Burnham SPACEMASTER SM Series Installation, Operating And Service Instructions

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Price - $3.00

IMPORTANT INFORMATION

PLEASE READ THIS PAGE CAREFULLY

This boiler has a limited warranty, a copy of which is

printed on the back page of this manual.

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.

This equipment shall be installed in accordance with

those installation regulations in force in the area where
the installation is to be made. These shall be carefully
followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.

Boiler should be positioned to provide minimum side

clearances of 1”, minimum top clearance of 6”, minium
front clearance of 2”, minimum rear and fl ue system
clearances of 0” and minimum fl oor clearance of 6”
between boiler surfaces and any combustible materials.
(See Figure 3).

Boiler must also be positioned to provide minimum

clearances between edge of vent terminal and exterior
obstructions. Provide minimum overhang clearance
of 7”, minimum above grade clearance of 12” and
minimum side obstruction clearance of 18”. (See
Figure 2).

In all cases, clearance between boiler jacket and

vent system surfaces and combustible materials
must comply with the National Fuel Gas Code, ANSI
Z223.1, and local jurisdictions.

Keep boiler area clear and free from combustible

materials, gasoline and other fl ammable vapors and
liquids.

Do not place any obstruction in the boiler room that

will hinder the fl ow of ventilating air.

Boiler must be installed with the vent/intake air system

supplied as part of the unit, without alteration.

The wall thickness through which the unit may be

installed must not exceed a minimum of 5” or a
maximum of 15”.

a. Misc. Parts Carton — Part No. 6050301
(5” to 9” thick walls) — Standard

b. Misc. Parts Carton — Part No. 6050302
(9” to 15” thick walls) — Optional

The boiler shall be installed such that the gas ignition

system components are protected from water (dripping,
spraying, rain etc.). during boiler operation and service
(circulator replacement, control replacement, etc.).

It is the responsibility of the installing contractor to

see that all controls are operating properly when the
installation is completed.

Service on this boiler should be undertaken only by

trained and skilled personnel.

Post instructions near boiler for reference by owner and

serviceman.

Maintain instructions in legible condition.

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a. Seal any unused openings in the common venting

system.

b. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
defi ciencies which could cause an unsafe condition.

c. Insofar as is practical, close all building doors and

windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fi replace dampers.

d. Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.

e. T est for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the fl ame
of a match or candle, or smoke from a cigarette,
cigar or pipe.

f. After it has been determined that each appliance

remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fi replace dampers and
any other gas burning appliance to their previous
conditions of use.

g. Any improper operation of the common venting

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

2

Figure 1

MAXIMUM DESIGN WORKING PRESSURE – 45 PSI; WATER ONLY

Table of Contents

I. General Installation Requirements ................... 4

II. Installation Instructions ..................................... 7

III. Operating Instructions ....................................... 13

IV. Service ................................................................. 23

V. Repair Parts ........................................................ 26

VI. APPENDIX

Low Water Cut Off ............................................. 27

SPACEMASTER WALL MOUNTED GAS BOILER – DIMENSIONAL DATA

3

I. General Installation Requirements

1 INSPECT SHIPMENT carefully for any signs of

damage. All equipment is carefully manufactured,
inspected and packed. Our responsibility ceases upon
delivery of Boiler to the carrier in good condition. Any
claims for damage or shortage in shipment must be fi led
immediately against the carrier by the consignee. No
claims for variances or shortages will be allowed by
Boiler Manufacturer, unless presented within sixty (60)
days after receipt of equipment.

2 BOILER INSTALLATION must conform to the

requirements of the authority having jurisdiction, or in
absence of such requirements to:

a. “National Fuel Gas Code, ANSI Z223.1 obtainable

from the American Gas Association, 1515 Wilson
Blvd. Arlington (Rosslyn), VA 22209.

b. When required by the authority having jurisdiction,

the installation must conform to American Society
of Mechanical Engineers Safety Code for Controls
and Safety Devices for Automatically Fired boilers,
No. CSD-1.

c. The boiler must be electrically grounded in

accordance with requirements of the authority
having jurisdiction or, in the absence of such
requirements, with the National Electrical Code,
ANSI/NFPA No. 70.

