Burnham Series E Installation and Operation Manual
Contents
1. YBNI H38WVHD 3 38 91515 l134VH32 z 30IA 2 X HHL Z NOILVIASNI 31V71d H3AOD 3 9NISY3JAJY 2 4183493390 H1 T 4000 XOSANOWS 1331959 99 19838134 3WV 33 831108 uvas 17 PERIODIC TESTING RECOMMENDED CHECK LIST item Frequency Accomplished by Remarks Gages monitors and Daily Operator Make visual inspection and record readings in indicators log Instrument and Daily Operator Make visual check against equipment settings recommended specifications Firing rate control Weekly Operator Verify factory settings Semiannually Service technician Verify factory settings Annually Service technician Check with combustion test Flue vent stack or Monthly Operator Make visual inspection of linkage check for outlet dampers proper operation Igniter Weekly Operator Make visual inspection check flame signal strength If meter fitted see Combustion safety controls Fuel valves Pilot and main Weekly Operator Open limit switch make aural and visual check check valve position indicators and check fuel meters if so fitted Pilot and main gas or Annually Service technician Perform leakage tests refer to main oil instructions Combustion safety controls Flame failure Weekly Operator Close manual fuel supply for 1 pilot 2 main fuel and or valve s check safety shutdown timing log Flame signal Weekly Operator If flame signal meter installe2. RETURN FROM SYSTEM DRAIN VALVE PRESSURE CONTROLS GATE VALVE STEAM PRESSURE GAUGE RECEIVER CHECK TANK VALVE GAUGE GLASS SOLENOID VALVE IF REQUIRED For D see Note 4 PUMP CONTROL LOW WATER CUT OFF BLOW OFF VALVE FRONT OF BOILER BLOW OFF VALVE RECOMMENDED BOILER PIPING SINGLE STEAM BOILER E 20 80 PUMPED RETURN NOTES 1 Return loop connection was designed to eliminate necessity of check valves on gravity return systems but in some localities a check valve is a legal requirement 2 When pump discharge piping exceeds 25 ft install swing check valve at pump discharge 8 If pump discharge is looped above normal boiler waterline spring loaded check valve at return header and at pump discharge 4 Pumped return piping size D must be calculated using pump size distance and standard piping tables MINIMUM PIPING REQUIREMENTS STEAM BOILERS Fig 4 8 om EXPANSION TANK SYSTEM RETURN SUPPLY TO SYSTEM TEMPERATURE PRESSURE GAUGE BOILER PIPE SIZE INCHES MODEL SUPPLY A RETURN RECOMMENDED BOILER PIPING WATER BOILER EW 20 EW 80 MINIMUM PIPING REQUIREMENTS WATER BOILERS Fig 5 D BOILER PIPING Attach flow and return piping lines and insert plugs and bushings in connections as required Flow and return piping headers are detailed in Figure 4 and Figure 5 CAUTION IT IS IMPORTANT TO COMPLY WITH THE
3. p ge Sls MAIA 3QIS 1 321104 LNOHLIM 39NVHO9 OL l193r8ns ONY 0 011721312395 9 BSVEUBVUNVIS i 7031799 73004 NO 3sv8 WNOlLdO 3 430 GINS QNOA38 1930084 4 I 1 WiBl 5537 HLOIM 1 83 VAVO VNOISN3WIO SONILVU 2 ONY M31V3H SS3TMNVL 03 I 31891 33S SH31V3H X amp 1 ne SS3TANYL SLINN JO LNOUJ JRL Q3NIVINIVM 38 ISAW 30 717108 1109 JHL T 9321111 38 9 AVA 39795 1104 Hv3H HO LNOYS H3HlI 3 SdN IIVGA G3dV3NHl SONILLI3 TW 2 fer ee ee S3HONI NI SNOISNSWO 71 AH9IS 9 S310N d33d 1noHSvM I LNOHSWM 5 SYM I 1 i T a E x PR M RIED 3ovds lind dOl saals AINN H38AVHO H108 SONILLI4 A NWN109 Y3LYAM I i l X000 SS320V 3ood 38083 3718VAOW3H 3ovds 1 133HS X sv3u ovas mma 38i A 0 ez 1 4 45 Tind 3801 s NOLV2O1 330 102 SNOILO3NNOO 1V1svnov YILYM 1H913H HV 102 3 8 OL 03073 SHOWS 3 IVNOILdO 1109 H31V
4. MINIMUM PIPING REQUIREMENTS IN ORDER TO ENSURE MAXIMUM PERFORMANCE AND RELIABIL ITY PARTICULAR ATTENTION SHOULD BE GIVEN TO THE CONSTRUCTION OF THE STEAM HEADER AND HARTFORD LOOP ON STEAM BOILERS WARNING The nominal temperature differential between supply and return water recommended for Burnham Series E water boil ers is 20 F As a precaution against thermal shock this differ ential should never exceed 40 F The boiler should not be operated for any length of time at a temperature setting that allows the formation of conden sate in the tubes or smokebox This generally dictates a mini mum setting of approximately 170 F on the low limit on sys tems with a 20 F system differential On cold start up con densation can be expected until the boiler warms up If for mation of condensate persists the low limit should be adjusted upward until condensate no longer forms 2 STEAM TRIM Install the gauge glass trim in the two 2 couplings located at the front right side of the boiler Mount the pres sure gauge in the 1 2 threaded connection located at the top of the front head Install the safety valve in the connection at the top rear centerline of the boiler Install the drain valve in the connection at the bottom rear centerline of the boiler The connections are labeled in Figure 3A WATER TRIM Install the combination pressure temperature gauge drain valve and pressure relief valve as shown in Figure 5 C
5. fid 1009 IHL S 703211121 38 AVW 32 95 7709 38n1 YO LNOYS YBHLIZ NOILOBNNOD 440 MOT ii 1 5 fo 437100 Wv31S NO GYVONVLS LO 13 ONY 02 73 S13G0W NO 3015 1337 NO Q31V201 S9NIddVl VNOILIGOV SAN 31VW33 Q30v3SHLl 3HV SONILLIA Y3HLO 71 39 713 81 OSI SI 3 9 Z S3HONI NI SNOISNSWIQ NY 1 5310 3215 NOLLOSNNOD Nun 34 7 32995 1109 W3NI1 YSSWVH 32795 ind YSEWVHD A Fe Foul ool Foe e gt Fool Bool es ee HLONAT 3 08 A 1 a08 3 fafa ES ESE S TIGOW H3 108 31045 J a3LYTNSNI 3SV8 QBVONVIS d 3578 4 E ONY r 21 9713 s d AfiOHS vM 1 NOIL23NNOO 3 3 Ji i WOISONFIAS S em 55350 uv3u I I j I ONLI e ILON 33S SONIddVL bwa 4 C kgl A A F 4A 2 31ON 33S NOILO3NNO2D 901 9 53015 0 SONILLIS NANTO Le X000 83 3 55779 39nv9 OL 030134 34OWS LNOH3 IVNOILdO 1109 LOH 91153409 NINd 381 fa v 3LON 335 A 39945 Nd 3 310N 335 39745 77089 1409 5537 HLOIM T1V83AO
