Burnham HF SERIES, HF-98, HF-122, HF-147, HF-173 Operating/service Instructions Manual
Price - $3.00
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
HF SERIES OIL FIRED BOILER
BEFORE INSTALLATION: READ THIS MANUAL
SAVE THESE INSTRUCTIONS
Installing contractor and homeowner should read and be informed as to the
proper installation and operation of this unit. The manufacturer will not be
responsible for improper installation or operation. This manual and all
associated instruction material should be conspicuously posted near the
equipment.
For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial N umber as shown on Rating Label.
Boiler Model Number Boiler Serial Number Installation Date
HF ____-____
Heating C ontractor Phone Number
Address
8143709R3-12/99
6_ _ _ _ _ _ _
1
IMPORTANT INFORMATION - READ CAREFULLY
All boilers must be installed in accorda nce with National, State and Local Plumbing,
Heating and E lectrical Codes and the regu lations of the servi ng utilities. These C odes and
Regulations may diffe r from this instruction manual. Authorities having jurisdiction should
be consulted before install ations are made.
In all cases, reference sh ould be m ade to the followi ng Standards:
All wiring on boil ers installed in the U SA shall be made in accor dance with the N ational
Electrical Cod e and/or Lo cal Regulations.
USA BOILERS
C urrent Editio n of American Na t iona l Standard ANSI/NFPA 31, “Installa t ion o f Oil Burni ng
A.
Equipment”, for r ecomm en ded installation practices.
Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,
B.
Vents, and Solid Fuel Burning Appliances”, For Venting requirements.
C.
Current Edition of Amer ican Society of Mechanical Engineers ASME CSD-1, "Con trols and
Safety Devices for Automatically Fired Boilers", for assembly and operations of controls
and safety devices.
CA NAD IAN B OILERS
Current Edition of Canadian Stand ards Association CSA B139, "Installation Code of Oil
A.
Burning Equipment", for recomm en ded installation practices.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels,
or to important information concerning product life.
DANGER
Indicates an imm in ently hazardou s situation
w hic h, if n ot av oid ed, w ill re su lt in d eath ,
serious injury or substantial property
damage.
WA R N I NG
Indic ates a potentially hazardous situation
which, if not avoided, could re sult in death,
serious injury or substantial property
damage.
Indic ates a potentially hazardous situation
which, if not av oided, may resu lt in
modera te or minor injury or property
damage.
Indicates special instructions on
installation, operation, or m aintenance
which are importa nt but not related to
personal injury hazards.
CAU TION
NOTICE
Th is boiler has a limited w a rra nty, a c o py o f which is printe d on t he back of t his m a nua l.
It is the respons ibility of the in stalling cont ractor to see th at all controls are correctly in stalled
and a re oper a t ing p rop e rly when the ins tallatio n is co mplete. The war ran ty fo r t his boiler is v a lid
only if the boiler h as been installed, maintained and operated in accordance with these
instructions.
NOTICE
2
DA NGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any
other appliance.
WAR NING
Impro per installation, ad justment, alteration, servic e or mainte na nce can cause p roperty
damage, personal injury or loss of life. Fai lure to follow all instructions in the proper order
can cause personal i njury or death. Read and understand all instructions, inc luding all
those con tained in compone nt manufac turers manuals w hich are p rovided with th e
appliance before installing, starting-up, operating, maintaining or servicing this applia nce.
Keep this manual and literature in legible condition and posted near appliance for reference
by owner an d service technic ian.
This boiler requires regular maintenance and service to operate safely. Fo llow the instructions
contained in this manual. Installation, maintenance, and service must be performed only by an
experienced, skilled and knowledgeable installer or service agency. All heating systems should
be designed by competent contractors and only persons knowledgeable in the layout and
installation of hydronic heating systems should attempt installation of any boiler. It is the
responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is completed. Installation is not complete unless a
pressure relief valve is installed into the tapping located on top of app liance - See Section III of
this ma nual for details.
This boiler is not su itable for installation o n c ombusti ble flooring, unless install ed with a
comb ustible floor shield (avai lable at extra cost). Do n ot install boiler on carpeting .
Do not tam per with or alter the boiler or controls. Re tain your contractor or a compet ent
se rv ice man to assur e th at th e unit is p ro perly adjus ted an d m ain tained .
Have Firetu be s cleane d at l eas t once a ye ar - prefe rab ly at th e star t o f the he ating sea son
to remove soot and scale. The inside of combustion cha mber should also be cle aned and
ins pecte d at the same time .
Have Oil B urn er and Contro ls ch ecke d at l eas t once a ye ar or as may be n ecess itate d.
Do not operate unit with jumpered or abs ent controls or safety devices.
Do no t operate unit if any control, switch, c omponent, or device has been subject to
water.
3
WARNING
Appliance materials of construction, products of combustion and the fuel contain alumina, silica,
heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful
substances which can cause death or serious injury and which are known to the state of California
to cause cancer, birth d efects and other reproductive harm. Always use pro per safety clothing,
respirators and equipment when servicing or wor king nearby the appliance.