3 THESE GAS BOILERS ARE DESIGN

CERTIFIED FOR INSTALLATION on an exterior
wall of buildings constructed with combustible
materials (wood framed walls with, paneling, drywall,
plaster, etc.) or masonry walls (brick, stone, stucco, or
cinder block).

d. Exterior wall surface must be fl at to ensure that wall

fl ange can be mounted without being distorted and
also provide a positive weather-tight seal to prevent
water damage.

If exterior wall surface is not fl at (i.e., uneven

masonry, stucco, aluminum siding, etc.) a fl at
surface must be provided of equal size or larger than
the exterior wall fl ange and vent terminal cover.

e. Locate the vent terminal in relation to adjacent

public walkways, adjacent buildings, operable
windows and buildings, consistent with the National
Fuel Gas Code Z223.1: Minimum clearance of
4 feet horizontally from and in no case above or
below (unless four [4] foot horizontal distance is
maintained), electric meters, gas meters, regulators
and relay equipment. At least 12” from any door,
window or other building opening. A minimum of
12” above grade, 7” from any overhang, 18” from
any side obstruction or wall and 3’ away from any
adjacent building. Increase minimum height above
grade to maintain adequate clearance above average
snow fall for geographical area in which unit is
installed. If the unit is to be vented over a public
walkway, it must be at least 7” above grade. If the
vent terminal is to be within 10’ of a building fresh
air intake, it must be at least 3’ above the opening.
In addition, avoid venting the unit in corners,
niches or areas which might have reduced fresh air
circulation. (See Figure 2).

4 DO NOT INSTALL ON CARPETING. These gas

boilers may be installed above carpeted areas. Note:
Protect carpeting or fl ooring to avoid possible damage
during installation and maintenance procedures.

5 BOILER LOCATION MUST MEET THE

FOLLOWING SITE REQUIREMENTS:
a. The boiler must be mounted on a fl at wall,

suffi ciently strong enough to carry the weight of
the unit. (See Figure 1). Minimum acceptable wall
construction would consist of 2” x 4” studding on
24” centers. Unit is designed for installation on
16” centers. Therefore, adequate supports must be
added between existing studding.

b. A suggested mounting height, where practical, is

fi ve feet - six inches from fl oor to center line of
intake air duct opening. (See Figure 1).

NOTE: depending on ceiling height, 6” combustible

clearance height from jacket top panel to ceiling
must be maintained. (See Figure 3).

c. Consider location of heating supply and return lines,

gas supply line, cold water piping and expansion
tank in selecting boiler location.

4

Figure 2

f. If boiler is to be installed above the level of the

radiation, a low water cutoff must be installed.

6 PROVIDE CLEARANCE between boiler jacket,

mounting bracket and vent system and combustible
material in accordance with local fi re ordinance.

Figure 3

** A minimum of 24” from left side and front jacket

panel is recommended for servicing.

MINIMUM CLEARANCE TO COMBUSTIBLE SURFACES

Minimum listed clearances from combustible materials
for non-closet installation or closet installation. (See
Figure 3).

Top — 6” *Left Side —1”
Rear — 0” Right Side — 1”
*Front — 2” Flue — 0”
Floor — 6”

Since the above dimensions are measured between

boiler jacket and combustible walls or ceiling, practical
service clearances for all external adjoining equipment
must be considered (see Figure 1). * A minimum of 24”

from left side and front jacket panel is recommended for
servicing.

In utility room installations, the door must be wide

enough to allow boiler to enter or to permit replacement
of another appliance in this room.

7 VENTILATION AND COMBUSTION AIR.

Provide provisions for combustion and ventilation air
in accordance with Section 5.3, Air for combustion
and ventilation, of the National Fuel Gas Code, ANSI
Z223.1 or applicable provisions of local building codes.
This boiler is equipped with a fan which produces
an induced draft through the unit. Combustion air is
pulled in from outdoors and the fl ue gases are exhausted
to the outdoors through the intake air/vent system. (See
Figure 4).

a. Combustion air is provided 100% from the

outdoors. Air is pulled in on all four sides of vent
terminal cover, through the air intake duct and to
the combustion area enclosure. The vent terminal
must be mounted on a fl at surface which is fl ush or
protrudes outward from the exterior wall. Avoid
recesses, niches or areas which might have reduced
fresh air circulation.

b. Ventilation — When the boiler is installed in

an unconfi ned space in a building of normal or
unusually tight construction, there is no additional
provision required to insure adequate air for
ventilation of the jacket or control compartment.

