Burnham PF-3 Installation and Operation Manual

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INSTALLATION

AND

OPERATING INSTRUCTIONS

FOR

PF-3

BOILER

SECTION SECTION I1 - INSTALLATION INSTRUCTIONS - Page SECTION I11 - OPERATING AND SERVICE INSTRUCTIONS - Page

NOTE

For optimum performance and serviceability from this unit adhere to the following recommendations:

1-Clean Flueways at least once a year-preferably at the end of heating season to remove soot and scale.

Inside of Firebox should also be cleaned at the same time. 2-Have Oil Burner and Controls checked at least once a year or as may be necessitated. 3-Retain your contractor or a competent serviceman to assure that the unit is properly adjusted and

,tained.

IMPORTANT: BEFORE STARTING TO INSTALL THIS OIL HEATING UNIT, READ THESE INSTRUCTIONS CAREFULLY. KEEP INSTRUCTIONS NEAR OIL HEATING UNIT FOR

I - GENERAL INFORMATION - Page

FORCED DRAFT

BURNER UNITS

main-

REFERENCE BY OWNER AND SERVICEMAN.

For service and repairs to the heating plant, call your Heating Contractor. When seeking information on the boiler, provide series and size designation shown on rating plate.

Boiler Number Type Firing Type System

Heating Contractor

Address

Wrm

No.

62008E-1/81-1200f

BURNHAM

HYDRONICS DIVISION

Laneaster,

--Phone No

CORPORATION

Pennsylvania

17604

DAMPER

FLUE OUTLET

UTILITY

3411

BELOW WATER

TAPPING

BOILERS

LINE ON STEAM

---d

SUPPLY

/3"

DAMPER

BRACKET

POSITIONIN

DIA. VENT

vzrl

REMOVABLE

PANEL

---

RETURN

ALTERNATE

DRAIN VALVE

REAR VIEh'

SIZE

VENT

DIAM.

L-LF

SECTION THRU BOILER WITH FLUSH JACKET

OPENING,

K.O.

'URN

SIDE VlEW EXTENDED JACKET

FRONT VlEW

FLUSH JACKET

SECTIONS

MODEL NO. OF

Figure

Dimensional Data

SECTION I

GENERAL

INSPECT SHIPMENT carefully for any signs of damage. All equipment is carefully masufactured, inspected and packed by experienced workmen. Our responsibility ceases upon delivery of boiler to the carrier in good condition. Any claims for damage in shipment must be filed If boiler is equipped with tanldess heater, additional

immediately against the carrier by the consignee.

claims for variances from, or shortage in orders, will be icing of heater, see table below:

allowed by the manufacturer, unless presented within

(60)

sixty

chimney is short and direct. Floor construction should have adequate load bearing characteristics to bear the weight of the boiler filled with water. See table below.

BOILER

F-34

F-35

F-36

F-37

ure

fectly level, weak, uneven or if a water condition exists. If the boiler is set on a combustible floor, a of foil-faced insulation or equivalent should be placed

beneath the boiler foil side up.

days after receipt of goods.

LOCATE BOILER so that smoke pipe connection

ASSEMBLED

SECTION

A boiler foundation similar to the one shown in Fig-

is recommended if the boiler room floor is not Per-

WEIGHT

(LBS.)

800 1000 1200 1400

Table "A"

WATER

CONTENT

FULL

(LBS.)

276 335 402 465

WEIGHT

thick layer

44.

50.

INFORMATION

PROVIDE CLEARANCE of at least

right side and back of the unit for cleaning of flues. Pro-

TOTAL

(LBS.)

1076 1335

1602 1865

vide a minimum of equipment,

allowance may have to be made for installation and serv-

Distances are measured from front of flush jacket.

designed for forced-draft firing and may be used with a conventional natural draft stack or a stub vent (see Fig-

3).

ure trols are not normally required, although they may be used on installations where a natural draft stack is used or on multiple boiler installations with a common stack. The boiler is provided with should be secured in the open position unless high breeching draft makes burner adjustment difficult.

must be provided. If natural ventilation is inadequate, provide a screened opening from the boiler room to the outside, which is based on one square inch free

3000

near the boiler the air inlet should be larger. Consult respective manufacturers.

30"

HEATER

226 232

445

CHIMNEY OR VENT. The PF-3 series boiler is

See Fig. 1 for the proper vent size.

AIR FOR COMBUSTION AND VENTILATION

btuh input. If other air consuming appliances are

24"

on the

20"

if boiler is equipped with jacket extension.

clearance in front for servicing of

HEATER

CLEARANCE

INCHES

2 3 29

Table "B"

Draft con-

breeching damper which

afea per

114 X 4

STEEL

PLATE

Figure

SUGGESTED BOILER Figure

FOUNDATION STUB VENT

ARRANGEMENT FOR

SECTION I1

INSTALLATION

Place boiler assembly on foundation provided. Shim

if necessary. The tie rod nuts should then be loosened until finger tight.