This boiler contains very hot water under high p ressures. Do not unscrew any pipe fittings nor
attempt to disconnect any comp onents of this boil er 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 temper ature and pressure of the b oiler. This boiler contains components
w hich become very hot when the boiler is operating. D o not touch any components unless they
are cool.
This appliance must be properly vented and connected to an approved vent system in good
condition. Do not ope rate boiler with the absence of an unapproved ve nt system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
The interior of the venting and air intake systems must b e inspected and cleaned before the start
of the heating season and should be inspected periodically throughout the heating season for
any obstructions. Clean and unobstructed venting and air intake systems are necessary to allow
noxious fumes that could cause injury or loss of life to vent safely and will con tribute toward
maintaining th e boiler's efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start
withou t service. If dam age du e to frozen pipe s is a pos sibility, the he ating system should
not be left unatttend ed in cold weather; or appropriate safeguards and alarms should be installed
on the heating system to prevent damage if the boiler is inoperative.
This boiler is designed to b urn No. 2 fuel oil only. D o not use gasoline, crankcase drai nings, or
any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any
solid fuel (i. e. wood, co al) or gaseous fuel (i. e. natu ral gas, LP/propane). All flam mable debris,
rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area
clean and free of fire hazards.
Do not operate boiler on combustible floor without a factory supplied floor shield. Concrete over
wood joists is considered combustible flooring. Do not operate on masonry floors, which may
contain moisture.
T ables of Contents
I. General Information ............................. 5
II. Installation Instructions ......................... 8
III. System Start-Up ................................... 18
I V . Service and Cleaning............................ 23
V . Repair Parts .......................................... 2 4
4
I: General Information
Figure 1: HF Packaged Boiler (HF-98/HF-173)
Table 1:
Description HF-98 HF-122 HF-147 HF-173
DOE Heating Capacity (MB H) 104 132 154 184
IBR Net Water rating (MBH) 90 115 134 160
Firing Rate (gal/hr) .85 1.10 1.25 1.50
Nozzle Spec ification .75 x 45° B .90 x 45° B 1.00 x 45° B 1.25 x 45° B
Stac k D ia me te r (inc h) 6 6 7 7
Nu mber of Tub es 12 12 18 18
Boiler Water Cap. (gal.) 20 20 40 40
Supply S i ze ( F PT) 1¼ 1¼ 2 2
Return S ize (FPT) 1¼ 1¼ 2 2
Tankless Heater Size (gal/min) 4 (5 Optional) 4 (5 Optiona l) 5 5
Chimney Size (min) 8" x 8" x 15' 8" x 8" x 15' 8" x 8" x 15' 8" x 8" x 15'
Approx. Shipping Wt. ( lb.) 450 450 720 720
DIMENSIONS Max. Working Pressure: 30 PSI (Water Only)
A O verall Width (in.) 18-1/8 18-1/8 24 24
B O verall Length Boiler (in.) 24-1/2 24-1/2 31-3/4 31-3/4
C Jacket Height ( in.) 37-3/4 37-3/4 46-3/4 46-3/4
D J acket Length (in.) 18 18 21-3/4 21-3/4
E Jacket Width ( in.) 18-1/8 18-1/8 22 22
F S moke Outlet Height (in.) 25-1/4 25-1/4 30 30
G Overall Leng th w/Burner (in.) 33 33 39 39
WATER RAT INGS AND S PECIFICATIONS
1.
Notes:
Firing rates based on 140,000 BTU per gallon of oil
2.
IBR net wa t e r r at in gs ba s ed o n a pi c k -up al lo wan c e of 1. 15
3.
Manufacturer should be consulted before selecting a boiler for installations having
unusual piping and pick-up requirements.
4.
Firebox d raft setting: -.02 in ches w ater column
5.
Ratings based on 13.0% CO
2
5
A. INSPECT SHIPMENT carefully for any signs of damage.
1 . ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of the crated boiler to the carrier in
good condition.
2. ANY CLAIMS for damage or shortage of shipment
must filed immediately against the carrier by the
consignee. No claims for variances from, or
shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after
receipt of goods.
B. LOCATE BOILER in front of final position before
removing crate.
1. LOCATE so that smoke pipe connection to chimney will be short and direct. BOILER IS NOT
SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR unless combustible floor shield,
supplied by Burnham, is used. DO NOT install on
carpeting.
2. FOR BASEMENT INSTALLATION, provide a
concrete base if floor is not perfectly level, or if
water may be encountered on floor around boiler.
3. PROVIDE SERVICE CLEARANCE of at least 48”
from the front of the jacket for servicing of burner
and removal of tankless heater.
For minimum clearances to combustible materials. See
Figure 2.
Figure 2: Minimum Clearances to Combustible Materials
NOTE:
1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.
2. HF boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances can not be
reduced for alcove or closet installations.
3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31
standard.