6. 4 000 BTUH In 220 In Free Area c 42 CONCRETE gt L 277 sown FOUNDATION Fig 1 NOTE IF THE BOILER ROOM FLOOR IS WEAK OR UNEVEN OR IF A WATER CONDITION EXISTS A BOILER FOUNDATION SIMILAR TO THE ONE SHOWN ABOVE IS RECOMMENDED lt Boiler Dimension Inches Model up THIMBLE 3 MIN SMOKEPIPE DO NOT REDUCE BELOW yo SIZE OF COLLAR ON REAR SMOKEBOX FRONT OF BOILER FLUE COLLAR Fig 2 TYPICAL ARRANGEMENT FOR STUB VENT 9 295 1994 OOOI U2ee 10 9161 1e p np eq 5 s8une1 BY 95 sepninje 104 528 uo 1991 0002 pue uo 199 OOOT 91 dn sepninje 3e Ajdde uwous 1 l roq 3e eins Said uuunio2 LOL 09 AZT uo peseq 9581181 uolle8 194 118 000 0 JO enjeA e Buey 148 uo peseq s u pedes 4 g8 eur 58 8 y g JO siseq uo 12995 5 191811 403 ul93S S ui 41918 4 021 uo peseq joa eJenbs 1 SZULI JON 919 uiejs s Suidid dais u 1x uonejedo 191545 se 5 sjuawWasINbas dnyoid pue 3uidid jensnun Buey 10 494njoejnueuJ 3jnsuoj 404 ST I pue w
7. as far as required Usually completely Make sure the vent valve on the top of the boiler remains open Open and lock the float control low water cutoff drain valves These will serve as an additional vent J Shut and lock all boiler feed valves and any blow down valves that can be affected by other boilers in the same facility i e bottom blow down valves can tie into a com mon blow down separator in a multiple boiler installation K If necessary to remove handhole and or manhole plates for water side inspection or maintenance use extreme caution Loosen the nuts securing the arch enough to allow the plate to drop approximately 1 8 inch when tapped loose with a mallet Once again ensure the pressure in the boiler is 0 before loosening the plate Remove the plate the re mainder of the way Wear gloves and eye protection at all times 13 CLEAN THE BOILER HEATING SURFACES AND FLUE at least once each year preferably at the end of the heating season A CLEAN THE VENT SYSTEM Vent system should be checked annually for 1 Obstructions 2 Accumulations of soot 3 Deterioration of vent pipe or vent accessories due to condensation or other reasons 4 Proper support no sags particularly in horizontal runs 5 Tightness of joints Remove all accumulations of soot with wire brush and vacuum Remove all obstructions Replace all deteriorated parts and support properly Seal all joints B CLEAN THE BOILER HEATING SURFA
8. c IDA etd eed Dimensional SECTION INSTALLATION INSTRUCTIONS Steam Tankless Heater Piping oie AER ME SECTION OPERATING INSTRUCTIONS Filling Sy Steam PPP RR Testing Initial Cleaning Steam Boilers u eret dE caasa Initial Cleaning Water Boilers c ccc ccscsescssssoseeseesstenctelesesteuscdvastisossatscveossdsededsondetenstvesvecueonursidscenetcosustedeatscenssestrosoes Water Boiler Boiler Water Treatment pH or Alkalinity Test CDL Warnings about Frequent Water Addition eee uuu SECTION IV SERVICE INSTRUCTIONS Boiler Shutdown and Cool Down Procedures uu Cleaning Boiler 5 65 Reversing Chamber Removal and Installation u u Maintenance of Low Water Cutoff Devices
9. immediately to dissi pate the dissolved gases which can otherwise cause in ternal corrosion to the boiler A STEAM BOILERS Fill boiler to normal water line as shown on figure 3A Water should be visible in the gauge glass After boiler is in operation make up water should be added slowly to maintain the water level B HOT WATER BOILERS In a hot water heating system the boiler and entire system other than the expansion tank must be full of water for satisfactory operation Water should be added to the system until the boiler pressure gauge registers normal system design operating pressure To ensure that the system is full water should come out of all air vents when opened WARNING ON A HOT WATER SYSTEM THE PRESSURE MUST NOT EXCEED 30 POUNDS UNLESS THE BOILER IS ESPECIALLY DESIGNED FOR A HIGHER MAXIMUM WORKING PRESSURE IF BOILER PRESSURE EXCEEDS PRESSURE SETTING OF SAFETY RELIEF VALVE VALVE WILL RELIEVE IMMEDIATELY BUT CAUSE OF RELIEF MUST BE INVESTIGATED AND CORRECTED EXCESS PRES SURE IS DANGEROUS IN ADDITION COULD CAUSE DAMAGE TO HEATING SYSTEM PER SONAL INJURY OR SERIOUS PROPERTY DAMAGE DO NOT draw water from boiler while in use When adding water while boiler is in operation do not open supply valve fully but add water slowly 8 ADJUST BURNER according to the burner manu facturer s specifications Refer to burner manufacturer s installation manual furnished with the boiler 4 TEST CONTROLS
10. l u Checking Burner amp Controls enne chee ecce does aoa oe EY apre US u ka tope dette UR die ette General Maintenance Considerations uu Attention to Boiler while not in Operation l seis u u Orderinig Repair Pari k ASS as E Reference circ Periodic Testing Recommended Check List u tonta Terms and Conditions of Sale Q SECTION I GENERAL INFORMATION D GENERAL INFORMATION The E Series is designed specifically for forced draft firing is available with light oil gas or combination gas light oil burners and operates with a combustion efficiency of over 80 In addition to the advantages of forced draft firing the elimination of the need for external draft devices such as a high chimney or mechanical draft equipment the E series offers such features as Compact 3 pass firetube design pack aged unit that will fit through a standard doorway Light weight vacuum formed reversing chamber Provision for instantaneous hot water tankless heater 7 models ranging from 684 MBH to 2821 M