"INSTALLATION OF BUILT-IN HEATERS AND

HEATER OPENING COVER PLATES"

INSTALLATION OF BUILT-IN DOMESTIC WA-

TER HEATER if furnished.

a. Slip Rubber Gasket over Heater Coil and place

against Heater Mounting Plate so that holes in Gasket are in line with holes in Heater Mounting Plate.

b. Install Built-in Heater Coil through

Front Section into the upper nipple port for water boilers or the lower nipple port for steam boilers.

(See Fig.

4).

c. Secure the Heater Mounting Plate with

Head Cap Screws and Flat Washers (if furnished). Snug all screws before final tightening.

d. Attach the Tapped Heater Cover Plate with Rubber

Gasket to the remaining opening in the Front Section. Secure with

3/8"

Hex Hd. Cap Screws and Flat Washers (if furnished). Snug all screws before tightening.

INSTALLMENT OF HEATER OPENING COVER PLATES if Built-in Domestic Water Heater is not furnished. (Steam and Water Boilers). See Figure

a. Attach Blank Heater Cover Plate with Rubber Gas-

openihg in

3/8

Hex

INSTRUCTIONS

ket to the lower nipple port in Front Section using

3/8"

Hex Hd. Cap Screws and Flat Washers (if

furnished). Snug all screws before final tightening.

b. Attach the Tapped Heater Cover Plate with Rubber

Gasket to the upper nipple port in Front Section using

3/8"

(if furnished). Snug all screws before final tight-

ing.

TEST BOILER FOR LEAKS before installing controls, trim, and jacket, and before connecting to heating system.

a. Install Pressure Gauge (at least

a hose to the City Water and a valve in one of the

supply tappings. Plug remainder of tappings.

b. Fill Boiler with water and apply a pressure of at

least pressure.

c. Examine Boiler carefully inside and outside for leaks

or damage due to shipment or handling.

DRAIN WATER FROM BOILER. Remove gauge, valve and plugs from those tappings to be used. other tappings plugged or bushed according to Figure

INSPECT JOINTS BETWEEN SECTIONS. All joints are factory sealed. If there are any spaces due to shipment or handling, seal them with silastic sealant.

Hex Hd. Cap Screws and Flat Washers

P.S.I. capacity),

pounds but no more than

pounds gauge

Leave

LOCATION

ON BOILER

SIZE

(INCHES)

Iml

1 1

(11/2

1/2

3/4

WATER

'ONTRoL

SAFETY RELIEF USED

LlMlT CONTROL OR COMBINATION HlGH LlMlT AND CIRCULATOR CONTROL (FOR INSTALLATIONS WITHOUT

TANKLESS

WATER

HEATER)

COMBINATION HlGH LIMIT, LOW LlMlT AND CIRCULATOR CONTROL (FOR INSTALLATIONS WITH TANKLESS HEATER)

COMBINATION PRESSURE AND TEMPERATURE GAUGE

AUXILIARY LlMlT CONTROL (WHEN NEEDED-TEQUIRES ADDITIONAL TAPPED HEATER OPENING COVER

P~OUT

TANKLESS HEATER)

NOT USED

AUXILIARY TAPPING

BUSH TO 1/4"

OR OPTIONAL CONTROLS

STEAM PRESSURE GAUGE

GAUGE GLASS AND LOW WATER CUT-OFF

AUXILIARY TAPPING-BELOW NORMAL WATER LINE

PRESSURETROL-

Fig.

WATER HEATER A

(OPTIONAL)=

STEAM BOILER

,3'

SUPPLY

IN BACK SECTION

1nw

OR9UI

VUkE

rnw~Amws~w

WATER BOILER

(1)

INSTALL CAST IRON CLEANOUT COVERS to the boiler with should be anchored to the slots in the cleanout openings of the sections with inside and a washer and nut outside. See Figure 5. The covers are placed on the bolts.and secured with washers and nuts.

CLEANOUT COVER

INSULATION

CLEANOUT NUT AND WASHER

2%''

long bolts provided. The bolts

the head of the bolt and

TOP

VIEW

COVER GASKET

WASHERS

CLEANOUT COVER ASSEMBLY

Fig.

FLUE COLLAR should be assembled next. Clean the ground surface on the flue collar and the mating ground surface on the back section with Then using a cartridge of silastic sealant provided, apply a smooth face on the back section. Place the collar on the back section and position the damper bracket on the collar as, shown in Figure

bolts provided.

ground surface on the burner plate and the mating sur-

face on the front section with a wire brush. Then using a cartridge of sealant provided, apply a smooth eter bead of sealant to the ground surface of the front

section. Secure the burner plate to the front section with

the 5/16 x until the burner plate makes contact with the front section.

IMPORTANT-THIS BOILER DOES NOT REQUIRE A COMBUSTION CHAMBER OR SEPARATE SMOKEHOOD.