When the boiler is installed in a confi ned space,

two openings in a wall or door to an adjoining
interior area which has adequate air supply shall be
provided. One opening should be near the fl oor and
the other near the ceiling. Each shall have a free
area of not less than one (1) square inch for each
thousand (1000) BTU input to all appliances in the
boiler room. (See Figure 3).

8 CONNECT GAS SERVICE from meter to gas

control assembly in accordance with local piping codes
and requirements of gas company, see Figure 1. They
may require piping of larger size than 1/2” control
assembly connection, especially if run from meter is
long or includes several elbows.

This piping is to be supplied by the installer and must

include a trap, a ground joint union and a manual shut­off valve upstream of the gas control assembly outside
of the jacket when codes require, see Figure 1. A pipe
thread compound resistant to the action of liquefi ed
petroleum gases should be applied to all threaded joints
in the gas piping. Pressure testing of the gas supply
piping, boiler and its connections is required before
placing the boiler in operation.

The boiler must be isolated from the gas supply piping

system by closing the manual shut-off during any
pressure testing at pressures equal to or less than 1/2
psig.

The boiler and shut-off valve must be disconnected

from the gas supply piping system during any pressure
testing at pressures greater than 1/2 psig.

RECOMMENDED SIZING OF GAS SUPPLY

PIPING TO BOILER shall be such as to provide the
required supply of gas without undue loss of pressure
between meter and the boiler. Gas supply piping should
be sized in accordance with Tables, I, II and III.

The following shall be taken into account:

a. Allowable loss of pressure to assure a burner

manifold pressure of 3½” water.
b. Supply of gas to be provided in cubic feet.
c. Length of piping and number of fi ttings.
d. Specifi c gravity of gas.
e. Correction factor for specifi c gravity.

5

TABLE I

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0229091053

0337251582

0436031542

0565511512

0605501591

076469081

083409071

090448061

0018397051

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TABLE II

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can be considered as the following equivalent in

length of straight pipe:
½” – 1.6 ft. 1” – 2.6 ft.
¾” – 2.1 ft.

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01571063086

02021052564

0379002573

0428071023

0537151582

0666831062

0716521042

0875811022

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6

II. Installation Instructions

DETERMINE BEST MOUNTING LOCATION for boiler which meets site requirements outlined in Section I, pages 4

through 6.

1 INSTALLING BOILER MOUNTING WALL

BRACKET (See Figure 5).
a. Locate wall bracket packed in miscellaneous parts

carton.

b. Hold wall bracket in desired location. On studded

walls, mounting bracket must be secured directly to
main vertical support studs. Interior wall coverings
such as paneling, plaster and drywall are not suitable
to support the unit’s weight. Place a 24” level
across top corners, adjust wall bracket until level.
Using the wall bracket as a template, mark the eight
(8) securing holes along the sides and the 4½” x
5¼” rectangular opening at the top. Remove wall
bracket from wall.

NOTE: The boiler mounting wall bracket is

suitable for two main methods of wall construction.
Masonry-built walls and stud-framed walls where
the main vertical support studs are on 16” centers
or alternately where adequate supports are added
between existing studs.

c. Drill eight (8) pilot holes, properly sized for the

fastener determined suitable for the type of wall
construction in the area where the boiler is to be
mounted (i.e., lag screw for wood, machine screw
with toggle for cinder block, etc.).

d. Before cutting rectangular opening on interior wall,

use a straight edge to draw an “X” inside the box
using the four (4) corners. Drill a hole in the center
of the “X” straight through the wall to the outside.
On the exterior wall draw a 4½” x 5¼” rectangular
box centered around the reference hole which
matches the rectangular box on the interior wall.