6
C. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate proper combustion. If natural ventilation
is inadequate, provide a screened opening or duct from
the boiler room to the outside. The opening or duct
must be sized so the boiler input will not exceed 4,000
BTUH/Sq. In. of free area. If other air consuming
appliances are near the boiler, the air inlet should be
larger. Consult respective manufacturers.
D. VENTILATION AIR must be provided to maintain the
ambient temperature at safe limits. Local and national
codes may apply and should be referenced.
1. In unconfined spaces (basement) in buildings of
conventional frame, brick, or stone construction,
infiltration normally is adequate to provide air for
ventilation.
2. In confined spaces, two permanent openings, one
near the top of the enclosure and one near the
bottom, shall be provided. Each opening shall have
a free area of not less than 1 sq. inch per 1000
BTUH of the total input of all appliances in the
space.
E. PROVIDE COMBUSTION AND VENTILATION AIR.
Local code provisions may apply and should be
referenced.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
1 . Determine volume of space (boiler room). Rooms
communicating directly with the space in which the
appliances are installed, through openings not
furnished with doors, are considered a part of the
space.
Volume(ft3) = Length(ft) x Width(ft) x Height(ft)
2 . Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round
the result to the nearest 1000 BTU per hour.
3 . Determine type of space. Divide Volume by total
input of all appliances in space. If the result is
greater than or equal to 50 ft3/1000 BTU per hour,
then it is considered an unconfined space. If the
result is less than 50 ft3/1000 BTU per hour then the
space is considered a confined space.
4 . For boiler located in an unconfined space of a
conventionally constructed building, the fresh air
infiltration through cracks around windows and
doors normally provides adequate air for combustion and ventilation.
5 . For boiler located in a confined space or an uncon-
fined space in a building of unusually tight construction, provide outdoor air with the use of two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 3
inches. Size each opening per following:
a. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 BTU per hour
input of all equipment in space.
b. Vertical ducts. Minimum free area of 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.
c. Horizontal ducts. Minimum free area of 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.
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.
6 . Louvers and Grilles of Ventilation Ducts
a. All outside openings should be screened and
louvered. Screens used should not be smaller
than 1/4 inch mesh. Louvers will prevent the
entrance of rain and snow.
b. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens
protecting the openings. If the free area of the
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.
c. Louvers and grilles must be fixed in the open
position, or interlocked with the equipment to
open automatically during equipment operation.
7
II. Installation Instructions
WARNING
Failure to properly pipe boiler ma y result in improper operation and d amage to boiler or
structu re .
Oxyg en c ont amin atio n of boile r wa te r will c ause c orrosio n o f iro n an d st eel bo iler
components, a nd c an lead to boiler failure. Burnham's Standard Warranty does not cover
problems caused by o xygen contam ination of boiler wa ter or scale (lime) bu ild-up caused
by frequent addition of water.
A. Design a piping system and install boiler which will
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
should 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 distribu-
tion system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
WARN ING
System supply and return piping must
be conn ected to corr ect boiler pipe.
Burnham recommends sizing the
s ystem circulator to su pply sufficient
flow (GPM) to allow a 20°F temper ature
diff eren tial i n the s ys tem . When s izing
the system circu lator, the pressu re
drop of all radiators, baseboard and
radiant tubing and all connecting
piping must be considered.
3. Connect System supply and return piping to boiler.
See Figures 8 and 9. Also, consult I=B=R Installation and Piping Guides. Maintain minimum ½ inch
clearance from hot water piping to combustible
materials.
a. If this boiler is used in connection with refrig-
eration systems, the boiler must be installed so
that the chilled medium is piped in parallel with
the heating boiler using appropriate valves to
prevent the chilled medium from entering the
boiler. See Figure 3. Also, consult I=B=R
Installation and Piping Guides.
b. If this boiler is connected to heating coils
located in air handling units where they may be
exposed to refrigerated air, the boiler piping
must be equipped with flow control valves to
prevent gravity circulation of boiler water
during the operation of the cooling system.
c. If boiler is used with an Alliance™ Indirect-
Fired Domestic Water Heater, install the
Alliance as a separate heating zone. Refer to
the Alliance Installation, Operating, and Service
Instructions for additional information.
d. Use a system bypass if the boiler is to be
operated in a system which has a large volume
or excessive radiation where low boiler water
temperatures may be encountered (i.e. converted
gravity circulation system, etc.) The bypass
should be the same size as the supply and
return lines with valves located in the bypass
and return line as illustrated in Figure 4 in order
to regulate water flow for maintenance of higher
boiler water temperature. Set the bypass and
return valves to a half throttle position to start.
Operate boiler until the system water temperature reaches its normal operating range. Adjust
the valves to maintain 180°F to 200°F boiler
water temperature and greater the 120°F return
temperature. Adjust both valves simultaneously.
Closing the boiler return valve while opening
the bypass valve will raise the boiler return
temperature. Opening the boiler return valve
while closing the by-pass valve will lower the
boiler return temperature.
e. A water boiler installed above radiation level
must be provided with a low water cutoff device
as part of the installation.
8
Figure 3: Recommended Piping for Combination
Heating and Cooling (Refrigeration) System
9
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