11. BH gross output This manual gives the necessary information for the proper installation operation maintenance and service of the units For special installation problems contact Burnham Corpora tion Commercial Steel Boilers PO Box 3079 Lancaster Penn sylvania 17604 Dimensional information is given in Figures 3A and 3B Ratings and data are given in Table I 2 INSPECT SHIPMENT carefully for any signs of damage A ALL EQUIPMENT is carefully manufactured inspected and packed Our responsibility ceases upon delivery of boiler to the carrier in good condition B ANY CLAIMS for damage or shortage in shipment must be 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 SETTING THE UNIT Front and rear heads are equipped with two lifting eyes each to be used in maneuvering the boiler into position The boiler can also be rolled into position on a series of pipes The unit should be located in the boiler room so as to pro vide ease of venting and adequate clearance for maintenance serviceability and installation of piping The tube pull space listed in Figures 3A and 3B must be provided at either the front or rear of the boiler Firetubes may be cleaned from the front of the boiler without disturbing the reversing chamber Care must be taken so as not to damage the reversin
12. CES At the end of heating season clean boiler heating surfaces thoroughly Access to boiler firetubes may be gained by re moving the front and rear smokeboxes Remove turbulators and clean firetubes with flue brush furnished with boiler Re place turbulators as shown in Figure 7 Remove soot and rust and reseal the boiler C PROPER REMOVAL AND INSTALLATION PROCEDURES FOR REAR REVERSING CHAMBER LINER See Figures 8 amp 9 Removal 1 Remove nuts washers and reversing chamber cover plate 2 Reversing chamber liner often can be removed in one piece by inserting several fingers through the observa tion port opening to support the weight of the liner as it is pulled clear of the wrapper 3 IMPORTANT The 2 ceramic fiber strip must be re placed whenever the reversing chamber liner has been removed 4 Remove all traces of fiber and adhesive from the rear tube sheet Also remove any fiber that adheres to the front edge of the liner INSTALLATION 1 Apply adhesive 1 9 waterglas to the perimeter of rear tube sheet and position the 2 ceramic fiber cerafelt strip 2 Ifthe reversing chamber liner was removed in one piece and is not cracked it may be reused If damaged the reversing chamber liner must be replaced Insert the reversing chamber liner until it is seated uniformly against the ceramic fiber strip on the rear tube sheet 3 IMPORTANT The blanket on the cover plate and the bolt hole gasket may be reused
13. COMPONENTS THAT REQUIRE ATMOSPHERIC AIR PRESSURE TO BALANCE A DIAPHRAGM 10 HIGH WATER TEMPERATURES INCREASE THE RISK OF BURNS OR SCALDING INJURY INSTALL AN AUTOMATIC MIXING VALVE AT THE TANKLESS HEATER OUTLET TO AVOID EXCESSIVELY HOT WATER AT THE FIXTURES 11 ALL COVER PLATES ENCLOSURES AND GUARDS MUST BE IN PLACE AT ALL TIMES EXCEPT DURING MAINTENANCE AND SERVICING NOTICE 1 THIS BOILER HAS A LIMITED WARRANTY A COPY OF WHICH IS PRINTED ON THE BACK PAGE OF THIS MANUAL 2 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 3 FOR OPTIMUM PERFORMANCE AND SER VICEABILITY FROM THIS UNIT ADHERE TO THE FOLLOWING RECOMMENDATIONS A CLEAN FIRETUBES AT LEAST ONCE A YEAR PREFERABLY AT THE END OF THE HEATING SEASON TO REMOVE SOOT AND SCALE INSIDE SURFACES OF THE FURNACE FRONT AND REAR SMOKEBOXES AND REVERSING CHAMBER SHOULD ALSO BE CLEANED AT THE SAME TIME B HAVE THE BURNER AND CONTROLS CHECKED AT LEAST ONCE A YEAR OR AS NECESSARY C RETAIN YOUR CONTRACTOR OR A COMPETENT SERVICEMAN TO ASSURE THAT THE UNIT IS PROPERLY ADJUSTED AND MAINTAINED TABLE OF CONTENTS SECTION GENERAL INFORMATION Ei Bj u uu Supply E u ie S Ratings Data e cabin Soest DERE
14. INSTALLATION AND OPERATING INSTRUCTIONS FOR SERIES E THREE PASS FIRETUBE GENERATOR ASME Stamping plate tack welded to shell FORCED DRAFT FOR Pop riveted to LIGHT OIL front flue door GAS LIGHT OIL OR GAS HOT WATER OR STEAM 7 SIZES GROSS OUTPUT 684 000 to 2 821 000 BTU HR D 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 Phone No S8urnham Phone 717 293 5846 COMMERCIAL STEEL BOILERS P O Box 3079 FAX 717 293 5877 Burnham Corporation Lancaster PA 17604 PartNo 8145105R2 7 97 IMPORTANT INFORMATION BURNER BOILER SYSTEM AS USED THROUGHOUT THIS MANUAL SHALL MEAN ALL MECHANICAL AND OR ELECTRICAL EQUIPMENT INCLUDING THE BOILER BURNER PUMPS COMPRESSORS FEED WATER SYSTEMS DEAERATOR SYSTEMS AND ALL ASSOCIATED PIPING ELECTRICAL AND CONTROL SYSTEMS USED AND MAINTAINED IN THE BOILER ROOM THE FOLLOWING DEFINED TERMS ARE USED THROUGHOUT THIS MANUAL TO BRING ATTENTION TO THE PRESENCE OF HAZARDS OF VARIOUS RISK LEVELS OR TO NOTE IMPORTANT INFORMATION CONCERNING THE OPERATING LIFE OF THE PRODUCT DANGER INDICATES PRESENCE OF A HAZARD WHICH WILL CAUSE SEVERE PERSONAL INJURY DEATH OR SUBSTANTIAL PROPERTY DAMAGE IFIGNORED WARNING INDICATES PRESENCE OF A HAZARD WHICH CAN CAUSE SEVERE PERSONAL IN