1/4"

diameter bead of sealant to the ground sur-

Secure the collar with the 5/16"

INSTALL BURNER PLATE as follows: Clean the

long bolts provided. Draw-up the bolts

washer

wire brush.

diam-

CONNECT SUPPLY AND RETURN PIPING TO

HEATING SYSTEM. NOTE-If jacket extension (special order only) is to be

installed now or in the future, return piping connected to front section must pass thru opening provided in extension, see Fig. circulator in this return (water boiler) must be selected so that circulator does not extend beyond sides of flush

jacket.

a. If boiler is equipped with tankless heater, hot and

cold water lines must be routed thru opening provided in Jacket Extension Top Panel. Refer to FIG. 18 for

b. All Piping must be installed so as to provide clear-

ance for running the Smokepipe as direct as possible between the Boiler and Chimney.

c. With Forced Circulation HOT WATER HEATING,

consult I-B-R Installation and Piping Guide No. NOTE: When Hot Water Heating Boilers are connected to Heating Coils located in Air Handling Units where they may be exposed to refrigerated air circulation, the Boiler Piping System must be equipped with Flow Control Valve or other automatic means to prevent gravity circulation of the Boiler Water during Cooling Cycle.

d. With STEAM HEATING, see Figures

Consult I-B-R Piping Guide No.

e. With COMBINATION HEATING AND COOLING

(REFRIGERATION) SYSTEMS having the same Distributing Units, Piping and Circulator, see Figure 6. NOTE: Valves must be installed in each Supply and Return Branch to the Heating Boiler and Water Chiller so as to prevent circulation of Chilled Water through the Boiler or Heated Water through the Chiller.

In addition, fittings used to connect

Tankless Heater Piping.

ARE CLOSED IN WINTER AND OPEN IN SUMMER

ARE OPEN IN WINTER AND CLOSED IN SUMMER

WATER CHILLER

200.

and 8.

--Ic

SUPPLY MAIN TO COMBINED HEATING

COOLING SYSTEM

SHUT- OFF

HEATING

[AIR CUSHION TANK

If"

BOILER

CIRCULATOR FROM

RECOMMENDED PIPING FOR COMBINATION

HEATING

COOLING IREFRIGERATION) SYSTEMS

Fig.

SHUT- OFF VALVE

RETURN MAIN

HFATING

.;;;;;

COOLING

COMBlNECl

M-

STEAM SUPPLY MAIN -SLOPE DOWN FROM HIGH POINT ABOVE BOILER AN0 DRIP ENDS OF MCllNS INTO WET RETURN

PIPE DISCHARGE TO DRAIN

KEEP STEAM BOILERS FILLED TO NORMAL WATER LlNE

1W.L

LOW POINT OF SUPPLY MAIN TO BE NOT LESS THAN

29' ABOVE WATER LlNE

CLOSE OR SHOULOER NIPPLE

GRAVITY RETURN

4" - PUMP RETURN

HEADER -24. MIN. ABOVE WATERLINE

Fig.

Minimum Piping Recommendations

and 5 Section Steam Boilers

PREFERRED HARTFORO RETURN

CONNECTION

STEAM PITCH DOWN TO BOILER

SUPPLY MAIN TO BE TAKEN

WADER VERTICALLY OR AT

GRAVITY RETURN

WET RETURN

OFF TOP OF

45'

ANGLE.

KEEP STEAM BOILERS FILLED TO NORMAL WATER LlNE

GRAVITY RETURN

PUMP RETURN

PROVIDE FLUSHING BOILER AND SYSTEM

Fig.

Minimum Piping Recommendations

and 7 Section Steam Boilers

PREFERRED HARTFORD RETURN

CLOSE OR SHOULDER NIPPLE

PREFERRED HARTFORD RETURN CONNECTION - GRAVITY RETURN

STEAM -WET RETURN PITCH DOWN TO BOILER

DRAIN COCKS FOR

AND

PLACE REAR PANEL IN POSITION

ATTACH LEFT AND LOWER RlGHT HAND

SlDE PANELS TO FLANGES ON REAR

PANEL WlTH S.M.S.

PANEL BY SLIDING DOWN UNTIL

INSTALL UPPER RlGHT HAND SlDE

BOTTOM FLANGE IS FULLY SEATED

PANEL. ATTACH TO FLANGES ON

BEHIND LOWER RlGHT HAND SlDE

FRONT AND REAR PANELS WITH S.M.S.

VOlD

LEAVING UPPER FRONT HOLE

UNTIL INSTALLATION OF TOP PANEL.

with

accordance

PANELS. SECURE WlTH S.M.S.

POSITIONED OUTSIDE REAR AND SlDE

INSTALL TOP PANEL WlTH FLANGES

PANEL

REAR

S-.

PANEL

ATTACH RATING PLATE

HERE USING S.M.S.

RlGHT HAND

UPPER

PANEL

ASSEMBLE LOWER RIGHT HAND SlDE PANEL

RlGHT HAND

LUWtK

PANEL FLANGE ON FRONT PANEL WITH S.M.S.

Fig.

FLUSH JACKET ASSEMBLY

-----k?

for knockouts to be removed.