e. Cut along outside edge of lines on interior and

exterior surfaces of the wall and remove all
material within the rectangular box. Check the wall
penetration by inserting one-half of the telescoping
intake air duct through the opening. Remove any
jagged edges or webbing that prevents the duct from
penetrating through the wall or from being level.
Remove duct from wall penetration.

f. Lay the wall bracket face down. Apply a ¼” thick

bead of silicone rubber type caulking around the
rectangular opening approximately 1” from the
edge.

g. Reposition boiler mounting wall bracket on wall,

using a 24” level across top corners, level wall
bracket and secure to wall with suitable fasteners.

h. Attach lower R.S. jacket mounting bracket to right

side of boiler mounting wall bracket with sheet
metal screws provided. (See Figure 5)

2 INSTALLING BOILER AND INTERIOR

TELESCOPING INTAKE AIR DUCT
(See Figure 5)

a. Separate two halves of telescoping intake air duct.

Interior half of duct has a 1” wide rectangular gasket
fl ange with four (4) weld studs for attaching to
back plate of boiler. Exterior half of duct has the
9” square stainless steel wall fl ange for securing to
exterior wall. (See Figure 5)

NOTE: 1. Standard telescoping intake air duct,

part No. 6110301, is for wall thickness
from 5” to 9”.

NOTE: 2. Optional telescoping intake air duct, part

No. 6110302, is for wall thickness from
9” to 15”.

b. Insert interior half of duct into rectangular opening

and push it all the way back against wall plate.

c. Place 6” x 7” rectangular gasket on interior duct

fl ange and ¼” weld studs.

d. Remove boiler from packaging.

1. Remove surrounding packaging material from
boiler and skid.

2. Remove screws holding enclosure cover.

3. Remove enclosure cover.

4. Locate and remove two (2) lag screws which
secure back plate of boiler to skid. One is
located in the upper left corner of the controls
area and the second one is located in the lower
right corner under the gas burner.

5. Remove boiler from skid and set unit upright on
fl oor in front of installation site.

NOTE: On the back plate of the boiler is a “Z”

bracket approximately 10” long. When
the boiler is lifted into place, this bracket
must be lowered into the ½” wide x 11”
long slot at the top of the boiler mounting
wall bracket. (See Figures 4 and 5)

e. Attach upper RS jacket mounting bracket to the

upper corner of back plate. Loosen the two (2)
corner screws, position bracket with fl ange facing
forward and engage slots over screws. Re-tighten
screws to secure bracket. IMPORTANT: Bracket
must be installed before lifting boiler into position.

f. Lift boiler up into position. Make sure that “Z”

bracket is properly engaged into slot and is resting
on ¼” wide fl ange in front of slot before releasing
the weight of the boiler.

g. Move boiler slightly to the left or right to align the

fi ve (5) clearance holes in the back plate with the
fasteners on boiler mounting wall bracket.

7

Figure 4

VENT SYSTEM CROSS SECTION

h. Secure boiler to boiler mounting wall bracket with

fi ve (5) ¼”-20 x ¾” long machine screws and
washers provided.

NOTE: Tools required — 7/16” socket, extension

bar(s) and drive ratchet

i. Secure interior telescoping intake air duct to

back plate of boiler. Pull duct forward until duct
and weld studs are engaged through 4½” x 5½”
rectangular opening and holes in back plate. Make
sure gasket is in place and fl at against back plate.
Attach duct with four (4) ¼”-20 brass hex nuts,
lockwashers and fl at washers.

3 INSTALLING EXTERIOR TELESCOPING

INTAKE AIR DUCT (See Figures 4 and 5)
a. Position the exterior telescoping intake air duct into

wall penetration and insert duct inside interior duct
already in place. Push duct inward until wall fl ange
is against the wall, check for level and mark the four
(4) ¼” diameter clearance holes for securing wall
fl ange to exterior wall. Remove duct from wall.