15. JURY DEATH OR SUBSTANTIAL PROPERTY DAMAGE IF IGNORED CAUTION INDICATES PRESENCE OF A HAZARD WHICH WILL OR CAN CAUSE MINOR PERSONAL INJURY OR PROPERTY DAMAGE IF IGNORED NOTICE INDICATES SPECIAL INSTRUCTIONS ON INSTALLATION OPERATION OR MAINTENANCE WHICH ARE IMPORTANT BUT NOT NECESSARILY RELATED TO PERSONAL INJURY HAZARDS DANGER 1 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 FOLLOW THE GAS OR OIL SUPPLIER S INSTRUCTIONS OR IF THE SUPPLIER IS UNAVAILABLE CONTACT THE FIRE DEPARTMENT 2 BURNER BOILER SYSTEMS PRODUCE STEAM OR HOT WATER IN A PRESSURIZED VESSEL BY MIXING EXTREMELY FLAMMABLE GASEOUS LIQUID OR SOLID FUELS WITH AIR TO PRODUCE COMBUSTION AND VERY HOT PRODUCTS OF COMBUSTION EXPLOSIONS FIRES 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 3 INSULATE ALL STEAM AND HOT WATER PIPING FITTINGS AND CONNECTIONS AND ALL OTHER HOT COMPONENTS AND EQUIPMENT FROM PERSONNEL CONTACT 4 ASSURE ALL PIPES FITTINGS ELECTRICAL CONTROLS AND ALL OTHER ASSOCIATED BURNER BOILER EQUIPMENT IS OF PROPER DESIGN AND CONSTRUCTION FOR THE INTENDED USE AND PROVIDES ADEQUATE PROTECTION FROM ELECTRICAL SHOCK AND HAR
16. LACES VENTS AND SOLID FUEL BURNING APPLIANCES C AMERICAN SOCIETY OF MECHANICAL ENGINEERS ASME CSD 1 CONTROLS AND SAFETY DEVICES FOR AUTOMATICALLY FIRED BOILERS 2 ALL WIRING ON BOILERS INSTALLED IN THE USA SHALL BE MADE IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE AND OR LOCAL REGULATIONS 3 INSTALLATION START UP OPERATION AND OR MAINTENANCE SERVICE OF THIS BURNER BOILER SYSTEM MUST BE UNDERTAKEN ONLY BY TRAINED AND SKILLED PERSONNEL 4 FAILURE TO FOLLOW ALL INSTRUCTIONS IN THE PROPER ORDER CAN CAUSE PERSONAL INJURY OR DEATH READ ALL INSTRUCTIONS INCLUDING ALL THOSE IN OTHER BOILER BURNER SYSTEM MANUALS WHICH WERE PROVIDED WITH THE EQUIPMENT BEFORE INSTALLING OPERATING OR SERVICING 5 KEEP BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS 6 PROVIDE POSITIVE ASSURANCE THAT ADEQUATE COMBUSTION AND VENTILATION AIR IS PROVIDED FROM THE OUTDOORS TO THE BURNER BOILER SYSTEM AND THE BOILER ROOM 7 DO NOT PLACE ANY OBSTRUCTIONS IN THE BOILER ROOM THAT WILL HINDER THE FLOW OF COMBUSTION AND VENTILATING AIR 8 CAREFULLY READ THIS AND ALL OTHER MANUALS AND INSTRUCTIONS PROVIDED BEFORE PROCEEDING WITH THE INSTALLATION OR SERVICE OF THE BURNER BOILER SYSTEM POST ALL INSTRUCTIONS AND MANUALS NEAR THE BOILER FOR REFERENCE BY SERVICE PERSONNEL 9 REFER TO BURNER MANUFACTURER S INSTALLATION MANUAL PROVIDED FOR PROPER VENTING OF THE GAS TRAIN
17. M 10 OI1S3WOQ YALSWVIG BV1109 1N3A Ale eat ash URN es Xi 1 9 3 39vds NNa NOILVIOT Xldans Q31V InSNI n 3ZIS 23 301 3 NOI1V901 38 ann iivs X08 SHOWS LNOUS 1 SHOWS LNOMJ H19N31 3508 QHVONVLS T I v 310N 335 S 310N 335 Ao YNVL NOISNVdX3 1N3A IV 1nd 3102 39vds Wind HLONST TTV33AO 331108 JHOISH 43108 H19N31 THS 43108 93708 propensius rn UI SECTION INSTALLATION INSTRUCTIONS ALVE Y FITTING STOP V GATE VALVE SYSTEM SUPPLY REDUCER BOILER MAKE UP WATER t LOW WATER CUTOFF AND PRESSURE CONTROLS NW L VALVE PREFERRED HARTFORD RETURN CONNECTION GAUGE GLASS 3 4 LLOWEST PERMISSIBLE WATERLINE SEE PIPING Qe DETAILS STEAM GAUGE CLOSE OR SHOULDER NIPPLE GATE VALVE CHECK VALVE ALTERNATE HARTFORD RETURN CONNECTION SEE NOTE l GRAVITY RETURN BLOW OFF VALVES FOR FLUSHING BOILER AND SYSTEM RECOMMENDED BOILER PIPING STEAM BOILER GRAVITY RETURN E 20 E 8o SUPPLY BOILER TO MAKE UP SYSTEM WATER ALL STEAM TAKE OFFS FROM TOP OF HEAOER ASME SAFETY OVERFLOW STEAM VALVE TRAP 2 TO 4 ABOVE NWL
18. MFUL PHYSICAL CONTACT TO PERSONNEL 5 A LEAK TIGHT FUEL DELIVERY CONDUIT AND CONTROL SYSTEM MUST BE MAINTAINED AT ALL TIMES 6 PRODUCTS OF COMBUSTION MUST BE TRANSPORTED FROM THE BOILER BURNER SYSTEM TO THE OUTDOORS IN AN APPROVED LEAK TIGHT INSULATED VENTING SYSTEM THE BOILER ROOM MUST BE POSITIVELY VENTILATED TO PREVENT A CONCENTRATION OF PRODUCTS OF COMBUSTION AND A REDUCTION IN THE AMOUNT OF OXYGEN IN THE AIR 7 BURNER BOILER MATERIALS OF CONSTRUCTION PRODUCTS OF COMBUSTION AND FUELS CONTAIN ALUMINA SILICA HEAVY METALS CARBON MONOXIDE NITROGEN OXIDES ALDEHYDES CARBON DIOXIDE PARTICULATES AND OR OTHER TOXIC OR HARMFUL SUBSTANCES WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS 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 EQUIPMENT WARNING 1 THE EQUIPMENT SHALL BE INSTALLED IN ACCORDANCE WITH REGULATIONS IN FORCE IN THEAREA WHERE THE INSTALLATION IS TO BE MADE THESE REGULATIONS SHALL BE CAREFULLY FOLLOWED IN ALL CASES AUTHORITIES HA VING JURISDICTION SHALL BE CONSULTED BEFORE INSTALLATIONS ARE MADE ALL BOILER INSTALLATIONS IN THE USA SHOULD COMPLY WITH THE CURRENT EDITION OF THE FOLLOWING STANDARDS A AMERICAN NATIONAL STANDARD ANSI NFPA 31 INSTALLATION OF OIL BURNING EQUIPMENT B AMERICAN NATIONAL STANDARD ANSI NFPA 211 CHIMNEYS FIREP
19. WARNING Before Installation of the boiler is considered com plete the operation of the boiler controls should be checked particularly the low water cutoff and the high limit control A CHECK OPERATING CONTROL OPERATION Raise and lower operating control setting as required to start and stop burner B WARNING CHECK HIGH LIMIT CONTROL Jumper Operating Control Terminals Allow burner to operate until shutdown by limit Installation is not considered complete until this check has been made REMOVE JUMPER C CHECK LOW WATER CUTOFF control with water level at normal water line see Figure 3A Raise op erating control setting to allow burner to operate Open boiler drain to allow water level to drop to bot tom of sight glass until burner operation is shut down by low water cutoff 11 Close boiler drain and refill to normal water line Unless boiler is equipped with a manual reset low water cutoff burner should automatically restart during fill Reset operating control IMPORTANT PROBE AND FLOAT TYPE LOW WATER CUT OFF DE VICES REQUIRE ANNUAL INSPECTION AND MAINTE NANCE Refer to step of Service Instructions for proper cleaning instructions D CHECK OPERATING CONTROL on a boiler equipped with a tankless heater With burner off draw hot water until burner starts then turn off hot water and check burner shutdown CLEANING A NEW STEAM BOILER Oil greases amp sediments which accumulate in a new boiler and pipin