Refer to Figure

INSTALL FLUSH JACKET

Fig.

UNTIL ALL PANELS HAVE BEEN TOP

INSTALLED.

DO NOT TIGHTEN ANY S.M.S.

REMOVE NECESSARY KNOCKOUTS.

PANEL TO FLANGE ON FRONT

@ASSEMBLE LEFT HAND SIDE

BLOCKS UNDER REAR OF

PANEL WITH S.M.S. LEAVING

UPPER HOLE VOlD UNTIL

INSTALLATION OF TOP PANEL.

ASSEMBLY.

SlDE PANELS WILL FACILITATE

ATTACH LOWEST

WATER PLATE USING S.M.S.

TION BY SLIDING DOWN BEHIND

PLACE FRONT PANEL IN POSI-

WITH S.M.S.

BURNER PLATE FLANGE. ASSEM-

BLE TO FRONT PANEL FILLER

PIECE

PIECE BELOW BURNER PLATE

INSTALL FRONT PANEL FILLER

POSITIONING BEHIND FLANGE.

FRONT PANEL FILLER PIECE

INSTALLATION OF TRIM AND CONTROLS

FOR WATER BOILERS. (See Figure

Locations.)

a. Screw COMBINATION ALTITUDE GAUGE AND

THERMOMETER into wrench applied to square shank back of gauge. DO

NOT APPLY PRESSURE ON GAUGE CASE since this may destroy calibration of gauge.

b. RELIEF VALVE-Install in

Supply Tapping in Front Section using fittings provided. CAUTION and open drain-full size of discharge outlet on Relief Valve and without any provision of "shut-off" between the Relief Valve and discharge into drain.

c. Install Hydronic

pings.

INSTALLATION OF TRIM AND CONTROLS FOR STEAM BOILERS. (See Figure locations.)

Screw Combination Pressure Vacuum Gauge into

designated

to square shank on back of gauge. Do not apply

pressure on gauge case since this may destroy cali-

bration

b. SAFETY VALVE. Install in

Supply Tapping in Front Section. CAUTION: Safety Valve should be piped to an open drain-full size of discharge outlet on Safety Valve and without any provision of "shut-off" between the Safety Valve and discharge into drain.

c. Install Pressure Limit Control with

Syphon into Heater Cover Plate Tapping bushed

G".

d. Install Operating Control (supplied with Tankless

Heater equipped boilers only) in designated tapping.

e. Install Gauge Glass and Low Water Cut-off (if fur-

nished) in tion.

INSTALL SMOKEPIPE so that connection

Chimney or vent is short and direct.

Safety Relief Valve should be piped to

Controls in their designated tap-

tapping. Tighten by wrench applied

of gauge.

y2"

tappings on left side of Front Sec-

tapping. Tighten by

for Control

Tapping next to

for control

Tapping next to

1/4"

Pig Tail

3/4"

a. Install in accordance with LOCAL FIRE ORI-

NANCES.

b. Smokepipe must not be smaller than the

collar. See Fig. For Stub Vent installation see Fig. to chimney.

c. Do not connect into same leg of Chimney serving an

open fireplace.

d. Inspect Chimney for obstructions or restrictions

which should be removed. Clean Chimney if necessary.

e. Smokepipe should slope upward from Boiler to

Chimney not less than one inch in four feet. Smokepipe must be securely supported so as to maintain, proper clearances from combustible materials and to prevent separation of joints.

f. Insert Smokepipe into but not beyond inside wall of

Chimney Flue Lining. Pipe should be installed above the extreme bottom of Chimney so as to prevent stoppage.

Seal between Smokepipe and Chimney connection to prevent draft leakage.

INSTALL ROOM THERMOSTAT on an inside wall about four feet above floor. stat on an outside wail or where it will be influenced by

drafts, hot or cold water pipes, lighting fixtures, television, rays of the sun, or near a fireplace. Keep large furniture away from Thermostat so there will be free movement of room air around this Control.

OIL BURNER INSTALLATION. Bolt burner to mounting plate with nuts and washers packed in boiler parts carton. REFER TO BURNER INSTALLATION and SERVICE MANUAL form No.

BOILER with JACKET EXTENSION refer to

Figure

NATIONAL ELECTRICAL CODE and Local Regula-

tions.

gram.

for assembly instructions.

INSTALL ELECTRIC WIRING in accordance with

A separate ELECTRICAL CIRCUIT should be run from Meter with a Fused Disconnect Switch in

this Circuit.

See Figures

thru

Never install Thermo-

52004.

for appropriate wiring dia-

dia. flue

if connected

MUST BE LOOSENED.

ALL FLUSH JACKET SCREWS ATTACHING

SlDE PANELS TO THE FRONT PANEL

FLUSH JACKET

ASSEMBLE THE TWO EXTENSION

SlDE PANELS WlTH THE NOTCHED

FLUSH JACKET SlDE AND FRONT

PANELS. TIGHTEN SCREWS TO

EDGE INSERTED BETWEEN THE

HOLD PANELS IN PLACE.