8

Figure 5

EXPLODED BOILER ASSEMBLY

b. Drill four (4) pilot holes, properly sized for the

non-corrosive fasteners (stainless steel, brass or
aluminum) to be used to secure the wall fl ange to
wall.

c. Attach four (4) ½” long threaded aluminum spacers

to the outer fl anges of the exterior telescoping
intake air duct wall fl ange with four (4) #10-32 x
¼” long stainless steel machine screws provided.
(See Figure 5).

d. Apply a ¼” thick continuous bead of silicone rubber

type caulking to the rear of the exterior telescoping
intake air duct wall fl ange approximately 1” from
duct.

e. Re-install exterior telescoping intake air duct and

secure to wall.

NOTE: Non-corrosive (stainless steel, brass or

aluminum) fasteners must be used.

f. Apply a bead of silicone rubber caulking to

perimeter of wall fl ange, where the wall and fl ange
join. Use a tool or your fi nger and apply pressure
while smoothing caulking to provide a weather-tight
seal.

4 INSTALLING VENT TUBE, ORIFICE PLATE

AND VENT TERMINAL COVER (See Figures 4
and 5).

a. The vent tube furnished has a standard length of

24”. This length is suitable for a wall thickness
from 5” to 15”.

b. To determine the proper length required, place a 24”

level horizontally across the exterior wall fl ange,
just below the aluminum spacers, measure the
distance between the outlet fl ange on the fan and
the level. Add 1” to this measurement for the total
length of the vent tube.

c. Measuring from the fl ange end of the vent tube,

mark the total length required. Cut off and discard
the remaining piece.

d. IMPORTANT! Before connecting vent tube to fan,

install the orifi ce plate and two (2) cerafi bre gaskets
on the fan outlet fl ange weld studs in the proper
order of assembly, gasket fi rst, orifi ce plate second
and remaining gasket last. (See Figures 4 and 5).

e. Insert the vent tube, fl ange fi rst, through the intake

air duct and secure to fan outlet fl ange with four (4)
¼” fl at washers, ¼” lock washers and ¼”-20 brass
hex nuts provided.

f. Position vent terminal cover over exterior intake air

duct. Insert end of vent tube into collar on rear of
vent terminal cover. Align four (4) holes on cover
with ½” long threaded aluminum spacers. Secure
vent terminal cover with four (4) #10-32 x ¼” long
stainless steel machine screws provided.

5 DO NOT REPLACE ENCLOSURE COVER until

boiler piping is completed and system is fi lled, vented
and checked for water leaks.

6 CONNECT SUPPLY AND RETURN PIPING TO

heating system.

OXYGEN CORROSION:
Oxygen contamination of the boiler water will cause

corrosion of the iron and steel boiler components,
which can lead to failure. As such, any system must
be designed to prevent oxygen absorption in the fi rst
place or prevent it from reaching the boiler. Problems
caused by oxygen contamination of boiler water are not
covered by Burnham’s standard warranty.

There are many possible causes of oxygen

contamination such as:

1. Addition of excessive make-up water as a result of
system leaks.

2. Absorption through open tanks and fi ttings.

3. Oxygen permeable materials in the distribution
system.

In order to insure long product life, oxygen sources

should be eliminated. This can be accomplished by
taking the following measures:

1. Repairing system leaks to eliminate the need for
addition of make-up water.

2. Eliminating open tanks from the system.

3. Eliminating and/or repairing fi ttings which allow
oxygen absorption.

4. Use of non-permeable materials in the distribution
system.

5. Isolating the boiler from the system water by
installing a heat exchanger.

a. For heating only, see Figure 6. Consult I=B=R

Installation Guides. Clearance between hot
water pipes and combustible material must not
be less than ½”.

b. If this boiler is used in connection with

refrigeration systems, the boiler must be installed
so that the chilled medium is piped parallel
with the heating boiler using appropriate valves
to prevent the chilled medium from entering
the boiler, see Figure 7. Also consult I=B=R
Installation and Piping Guides. 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 fl ow control valves to prevent
gravity circulation of boiler water during the
operation of the cooling system.

c. Pipe safety relief valve to suitable drain.

CAUTION: Safety relief valve should be piped

to an open drain — full size of discharge outlet on
relief valve without any provision of “shut-off”
between the relief valve and discharge into drain.

d. Install diaphragm type expansion tank (not

furnished) in system piping.

9