure 3.
Gauge tapping should face forward.
b. Insert Temperature-Pressure Gauge. Tighten
by applying pressure to square shank on back
of gauge. DO NOT APPLY PRESSURE ON
GAUGE CASE since this may ruin gauge
calibration.
2. Alternate Temperature-Pressure Gauge Piping. See
Figure 19.
a. Install 2 NPT x 10” Nipple into Supply Tapping
“A”. See Figure 3.
Figure 20: Recommended Piping for Combination
Heating & Cooling (Refrigeration) System
25
entering boiler. See Figure 20. Also, consult I=B=R
Installation and Piping Guide No. 250.
2. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
ow control valves to prevent gravity circulation of
boiler water during cooling system operation.
3. The piping diagrams shown (Figure 21, Detail “A”
and Detail “B”) are recommended for optimum
operation and long term reliability.
Burnham Commercial recommends maintaining
temperature differential (drop) across the system
at 40°F or less, and return water temperature at
minimum of 135°F.
Continued boiler operation for prolonged periods of
time under conditions when temperature differential
across the system exceeds 40°F and/or return water
temperature stays below 135°F, may result in
premature boiler failure due to ue gas condensation
and/or thermal shock.
Pump ow rates and minimum boiler supply and
return pipe sizes are shown in Table 4.
26
Figure 21: Recommended Boiler Piping for Circulator Zoned Heating Systems
Detail “A”: Blend Pump Piping
Detail “B”: Primary/Secondary Piping
with By-Pass
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