HAND

RIGHT

SlDE

PANEL

FOUR

THE

WITH

BOTTOM FRONT TIE PANEL

Fig.

Jacket Extension Assembly

SECURE WlTH THE SIX SHORT S.M.S.

POSITION WlTH THE FLANGES EXTENDING

PLACE THE EXTENSION TOP PANEL IN

DOWN OVER THE EXTENSION SlDE PANELS.

ENGAGE THE BOTTOM

FLANGE FIRST, FULLY SEAT

TO INSTALL THE FRONT DOOR

'PANEL

THE TOP OF PANEL WHILE

LATCH AND RELEASE LATCH

HOLDING DOWN THE DOOR

TO SECURE PANEL IN POSITION.

PANELS

TIE PANEL TO THE EXTENSION

SIDE

LONG SHEET METAL SCREWS.

ASSEMBLE THE BOTTOM FRONT

LOW WATER

CUTOFF PRESSURE LIMIT

HONEYWELL PA 404A

CONTROL

THERMOSTAT

HOT

LlNE

NEUTRAL

When the thermostat calls for heat, it energizes the cad cell protectorelay, bringing on the burner. The burner operate until the thermostat is satisfied or the limit setting on ,the high limit is reached. When the high limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The low water cut-off will stop the burner if the water level in the boiler drops too low.

On burner start, if the cad cell does not see flame within approximately and must be reset before burner can be restarted.

E$go'S:D

SWITCH

IGNITION-

TRANSFORMER

No.

Wiring

LOW WATER

CUTOFF

;

W-

HONEYWELL R8184

PRIMARY CONTROL

I I

OIL BURNER

SEQUENCE OF OPERATION

Diagram

for

Steam

HONEYWELL PA 404A THERMOSTAT PRESSURE LIMIT CONTROL

TFOI.

seconds, protectorelay will lock out on safety

Boilers

Less

I,(/I IMC

Heater

.,-...a-

,.-.

UtLAT

VALVE

...

Fig.

will

HOT

LlNE

NEUTRAL

When the thermostat calls for heat, it energizes the cad cell protectorelay, bringing on the burner. The burner will operate until the thermostat is satisfied or the limit setting on the high limit is reached. When the high limit control restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The low water cut-off will stop the burner if the water level in the boiler drops too low.

On burner start, if the cad cell does not see flame within approximately and must be reset before burner can be restarted.

When there is no demand for heat, the operating con,trol will maintain the boiler water temperature at the selected setting

for the proper operation of the domestic water heater.

E~~oS<O

SWITCH

No.

TRANSFORM

Wiring

SEQUENCE OF OPERATION

Diagram

OIL BURNER

for

Steam

Boilers

IMMERSION

OPERATING CONTROL

seconds, protectorelay will lock out on safety

with

Tankless

Heater

Fig.

HONEYWELL L40818 IMMERSION CIRCULATOR

AND

LIMIT CONTROL

Fig.

SEQUENCE OF OPERATION

A call for heat by the thermostat energizes the R8184 control to bring on the burner. If burner ignites within approximately 45 seconds (safety switch timing), cad cell sees flame and burner continues to operate until call for heat is satisfied.

Circulator will run as long as boiler water temperature is up to the low limi,t setting of the L4081B controller. (terminals R-W).

If boiler water temperature reaches setting of the high limit control (part of the L4081B controller) burner operation will be discontinued but circulator will continue to operate as long as boiler water temperature is up to the setting of the low limit side of the drop in boiler water temperature the burner will resume operation if the thermostat is still calling for heat.

L4081B controller.

When the high limit side of the

L4081B restores the circuit (terminals R-W)

on a

No. 4 Wiring Diagram for Forced Hot Water Boilers Less Heater

HONEYWELL RE184

IMMERSION

TRANSFORME

Fig.

CIRCULATOR

OIL BURNER

SEQUENCE OF OPERATION

call for heat by the thermostat energizes the L8124C Control which in turn energizes the R8184 control to turn on the burner. If burner ignites within approximately 45 seconds and the cad cell sees flame the burner will continue to operate until the call for heat is satisfied. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low limit in the L8124C control.

boiler water temperature is below the low

limit setting the burner will operate but the circulator will not, giving preference to the domestic hot water demand. On call for heat by the thermostat the burner will continue to operate until the thermostat is satisfied or the setting of

the high limit is reached. If the thermostat is not satisfied when the high limit is reached the burner will stop but the circulator will continue to operate until the thermostat is satisfied.