20. bjectives of boiler water treatment are A Remove corrosive gases from feedwater and boiler water B Prevent sludge and scale deposits on the water side heat ing surfaces C Prevent foaming and carryover Consult with a local water treatment company regularly en gaged in the treatment of boiler water for advice on maintaining the proper feedwater boiler water and condensate chemistry Certain state and local codes may restrict the use of some of the chemicals listed for cleaning and maintaining the boiler Check with local authorities before proceeding to use any chemicals 9 MAKE PH ORALKALINITY TEST After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except it gives specific read ings small color chart on the side of the hydrion dispenser gives the reading in pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add some of the washout chemical caustic soda if neces sary to bring the pH within the specified range 00 IMPORTANT If during normal operation it is necessary to add water to this boiler more frequently than once a month consult a quali fied service technician to check your system for lea
21. burner and operate sufficiently to boil the water with out producing steam pressure Boil for about 5 hours Open boiler feed pipe sufficiently to permit a steady trickle of water from the surface blowoff pipe Continue this slow boiling and trickle of overflow for several hours until the water coming from the overflow is clear E Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety E When the boiler has cooled down to 120 F or less refill boiler to normal water line If water in gauge glass does not appear to be clear repeat steps A through E boiling out the boiler for a longer time G Remove temporary piping plug tapping and or reinstall safety valve Boil or bring water temperature to 180 F promptly in order to drive off any dissolved gases in the fresh water CLEANING A WATER BOILER The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner A Remove safety relief valve using extreme care to avoid dam aging it Certain state and local codes may restrict the use of some of the chemicals listed for cleaning and maintaining the boiler Check with local authorities before proceeding to use any chemicals Add an appropriate amount of recommended boilout compound Add solution through exposed tapping and reinstall safety valve Fill the entire system with water Start firing the boiler Circulate the water thr
22. d read and log strength for both pilot and main flames notify Pilot turndown tests Refractory hold in Low water fuel cutoff and alarm High limit safety control Operating control Low draft fan air pressure and damper position interlocks As required annually As required annually Daily weekly Semiannually Annually Annually Monthly Service technician Service technician Operator Operator Service technician Service technician Operator 18 service organization if readings are very high very low or fluctuating refer to instructions Required after any adjustments to flame scanner mount or pilot burner verify annually refer to instructions See Pilot turndown tests Refer to instructions Perform a slow drain test in accordance with ASME Boiler and Pressure Vessel Code Section VI Refer to instructions Refer to instructions Refer to instructions continued on next page PERIODIC TESTING RECOMMENDED CHECK LIST cont d Item Frequency Accomplished by Remarks Atomizing air steam Annually Service technician Refer to instructions interlock High and low gas Monthly Operator Refer to instructions pressure interlocks High and low oil Monthly Operator Refers to instructions pressure interlocks High and low oil Monthly Operator Refer to instructions temperature interlocks Fuel valve interlock Annually Service technician Refer to instructions switch Purge switch A
23. eas 10 882 1 ESET ydym 58906 dnyoid pue Buldid uo peseq uwous 8 8 P 41J 528 59169 APU 9 O 528 9 XHINS 54 WEAS ISd SI 3 XYadd 1 SOE TSE 492 00 866 EEIZ ose 60T O6T 841 TOO 8 98 889 88 08 418 9 684 969 ETS 8EIZ ewe c TE ws 02 3 4918 5 5971 1103 JUBION 5129 weas 165 34 8 P S 4143 uqu sey Medo Suneosn SONILVY I 37971 10 3481 saung 4918AA weas weas Haw Haw urbs 2 8 1 JON saog ve Sid NOLLVIWHOHNI IVWNOISNAWIG WNV3lS MJA 24918 MJA LNOYS 329ILON 39 OL 1233r ns VLYG SNOISN3MIQ SNOI1V2I3ID3dS O3rlddv 1300W 3 NO 9NIQN3d30 GINS ONOA38 103fOBd 3 SONILVY M31V3H SS3MNVL E 318V1 33S SH31V3H SS3T INVL HLIM 03991003 SLINN 30 1 4 JHL Q3NIVINIVW 38 LSNW 39795
24. g cham ber with the end of the flue brush The reversing chamber pull space must always be provided at the rear of the unit see Figures 3A and 3B The coil pull space listed in Table II must be maintained at the front of units equipped with tankless coils Floor construction should have adequate load bearing char acteristics to bear the weight of the boiler filled with water see Table I A boiler foundation similar to the one shown in Figure lisrecommended if the boiler room floor is weak or uneven or if a water condition exists These boilers are not approved for installation on combus tible flooring CHIMNEY OR VENT The E Series boiler is designed for forced draft firing and may be used with a conventional natural draft stack or stub vent see Figure 2 For proper Vent Size see Figures 3A and 3B Draft controls are not normally required although they may be used on installations where a natural draft stack is used or on mul tiple boiler installations with a common stack If high breeching drafts make burner adjustment difficult a locking blade type adjustable damper should be installed at the boiler breeching B AIR SUPPLY A sufficient air supply must be maintained at all times to the boiler room for proper performance of the unit perma nent opening or duct should be provided so that the boiler input will not exceed 4 000 Btuh in of free area Example Model E 20 Firing Rate Gas 877 MBH 877 000BTUH
25. g must be removed from the system in order to pre vent an unsteady water line and carry over of the water into the supply main above boiler 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 returned to the boiler boil out the boiler using the SURFACE BLOWOFF connection Refer to figure 3A note 3 for location of surface blowoff connection A Drain boiler until water is just visible in gauge glass Run temporary pipe line from the surface blow off or safety valve connection to an open drain or some other location where hot water may be discharged safely Do not install valve in this line Certain state and local codes may restrict the use of some of the chemicals listed for cleaning and maintaining the boiler Check with local authorities before proceeding to use any chemicals B Drain about 5 gallons of hot water from boiler into a con tainer and dissolve into it the appropriate amount of a recommended boilout compound Additional containers may be required to dissolve sufficient chemicals for large mod els Remove safety valve and add solution to boiler water through exposed tapping C Close all valves leading to and from the system to isolate the cleaning solution from the system D Start
26. handling phospho ric acid and follow the instruction label on its con tainer 8 9 10 11 12 13 14 15 16 17 18 Wire brushing of the probe is not recommended Clean the pipe threads of the probe to remove old hardened pipe dope and other foreign matter Apply a moderate amount of good quality pipe dope to the pipe threads on the probe leaving the two end threads bare Do not use PTFE Teflon tape Screw the probe into the boiler tapping Mount the low water cutoff control on the probe Reconnect the control to probe wiring Fill the boiler to its normal waterline Add boiler water treatment compound as needed see Section III Item 8 Restore electric service to the boiler Fire burner to heat the water in the boiler to drive off free oxygen WARNING BEFORE RETURNING BOILER TO SERVICE Follow the low water cutoff check out procedure in Section III Item 4 Part C B FLOAT TYPE LOW WATER CUTOFF During the heating season if an external low water cutoff is on the boiler the blow off valve should be opened once a month use greater frequency where conditions warrant to flush out the sediment chamber so the device will be free to function properly Low water cutoffs and water feeders should be dis mantled annually by qualified personnel to the extent necessary to insure freedom from obstructions and proper functioning of the working parts Inspect con necting lines to boiler for accumu
27. if both are in good condi tion If damaged they must be replaced 4 Install Cover Plate washer and nuts Sufficiently tighten for gas tight seal MAINTENANCE OF LOW WATER CUTOFF DEVICES IMPORTANT PROBE AND FLOAT TYPE LOW WATER CUTOFF DEVICES REQUIRE ANNUAL INSPECTION AND MAINTENANCE A PROBE TYPE LOW WATER CUTOFF Although these devices are solid state in the operation the probe is exposed to possible contamination in the boiler water and subject to fouling It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scale or sediment Follow these steps to inspect clean and or replace the probe 1 2 3 J Turn off electric service to the boiler Drain boiler water to a level below the tapping for the probe Disconnect wiring connections between the low water cutoff control and the probe Dismount the low water cutoff control from the probe Unscrew the probe from the boiler tapping Inspect that portion of the probe that is exposed to the boiler water for scale or sediment buildup Light deposits may be removed by wiping the probe with a damp cloth Wiping the probe with a cloth soaked in vinegar will remove more tena cious lime deposits The most stubborn deposits may be removed from the probe by using a diluted amount 3 part of water to 1 part of phosphoric acid H P0 CAUTION Exercise caution when
28. ks A leaky system will increase the volume of make up water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up water are dissolved minerals and oxy gen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas Both can result in reduced boiler life Problems caused by oxygen and mineral contamination of boiler water are not covered by Burnham s standards war ranty Therefore it is in everyone s best interest to prevent this type of failure The maintenance of system integrity is the best method to achieve this SECTION IV SERVICE INSTRUCTIONS D IMPORTANT See Item under Operating Instruc tions if it becomes necessary to add water to the boiler more frequently than once a month GENERAL Inspection should be conducted annually Service as frequently as specified in paragraphs below Before service or maintenance is performed complete boiler shut down cooldown procedure BOILER SHUTDOWN AND COOLDOWN PROCEDURE NOTE This procedure is generally required in preparation for corrective or preventative maintenance on the unit This procedure must be supervised by an individual who is thor oughly qualified in operation and maintenance of the equip ment at hand This is written with Low Pressure Heating Boilers in mind but the principles are applicable to Hot Wa ter Boilers as well A Decrease
29. lation of mud scale etc and clean as required Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly Give special attention to sol der joints on bellows and float when this type of control is used Check float for evidence of collapse and check mercury bulb where applicable for mercury separation or discolora tion DO NOT ATTEMPT TO REPAIR MECHANISMS IN THE FIELD Complete replacement mechanisms including neces sary gaskets and installation instructions are available from the manufacturer CHECKBURNER AND CONTROLS at least once a year See Item under Operating Instructions for control checks See Burner Manual for burner tests and adjustments D LUBRICATE BOILER COMPONENTS according to manufacturer s instructions Generally this involves the burner and circulator This includes the type of lubricant to use fre quency of lubrication and points to lubricate CHECK SAFETY VALVE at the start of each heating season and once or twice during the season to be sure it is in working condition To do this fasten wire or cord to lever of valve and pull lever standing a safe distance away from valve GENERAL MAINTENANCE CONSIDERATIONS A Keep radiators and convectors clean B If a hot water radiator is hot at the bottom but not at the top it indicates that air has accumulated inside and should be vented To vent radiator hold small cup under ai
30. ll 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 temperature to his liking Higher temperature hot water required by dish washers and automatic washers is available by piping the hot water from the heater prior to entering the mixing valve The mixing valve should be trapped by installing it below the cold water inlet to heater to prevent lime formation in the valve TABLE 11 TANKLESS HEATER RATINGS Steam and Water Boilers INA 200 INA 210 All Sizes Except E20 COLD WATER TANKLESS HEATER HIGH TEMP TEMPERED WATER AUTOMATIC HOT WATER WASHERS ETC TO FAUCETS ETC AND SHOWERS HOSE BIB IN HOT WATER LINE FOR PERIODIC SEDIMENT 2 d MIXING VALVE GLOBE VALVE b us HD COCK SUPPLY Y s FLOW REGULATOR SAFETY IN COLD WATER RELIEF LINE AT LEAST 3 FEET AHEAD OF TANKLESS HEATER Heater For Use on the Coil Following Boiler 180 F Number Sizes GPM Rated Capacity Gallons Heated 40 to 140 F with Boiler Water Temperature VALVE SCHEMATIC TANKLESS HEATER PIPING SCHEMATIC TANKLESS HEATER PIPING FIG 6 FLUSHING OF HEATER All water contains some sediment which se
31. nnually Service technician Refer to instructions Burner position Annually Service technician Refer to instructions interlock Rotary cup interlock Annually Service technician Refer to instructions Low fire start interlock Annually Service technician Refer to instruclions Automatic changeover At least annually Service technician Under supervision of gas utility control dual fuel Safety valves As required Operator In accordance with procedure in Section VI ASME Boiler and Pressure Vessel Code Recommended Rules for Care and Operation of Heating Boilers Inspect burner Semiannually Service technician Refer to instructions components 19 PS
32. onnec tions for the trim are labeled in Figure 3B 4 BURNER INSTALLATION Refer to burner manufacturer s installation manual fur nished with the E Series boiler for proper installation fuel piping wiring burner adjustment and service instructions 5 TANKLESS HEATER A IF BOILER IS ORDERED WITH TANKLESS HEATER CONNECT TANKLESS HEATER PIP ING AS SHOWN IN Fig 6 See Table II for Tank less Heater Ratings Install an automatic mixing valve at the tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at the fixtures Adjust and maintain the mixing valve in accordance with the manufacturer s instructions B THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER 1 FLOW REGULATION If flow through the heater is greater than its rating the supply of ade quate hot water may not be able to keep up with demand For this reason a flow regulator match ing the heater rating should be installed in the cold water line to the heater The flow regulator should preferably be located below 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 pressure varia tions in the range of 20 to 125 psi 2 TEMPERING OF HOT WATER Installation of an automatic mixing valve wi
33. ough the entire system G Vent the system including the radiation H Allow boiler water to reach operating temperature if possible I Continue to circulate the water for a few hours J Stop firing the boiler K Drain the system in a manner and to a location that hot water can be discharged with safety L When the boiler has cooled down to 120 F or less remove plugs from all available returns and wash the water side of the boiler as thoroughly as possible using a high pressure water stream M Refill the system with fresh water and bring water tem perature to 180 F promptly in order to drive off any dis solved gases m 7 WATER BOILER OPERATION The following guidelines relating to system water tempera ture fluctuation and flow through the boiler must be observed A It is important to operate your boiler in such a manner as to prevent temperature fluctuation of more than 40 F at any time Rapid temperature changes within the boiler can create stresses in the boiler metal These stresses can cause damage to the boiler by loosening tubes or in more severe instances can crack tube sheet ligaments furnaces or waterlegs B It is equally important to insure that there is circulation through the boiler of at least 1 2 GPM BHP at all times when the burner is firing BOILER WATER TREATMENT Boiler water treatment will help maximize the effective ness and projong the life of pressure vessels The general o
34. plant load as low as possible B Turn burner switch off If control power from burner is used to support accessories leave on until boiler system has cooled down C Shut and lock manual gas and oil valves as applicable D In single boiler installations some small steam loads can remain on to assist in a controlled cooldown of the boiler i e deaerator In multiple boiler installations shut the non return valve and back up valve Lock them shut E Allow the boiler feed pump to remain active As the boiler cools down the water level is reduced by demand or shrink It is best to be aware of boiler water level at all times E When boiler pressure has decreased to 5 to 10 psi on the pressure gauge open the boiler manual vent valve on the top of the boiler This is to act as a sentinel against an increase in pressure and to prevent the boiler from going into a vacuum Lock the valve open NOTE Depending on the size of the boiler the large mass of heating surfaces that are still hot can cause the boiler water temperature to increase even if the gauge pressure is 0 It is better to allow the entire system to cool gradually Never force cool the boiler or system as damage can also be inflicted due to thermal shock G When boiler and water are below 120 degrees secure power to the unit and lock out the circuit breakers H If required open front and rear doors for observations of fireside surfaces I Drain boiler down
35. r vent located near top of radiator open vent until water escapes and then close C If much water is added to system it is advisable to heat system to a high temperature and vent again This will make less venting necessary during the winter D Where an expansion tank is used make sure that neither the tank nor its drain pipe is exposed to freezing tempera tures Never place valves in piping leading to or from ex pansion tank E Boiler and system cleaning will help assure trouble free operation See Item 5 amp under Operating Instructions for procedure Q ATTENTION TO BOILER WHILE NOT IN OPERATION IMPORTANT A IF BOILER IS NOT USED DURING WINTER TIME IT MUST BE FULLY DRAINED TO PREVENT FREEZE DAMAGE B STEAM BOILERS Procedure for taking steam boilers off line at the end of the heating season Drain off boiler water unti it runs clear while holding the boiler temperature between 180 to 200 F Then refill to the top of the gauge glass and add necessity of adequate water treatment C WATER BOILERS Procedure for taking water boilers off line at the end of the heating season While the boiler tem perature is still between 180 to 200 drain water from the bottom of the boiler until it runs clear Then refill the sys tem to normal water pressure and add necessity of adequate water treatment D Note any time raw water is introduced into the boiler it must be immediately heated to 180 F to drive off dissolved gase
36. s If water treatment is used sufficient water treatment compound should be added to condition the make up water T REPAIR PARTS Give boiler series and model number when ordering repair parts All repair parts can be ordered through the commercial steel sales office See figures 8 and 9 for rear smokebox and reversing chamber part descriptions Burnham Corporation Commercial Steel Boilers P O Box 3079 Lancaster PA 17604 Phone 717 293 5846 Fax 717 293 5977 FRONT VIEW MODELS E 20 THRU E 40 MODELS E 50 THRU E 80 48 TURBULATORS 40 TURBULATORS NOTE TUBES MARKED X HAVE TURBULATORS INSTALL TURBULATORS FLUSH WITH Fig 7 FRONT END OF TUBES FIRETUBE CONFIGURATION VERSUS TURBULATOR LOCATIONS 15 I THK INSULATION 2 THK X WIDE ADHESIVE FIBERGLASS TAPE GASKET Sa ae 5i REAR SMOKEBOX DOOR REAR SMOKEBOX DIVIDER PLATE T VENT COLLAR THK CERAFELT INSULATION REAR REVERSING CHAMBER COVER PLATE NJ L3 L ig THK X 15 1 0 X 215 O D FIBER GASKET 2 NPS CONDUIT BUSHING REVERSING CHAMBER LINER L 3 g THK X 216 DIA PYREX GLASS 4 THK X I WIDE ADHESIVE FIBERGLASS TAPE GASKET DOOR GUIDE d THK CERAFELT INSULATION REAR SMOKEBOX AND REVERSING CHAMBER DETAIL Fig 8 31V ld H3AOO H38ANVHO 9NISH3A3H 6 31 SLYYd H38WVHO SNISH3A3M XOS3MOWS uv3H JO
37. ttles 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 hosebib A through the heater and out hosebib B until the discharge is clear The tees in which the hosebibs are located should be the same size as heater connections to minimize pres sure drop k HARD WATER May be applicable to some city water and particularly to well water Have your water analyzed by a qualified water treatment specialist to determine if a water softner condi tioner or filtration is required Treated water will ensure longer tankless heater life and performance and is also beneficial to all the piping and fixtures in the building Heater Coil 180 F 212 F Pull Space GPH GPH Inches INA 300 All Sizes Except E20 360 All Sizes Except E20 INA 450 Sizes Except E20 E60 and Larger 60 and Larger INA 750 INA 900 E40 and Larger INA 1125 E60 and Larger E70 and Larger 10 INA 1350 INA 1500 oN SECTION III OPERATING INSTRUCTIONS ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER FILL HEATING SYSTEM WITH WATER IMPORTANT Any time that raw water is introduced into the boiler it must be heated to at least 180 F
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