Any time the boiler water temperature drops below the maintain domestic water temperature.

setthg of the low limit ,the burner will be energized in order to

No. 5 Wiring Diagram for Forced Hot Water Boilers with Tankless Heater

--I

K0d

ENCLOSED

TCH

NEUTRAL

LINE

HOT

THERMOSTAT

HONEYWELL

L8124C

IMMERSION

CONTROL

RELAY

THERMOSTAT

CIRCULATOR

SEQUENCE

call for heat by the thermostat for Zone turn energizes the R8184 control to turn on the burner. If burner ignites within approximately 45 seconds and the cad cell sees flame the burner will continue to operate until the call for heat is satisfied. The circulator will also operate when the thermostat calls for heat if the boiler water temperature is up to the setting of the low limit in the control. If boiler water temperature is below the low limit setting ,the burner will operate but the circulator will not, giving preference to the domestic hot water demand.

On call for heat by the thermostat the burner will continue to operate until the thermostat is satisfied or the setting of the high limit is reached. If the thermostat is not satisfied when the high limit is reached the burner will stop but the circulator will continue to operate until the thermostat is satisfied.

Any time the boiler

maintain domestic water temperature. For any of the "add on" zones the operation is basicallv the same as Control Set #5 except for the fact that the thermo-

stat for the add on zones energizes the R845A switching re,ay which then energizes the burner through -the L8124C controller and the none of the "add on" zone circulators can be energized unless the boiler water temperature is up to the low limit setting again giving preference to the domestic water demand.

water temperature drops below the setting of the low limit the burner will be energized in order to

R8184 control. Since the power to the Ka45A switching relays is supplied by the L8124C low limit switch

connected to the L8124C control energizes the L8124C control which in

OPERATION

RELAY

CIRCULATOR

HONEYWELL

L8124C

52 Wiring Diagram for "Add-On" Zone Control Set

SET NO. BOILER WITH CIRCULATOR AND STORAGE TANK DOMESTIC HOT WATER

HONEYWELL L4006A

IMMERSION OPERATING

CONTROL

I,(

No. 6 Wiring Diagram for Forced Hot Water

Boilers with Storage Tank Heater

THERMOSTAT

SET NO. BOILER WITH CIRCULATOR AND TANKLESS DOMESTIC HOT WATER

IGNITION

TRANSFORME

OIL

HONEYWELL

IMMERSION

CONTROL

HONEYWELL

BURNER

L4080B

LIMIT

HONEYWELL

-0B

IMMERSION

R8184

No. 7 Wiring Diagram for Forced Hot

Water Boilers with Tankless Heater

VALVE

-OIL

OPERATING

CONTROL

CIRCULATOR

L6006A

ENCLOSED

THERMOSTAT

HOT

NEUTRAL

Fig.

SECTION I11

OPERATING

INSPECT INSTALLATION BEFORE STARTING

BURNER.

a. WITH HOT WATER BOILER, fill entire Heating Limit Control at 210°F. This temperature may

System with water and vent air from System.

WITH

Water Level. (See Figure 1).

CHECK CONTROLS, WIRING AND BURNER to

be sure that all connections are tight and burner

is rigid, that all electrical connections have been

made and fuses installed, and that oil tank is fill-

ed and oil lines have been tested. LUBRICATE MOTORS on Oil Burner and Circu-

lator (Hot Water Boilers), also bearing on Cir-

culator, according to instructions on Circulator.

SET CONTROLS with Burner service switch turn-

ed "OFF."

a. SET ROOM THERMOSTAT about 10°F above

room temperature. b. Press reset button on PROTECTORELAY.. c. On STEAM BOILERS, set cut-in pressure for

three

two (2) pounds. These pressures may be varied

to suit individual requirements of installation.

STEAM BOILER, fill Boiler to Normal

(3)

pounds and differential pressure for

and

SERVICE INSTRUCTIONS

d. On WATER BOILERS WITHOUT DOMESTIC

WATER HEATERS, set water temperature High

be varied to suit requirements of installation.

e. On WATER BOILERS WITH DOMESTIC

WATER HEATERS, set Operating Control at 190°F and High Limit Control at 210°F (at least 20°F higher than setting of Operating Control).

f. On STEAM BOILERS WITH TANKLESS

DOMESTIC WATER HEATERS, set boiler water temperature Operating Control at 200°F.

START OIL BURNER. Refer to oil burner instal-

lation and operation manual FORM NO. 52004 for start-

up, adjustments

TEST CONTROLS.

WARNING

considered complete, the operation of the boiler controls

should be checked, particularly the low water cut-off (if applicable) and the high limit control.

servicing.

Before installation of the boiler

(5)

CLEAN STEAM HEATING SYSTEM for trouble free operation. Oil, greases and sediments which accumulate in a new boiler and piping must be removed from

the system in order to prevent an unsteady water line and carry over of water into the Supply Main above boiler.

a. Operate the boiler with steam in the entire system

for a few days allowing the condensate to return to the boiler. If the condensate can temporarily be wasted, operate boiler only for the length of time

it takes for condensate to run clear. If the latter cannot be achieved or if the condensate is return-

ed to the boiler,

FACE

1). Drain boiler until water is just visible in gauge glass. Run temporary Blowoff Connection to an open drain or some other location where hot water may be discharged safely. Do not

install valve in this line.

Drain about 5 gallons of hot water from boiler into

2). a container and dissolve into it

and

pound of trisodium phosphate for each 50 gallons of boiler water. See table below. Remove safety valve and add solution to boiler water thru exposed tapping.

Boiler Water Capacity

No.

PF-34 27 0.5 0.5 PF-35 33 0.7 0.7 PF-36 40 0.8 0.8 PF-37 46 0.9 0.9

(Caution Caustic Soda is harmful to skin, clothing, and eyes. not permit the dry material or the concentrated solution to come into contact with skin or clothing.)

Start burner and operate sufficiently to boil the

3).

water without producing steam pressure. Boil for about 5 hours. Open boiler feed pipe sufficiently to per-

mit a steady trickle of water from the surface blowoff. Continue this slow boiling and trickle of overflow for several hours until the water coming from the overflow is clear.

Stop burner and drain boiler in a manner and to

4).

a location that hot water can be discharged with safety.

5). Refill boiler to normal water line. If water in gage glass does not appear to be clear, repeat steps 1) thru

6). Remove temporary surface blowoff piping, plug

tapping and reinstall safety valve.

temperature to 180°F promptly in order to drive off the dissolved

BLOWOFF connection, see Figure 4.

to Water Line Soda

Use extreme care in handling these chemicals.

and boil out the boiler for a long time.

g.ases in the fresh water.

boilout the boiler using the SUR-

1%"

pipe line from the Surface

pound of caustic soda

Caustic Trisodium

gals. Ibs. lbs.

Boil or bring water

Phosphate

If unsteady water line, foaming or priming persist, install gate valve in Hartford Loop and drain valves in return main and at boiler as shown in Figures 7 and

proceed as follows:

7).

Connect hoses from Drain Cocks to floor drain. Close Gate Valve in Hartford Loop and open Drain Cock in Return Main. Fill Boiler to normal water level, turn on Oil Burner and operate Boiler at this water level for at least 30 minutes after the condensate begins to run hot, then turn off Burner.

8). Close all Radiator Valves. Remove all Supply Main

Air Valves and plug the openings in Supply Main.

9). Draw about into a container and dissolve into it the quantities of caustic soda and trisodium phosphate shown in 2.) above. Remove Safety Valve from Boiler and pour this wlution into Boiler, then reinstall Safety Valve.

10). Turn on Oil Burner and keep operating while feeding water to Boiler slowly. This will raise water level in Boiler slowly so that Water will be boiling hot and will

rise slowly into Supply Main and back through Return Main, flowing from drain hose at about 180°F. Con-

tinue until water runs clear from drain hose for at least

30 minutes.

11). Stop feeding water to Boiler but continue operating

Oil Burner until excess water in Boiler flows out

through

until it reaches normal level in Boiler. Turn off Oil

Burner. Drain Boiler. Open all Radiator Valves. Re-

install all Supply Main Air Valves. Open Gate Valve in Hartford Loop.

12). sheet of Sections are not too hot to touch), close the Drain Cocks at Boiler and in Return Main and feed water slowly up to normal level in Boiler. Turn on Oil Burner and allow Boiler to steam for 10 minutes, then turn off Burner. Draw off one quart of water from bottom Gauge Glass Fitting and discard. Draw off another quart sample and if this is clear, the Boiler is ready for service. If this sample is not clear, repeat the cycle of draining the Boiler and Return Main and refilling the Boiier until sample is clear.

13). If the Boiler water becomes dirty again at a later date due to additional sediment loosened up in the piping, close Gate Valve in Hartford Loop, open Drain Cock in Return Main, turn on Oil Burner and allow Conden-

sate to flow to drain until it has run clear for at least 30 minutes while feeding water to Boiler so tain normal water level. Turn off Oil Burner, drain Boiler, open Gate Valve in Hartford Loop, then repeat step 12 above.

Supply Main and water lowers (by steaming)

When Boiler has cooled down sufficiently

gallons of Hot Water from Boiler

(crown-

to main-

and

ATTENTION TO BOILER WHILE IN OPER-

ATION.

a. On steam boilers at the start of each heating season

and once or twice during the season try SAFETY VALVE to be sure it is in working condition. A

try lever test should be performed as follows: with the boiler under a minimum of 5 psi pressure, lift the try lever on the safety valve to the wide open position and allow steam to be discharged for 5 to

sec. release the try lever and allow the spring to snap the disk to the closed position. If valve leaks operate lever two or three times to seat disk

properly. If valve continues to simmer it must be replaced or repaired. It is advisable to have a chain or wire attached to lever of valve so test can be conducted in a safe manner.

b. On a water system at the start of each heating sea-

son and once or twice during the season try safety relief valve to be sure it is in working condition. A try lever test should be performed as follows:

1) Lift the try lever to the open position and hold it open for at least 5 ed.

2) Release the lever and allow the spring to snap the

disk to the closed position.

the try lever two or three

sec or until clear water is discharg-

If the valve leaks, operate

times to clear the seat of any

object that is preventing proper seating. As safety relief valves are normally piped to the floor or near a floor

drain. it may take some time to determine if the valve has shut completely.

3) If the safety relief valve continues to leak it shall be replaced with turer for repair or field repaired by the manufacturer.

ATTENTION TO BOILER WHILE NOT IN OPERATION. inspected man to insure continued reliable, safe operation.

season.

a. Remove upper right hand jacket panel by remov-

b. Access to boiler flue ways may be gained by remov-

c. Thoroughly clean flue ways using a flue brush.

e. Replace smokepipe and cleanout covers.

f. Replace upper right hand jacket panel.

Clean Boiler as follows at the end of each heating

ing screws, lifting and swinging out bottom of panel using two finger holes.

ing nuts and washers securing cast iron

covers. Refer to Figure 5..

Remove and clean smokepipe where feasible.

new valve, returned to the manufac-

The boiler and steam system should be

least once each year by a competent .service-

cleanout

TANKLESS HEATER PERFORMANCE

Tankless and water) are given in gallons per minute continuous draw of water heated from 40°F to 140°F with 200°F boiler water.

(

Boiler Model Heater Number Pressure

Number 226 232 445 Drop (psi)

PF-34 6.0 PF-35 6.0 7.5 PF-36 PF-37

er is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand. For this reason a FLOW REGULATOR matching the heater rating should be installed in the cold water line to the heater. The flow regulator should preferably be located below the inlet to the heater and from the inlet so that the regulator is not subjected to

excess temperatures that may occur during "off" periods when it is possible for heat to be conducted back through the supply line. The flow regulator also limits the flow

of supply water regardless of inlet press variations in the

range of 20 to 125 psi.

water heater ratings for PF-3 boilers (steam

Tankless Water

FLOW REGULATION-If flow through the heat-

6.0 7.5 9.0 37

minimum of 3' away

23 36

FLUSHING OF HEATER - All water contains some sediment which settles on the inside of the coil. Consequently, the heater should be periodically backwashed. This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hodebib A, through the heater, and out hosebib B until the discharge is clear. The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop.

(?)

HARD WATER - This is applicable to some city water and particularly to well water. This should not be a deterent but precautions are necessary. A water analysis ncr installed. but to piping and fixtures plus the many other benefits

derived from soft water.

is necessary and an appropriate water softe-

This is not only beneficial to the heater

TANKLESS

HEATER

TEMPERED HOT WATER AUTOMATIC TO FAUCETS

AND SHOWERS

HIGH TEMP. WATER FOR

TEMPERING OF HOT WATER a tempering or mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents excessive and possibly scalding hot water at the fixtures. In addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking water temperatures to his liking. Higher temperature hot water required by dishwashers and automatic washers is possible by piping the

hot water from the heater prior to entering the mixing

valve. The mixing valve should be "trapped" by install-

ing it below the cold water inlet to heater to prevent lime formation in the valve.

Installation of

COLD WATE~

SUPPLY

GLOBE VALVE

SQ.

HD. COCK

;

SAFETY

RELIEF

VALVE

SCHEMATIC

IN COLD WATER LINE AT LEAST AHEAD OF TANKLESS HEATER

FEET

TANKLESS HEATER PIPING

Fig.

LIMITED WARRANTY

Burnham Corporation warrants to the original owner at the original installation site that products manufactured by the Hydronics Division comply at the time of manufacture with recognized Hydronic industry regulatory agency standards and requirements then in effect and will be free from defects in materials and workmanship for a period of 12 months after the date of the installation.

THE REMEDY FOR BREACH OF THlS WARRANTY IS EXPRESSLY LIMITED TO THE REPAIR OR REPLACEMENT OF ANY PART FOUND TO BE DEFECTIVE UNDER CONDITIONS OF NORMAL USE AND DOES NOT EXTEND TO LIABILITY FOR INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES OR LOSSES SUCH AS LOSS OF THE USE OF THE MATERIALS, INCONVENIENCE OR LOSS OF TIME. THlS WARRANTY IS IN LIEU OF ALL

OTHERS AND ANY IMPLIED WARRANTIES (INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) ARE EXPRESSLY LIMITED

THE PERIOD OF 12 MONTHS AFTER THE DATE OF INSTALLATION.

Warranty service can be obtained by contacting the original installer of the equipment and providing him with a detailed description of any apparent defect.

satisfactory warranty service, the owner should notify the Burnham Corporation, Hydronics

Division, PO. Box 3079, Lancaster, Pa. 17604. Transportation to a factory or other designated facility

for repairs of any materials or items alleged defective shall in all events be the responsibility and at the cost of the owner. Failures resulting from misuse, improper installation or lack of maintenance

are not covered by this warranty. In no event shall the exceed the selling price of the product found to be defective.

Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

Burnham Corporation's liability hereunder

this procedure fails to result in

!N DURATION

BURNHAM CORPORATION

Hydronics Division

Lancaster,

Pa.

17604

Burnham PF-3 Installation and Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual