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Burnham Series 8B Installation and Operation Manual

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1. eso 96 203 Hayy k Q Y uy Wry 7 A 97 Item D 2 Part N Quantity escription art No No P 805B 8068 8078 8088 809B 8108 7 Trim and Miscellaneous Controls Limit 140 220 F Honeywell L4080D1218 El amp Standing Pilot 80160251 L4080B1212 EP amp OP 80160474 Immersion Wel 1 1 Cs emere Immersion Well 34 NPT x 3 Insul Depth ee C1 2 NPT x 10 w Gauge Tapping Ratt Vato NPT r Backer new Pi Pri wwe mo vsa EUN dd ES SE Transtormer 50 Continuous Circulation builds 80160249 1 1 e eee m e Vestibule Wiring Harness Complete with Vent Damper 81316010 1 Bypass Plug El and Standing Pilot Not Depicted 81316011 98 VENT DAMPER DRAFT HOOD OPTIONAL 806 810 REQUIRED 805B Description Part No Quantity 2 8058 8068 8078 8088 8098 8108 8 Draft Hood and Automat
2. Item Quantity No Description Part No 805B 806B 807B 808B 809B 810B 6 Jacket 60416051 d ee s gt ee e Ss m owe 60416101 20318013 125151 Jacket Top Panel Assembly 70416088 1 20082 Ea 1 Po eee E sm ee 8 Jacket 60416075 1 pper Rear Panel 60416085 1 _ a 2 2118 18016058 s ewe 6C Jacket Lower Rear Panel 60416088 1 s Kuas RUNI 2 22428 28 acket Upper Front Panel 6041684 1 ie ENT REC RES 704608 1 Jacket Front Removable Panel ES ee p p wp ee 95 Item Quantity No Description Part No 805B 8068 8078 8088 8098 8108 6 Jacket Continued
3. p PILOT 120 SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C F1 LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105C LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE 37 INSUL 200 FLAME ROD LEAD HONEYWELL R1298020 IGNITION LEAD HONEYWELL R1061012 NOTE 4 EP PANEL COMPONENT LEGEND PANEL FUSE 51 POWER SWITCH 52 GAS VALVE SWITCH L1 POWER INDICATOR LAMP GREEN L2 GAS VALVE INDICATOR LAMP GREEN L5 FLAME FAILURE LAMP RED REVERSE ACTING CIRCULATOR CONTROL IF USED CIRCULATOR SEE NOTE 3 LWCO AUX LIMIT 20V THERMOSTAT IF USED IF USED LIMIT OR CONTROL PILOT SOLENOID GAS VALVE SENSING ROD PILOT BURNER GROUND 50 GAS VALVE LADDER DIAGRAM LEGEND 24V WIRING 120V WIRING 97800 suB BASE TERMINAL o EP TERMINAL STRIP TERMINAL 150 TRANSFORMER TERMINAL Figure 43 Wiring Diagram EP EP CSD 1 Ignition System USA Continuous Circulation 55 BURNHAM EP PANEL GROUNDING LuG 6 amp G WIRE CODE BK BLACK BL BLUE GR GREEN GY GRAY GY WH GRAY WITH WHITE TRACE PINK OR ORANGE RED RED WITH YELLOW TRACE WH WHITE YE YELLOW Low LOW VOLTAGE SIZE 18 R
4. FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULE Figure 37 Wiring Diagram Honeywell El Canada Continuous Circulation 47 CIRCULATOR BY OTHERS ITEMS SUPPLIED BY INSTALLER POWER SUPPLY 1120 80 1 12 8 Fl DISCONNECT SWITCH PILOT BURNER ASSEMBLY PILOT SOLENOID VALVE mn BRI 8 10 SECT OPTIONAL 5 7 SECT 1 6 HONEYWELL 82850 CONTROL CENTER YE HONEYWELL RB222U RELAY BOTTOM VIEW THERMOSTAT OR OPERATING CONTROL BY OTHERS 50VA TRANSFORMER TOP VIEW VENT DAMPER RECEPTACLE 1 AUX LIMIT IF USED LIMIT VENT DAMPER WIRING HARNESS SEE NOTE 5 ROLL OUT T Y SWITCH FRS a BLOCKED VENT SWITCH E CODE BLACK BLUE BROWN GREEN GRAY GRAY WITH WHITE TRACE ORANGE RED WHITE IGNITION YELLOW MODULE SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105C LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE HONEYWELL IGNITER SENSOR CABLE 250C GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE THK INSULATION 200 POWER SUPPLY 120 60 1 FUSED DISCONNECT SWITCH SERMCE SWITCH REVERSE ACTING CIRCULATOR
5. Install Canopy See Section II Boiler Assembly Paragraph G Install Jacket Top Panel Draft Hood Vent Damper 1f used and Vent System Warning This product contains refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen After this product is fired RCF may when exposed to extremely high temperature gt 1800F change into a known human carcinogen When disturbed as a result of servicing or repair RCF becomes airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace previously fired RCF combustion chamber insulation target walls canopy gasket flue cover gasket etc or attempt any service or repair work involving RCF without wearing the following protective gear A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an air tight plastic bag First Aid Procedures f contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with
6. NEUTRAL SUPPLY 5 HOT ALARM IF USED TERMINAL OF R8285D a TO 24V LIMIT CIRCUIT 4 TO TERMINAL C OF R8285D INTERMITTENT CIRCULATION Figure 47 Hydrolevel OEM 170 550 650 750 120V L W C O Wiring for Boilers with 24V Limit Circuits 120 VAC NEUTRAL SUPPLY HOT TO TERMINAL 3 ON TERMINAL STRIP OR SUB BASE TO 120V LIMIT CIRCUIT NEUTRAL 120 VAC SUPPLY ua IF USED TO DISCONNECT IN R8239 CONTROL CENTER JUNCTION BOX TO 120V LIMIT CIRCUIT Figure 48 Hydrolevel OEM 170 550 650 750 120V L W C O Wiring for Boilers with 120V Limit Circuits VIII System Start up WARNING Completely read understand and follow all instructions in this manual before attempting start up A Safe operation and other performance criteria were met with the gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas Fired Low Pressure Steam and Hot Water Boilers ANSI Z21 13 B Check Main Burners Main burners must be properly located on support bracket in Base Rear Panel seated on Main Burner Orifices and secured with hitch pin clips C Verify that the venting water piping gas piping and electrical system are installed properly Refer to installation instructions contained in this manual D Confirm all electrical water and gas supplies are turned off at the source and that vent is clear
7. SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ALL CSD 1 BOILERS SUPPLIED WITH SECOND LIMIT ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULE PILOT SAFETY SWITCH REQUIRED ON CSD 1 BUILDS ONLY lt CIRCULATOR L62 GB PILOT SAFETY SWITCH LEGEND 24V WIRING 120V WIRING L 97800 suB BAsE TERMINAL OP TERMINAL STRIP TERMINAL AT150 TRANSFORMER TERMINAL Figure 33 Wiring Diagram OP OP CSD 1 Ignition System Continuous Circulation 42 BURNHAM OP PANEL GROUNDING o HONEYWELL RABO OPTIONAL 24V THERMOSTAT WIRING PANEL SCHEMATIC DIAGRAM LEGEND COMPONENT LEGEND LOW VOLTAGE SIZE 18 TEW AWM STRANDED WIRE 1050 Fi PANEL FUSE LOW VOLTAGE 18 STRANDED WIRE 105 POWER SWITCH LINE VOLTAGE SI TYPE TW OR TER AM WIRE S2 GAS VALVE SWITCH UNE VOLTAGE Er 18 AWG TYPE TW OR AWM WIRE L1 POWER INDICATOR LAMP GREEN GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED L2 GAS VALVE INDICATOR LAMP GREEN INSUL 200C 15 FLAME FAILURE LAMP RED FLAME LEAD HONEYWELL R1298020 REVERSE ACTING CIRCULATOR CONTROL IF USED SEE NOTE 2 LWCO AUX LMI 120V THERMOSTAT USED F 080 LIMIT OR OPERATING CO
8. 10114 2 IN3LLIAS INI 66 NN3d 41815 JINGOW NOILIN9I 01 0911 N31SV4 LON 04 ONIGNL 107 WANINNTY O O 2 4 5544 40103 55 901911934 599 10114 9 310 Sv9 1014 9 9MI6H 510 1 5 O1 AINO 8018 8808 NO Q3NInO33 ATAWASSV LOTId e 12 xassa 32009 1014 j 1014 OL qv3H 05 27 x mo J SAL did 5534 NOD e Ne 3ATVA 1 OL AINO 8 08 8908 NOISS3NdWOO 55 8 d ATANASSV HATVA GIONWIOS SVD LOTId 3J3A VA GION31OS 5 9 1014 X 31ddlN 1InQNOO 48 ONILVINSNI OILSV Id 8018 8908 5 sed 6 9 9 1614 E NOINA NOISS3NdW O SSVHB AINO VQVNVO SNOILO3S OL 8 NO 70092 Qalvolsgn ANWA SV9 GION310S 3NIVA 5 9 3A Q3HSINSO LON 3NIT1100 N3QGIH NI NMOHS L4 N AD 0002 mu E PME
9. SUPPLY 120 60 1 u gt 9 GND 8 ITEMS SUPPLIED BY INSTALLER 8 9geuqgugeuvu SR GROUNDING LUG RD us I 24V THERMOSTAT rg OTHERS s useD L LIMIT THERMOSTAT OPERATING CONTROL RD SOVA 5259 HONEYWELL OPTIONAL 24V THERMOSTAT WIRING ROBERTSHAW SEE NOTE 5 VALVE a T PA JUNCTION BOX SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105C LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE x5 THK INSUL 200C FLAME ROD LEAD HONEYWELL 1298020 R il BURNHAM OP PANEL 29 IPH 2 96060004040 PILOT BURNER ASSEMBLY OP PANEL COMPONENT LEGEND a PANEL FUSE POWER SWITCH B GAS VALVE SWITCH POWER INDICATOR LAMP GREEN 12 GAS VALVE INDICATOR LAMP GREEN L3 FLAME FAILURE LAMP RED POWER SUPPLY 120 60 1 REVERSE ACTING CIRCULATOR CONTROL IF USED SEE NOTE 3 LWCO AUX LIMIT eto P us 120V THERMOSTAT LIMIT OR OPERATING CONTROL RM7890C INTERNAL CIRCUITRY SENSING ROD gt LADDER DIAGRAM ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT
10. jn iii hin lii i anil bs ou i mn ng f BLOCKED M IGNITION MODULE CODE SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 LOW VOLTAGE SIZE 18 2 AWG CL2X STRANDED WIRE 105 GRAY WITH WHITE UNE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE ORANGE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE RED e 9 HONEYWELL IGNITER SENSOR CABLE 250C WHITE 8 4 0 GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE 3b THK INSUL 200 C YELLOW L2 GND POWER SUPPLY 120 60 1 FUSED DISCONNECT SWITCH SWIICH REVERSE ACTING CIRCULATOR CONTROL CIRCULATOR AUX LWCO LIMIT s IF USED IF USED BVS LIMIT E NET 3 2 FRS L 6 E Bod ES oo 06 6 DAMPER f o d THERMOSTAT SEE NOTE 5 LESS lt HONEYWELL DAMPER 5 2 IGNITION LADDER DIAGRAM LEGEND MODULE SAVED 24V WIRING L NOTES 120V WIRING 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER VENT DAMPER REQUIRED ON 805B VENT DAMPER OPTIONAL ON 806B AND 807B VENT DAMPER MUST NOT BE USED ON MODELS 808B 8108
11. 09 2 8018 4808 932110322 AISWHSSV LOTId AINO VGVNVO SNOILO3S OL 8 NO 000 9nd 41 8 189 3553 579 10 3105 1014 OL 95 aT i NS x 4 s Y3ldyay au 331 NOISS3HdWOO SSYX8 0 31 5 9 j N N IMYA 2 10114 OL 2 a Pd 7 8 2229 NOISS3MdWOO SSvMB EX 20 1 JAVA GION310S NOISS34dWOO ELM O68 NW 3 01 Y YML6H Qv31 008 3Wv14 0 STOMINOO NOSNHOf Cos Tana 22 TZ NOLLVTIVISNI HATVA Ju annoio lt LES GIONXIOS SVD 1014 4 JAVA QION310S 1019 OINOMLO313 26 10 TI3MA3NOH lt SVO 10119 1934 1014 afl X 20 9NIHSng ONILVINSNI 5 25 8018 8808 uiejs S 5 L QS2 d3 Buldig seo neuieuss 6 4 YaYNLOVANNVAW AG 5 LON SNNLNO N3QGIH NI NMOHS ONIdid 3909 9fYld G3lVv9l3801 AlddNS 5 9 10114 D NOINN NOISS3HdWOO SSVHB abba TWNINH3L 068 4 OL x 0 31 04 8 0 M3ldvav NOISS3HdWOO ssvud O68ZNY 01 JATA QION310
12. 10 EP SYSTEM e Turn gas control knob counterclockwise w from MAIN GAS ROCKER OFF to PILOT When the proper position is reached 277 the gas control knob will pop up SWITCH e Turn on all electric power to the appliance the thermostat or operating control to desired setting CONTROL LOCATION DIAGRAM See control location diagram On the electronic control 4 EP SYSTEM Flip both rocker switches to O position off panel flip the main power rocker switch to I position 5 This appliance is equipped with an ignition device on The POWER status indicator will light which automatically lights the pilot Do not try to light e The pilot will light electronically If pilot failure occurs the pilot by hand the ALARM indicator will light In case of pilot Remove font door failure proceed to step 11 Turn gas control knob counterclockwise P w to ON On the electronic control panel flip the main gas valve rocker switch to I position on The MAIN gas valve indicator will light Main burners will operate T Locate the gas control valve at the end of the gas supply pipe going into the boiler The gas control knob is the knob located on top of the gas valve see diagram to right MAIN gas valve indicator will cycle on and off at the 8 Rotate gas control knob clockwise from ON same time as the thermostat or operating control and position to OFF Make sure knob rests agai
13. 5 2 6 IVNINS3L FINGOW NOILIN9I 01 FINGOW OL Qv31 05 35 q o at NOISSSNdWOD SSVM8a 1014 WANIANW 7 SV9 7 ONIddVL 1014 JANA SVD OL 10114 193NNOO 10 4 LNALLINYALNI 13 1014 1019 YANN 19 ay SNIddV L 1311 0 1014 ANWA 5 9 10114 NOILINSI AN3LLIASGLNI av 310QON NOILINOI OL ONIGNL 2019 WANINNTY O O 6 TVNIN2331 FINGON 01 Qv31 MOSN3S HOLINOI 8 08 8908 529 d7 8018 98908 sed I3 6 9 1614 8018 8808 3517035 AIHNWHSSV HATVA LOTId gt 2 2 x3ss3 3200 1014 3 10114 01 331 ANIVA 10114 OL Pa AINO 8408 8808 a 8 m X 00 NOISS3HdWOO SSVHB M3ldvQv NOISS3NdWOO 55 Ss N N N avaH 05 27 x NOISS3HdWOO LT 2 TYVLAA ATANASSV HATVA GIONAIOS SV LOT
14. 72 Regulator Maxitrol RV12LT Natural Gas 8226005 8058 CTUM Natural Gas Only 2 SOLENOID VALVE PILOT GAS SOLENOID VALVE ASSEMBLY DETAIL 2 TAPPING 4 VALVE 4 gt GAS VALVE 2 1 TO 5 BURNER I 7 768 no eS PILOT FIRING VALVE ASSEMBLY REQUIRED ON 808B 810B ONLY ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 9 Pilot Assembly and Piping Intermittent Ignition Johnson El USA 5 10 Section Natural and LP Gas Pilot Burner Johnson J991LYW7225 Natural Gas 8236050 Includes Ignition Lead Pilot Burner Johnson J991LYW9840D LP Gas 8236086 Includes Lead B Sensing Probe Johnson Y75AA C Probe Johnson Y75AA C 8236040 8058 8108 Sensor Lead Johnson Y57AH 36 8236051 Le Ground Wire Assembly 6136054 Brass Compression Union OD Tube 8236008 1 O D ALUMINUM PILOT TUBING TAPPINC 0 0 ALUMINUM PILOT TUBING 88 ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 10 Pilot Assembly and Piping Intermittent Ignition Johnson El Canada 5 10 Section Natural Gas 5 7 Section LP Gas Pilot Burner Johnson J991LYW7225 Natural Gas 8236050 805B 810B Includes Ignition Lead Pilot Burner Johnson J991LYW9840D LP Gas 8236086 805B 807B Includes Ignition Lead Sensing Probe Johnson Y75AA C 8236040 NM 1 All 1 Brass Compression Union OD Tube 1 Pipe Tee
15. Alterations Claims arising from or relating to any alteration or other modification not authorized by Burnham in writing are not covered by these warranties Misuse The following claims not covered by these warranties clalms arising from or relating to I misuse abuse mishandling accident neglect or improper service or operation of a Boiler including but not limited to improper burner adjustment control setting or maintenance and thermal shock from low water temperatures 1 operation of a Boiler over its rated capacity iii operation of a Boiler with insufficient water excessive fresh make up water or Inadequately deareated water Iv freezing of a Boiler or any part or component thereof v operation with combustion air contami nated externally by chemical vapors or other contaminants vi use of improper fuel additives or vii operation of a Boiler with inadequately or improperly treated water that causes deposit build up in the cast iron sections or other Boiler components 1 Subsequently Installed Accessories Claims arising from or relating to Boiler accessories including but not limited to circulators air elimination devices deaerators flow controls and low water cutoffs which are installed by Owner after delivery of the Boiler are not covered by these warranties 5 If any Boller cast iron section or covered compo part fails to conform to these warranties Owner s exclusive remedy shall ba
16. Ifresult is less than 50 ft per 1 000 Btuh space is considered a confined space 4 Determine building type A building of unusually tight construction has the following characteristics a Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed and b Weather stripping has been added on openable windows and doors and c Caulking or sealants applied in joints around window and door frames between sole plates and floors between wall ceiling joints between wall panels at plumbing and electrical penetrations and at other openings For boiler located in an unconfined space in a building of other than unusually tight construction adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors For boiler located in an unconfined space in a building of unusually tight construction or in a confined space provide outdoor air through permanent opening s which communicate directly or by duct with the outdoors or spaces crawl or attic freely communicating with the outdoors Minimum dimension of air opening s 15 3 7 6cm a Two permanent openings Locate one opening within 12 30 5cm of top of space Locate remaining opening within 12 30 5cm of bottom ofspace Size each opening per following i Direct communication with outdoors Minimum free area of e
17. USED ON MODELS 8088 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULE Figure 41 Wiring diagram Johnson El Canada Continuous Circulation 52 CIRCULATOR BY OTHERS HONEYWELL RB2B5D CONTROL CENTER ITEMS SUPPLIED BY INSTALLER 682220 RELAY BOTTOM VIEW POWER 12 SUPPLY 1120 60 1 FUSED DISCONNECT SWITCH THERMOSTAT OR OPERATING CONTROL BY OTHERS SOVA PILOT 8 PILOT wo m SOLENOID _ Teor VIEW BURNER 8 10 SECT VALVE ASSEMBLY 2 OPTIONAL 5 7 SECT VENT DAMPER RECEPTACLE AUX LIMIT IF USED YE VENT Ei p R DAMPER SEE NOTE 4 VENT DAMPER WIRING HARNESS SEE NOTE 5 ROLL OUT SWITCH FRS CODE BLACK BLUE BROWN GREEN GRAY GRAY WITH WHITE TRACE ORANGE RD RED WH WHITE YE YELLOW 4 IGNITION YE MODULE GAS VALVE SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105 LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE LINE VOLTAGE SIZE 18 TYPE TW OR TEW AWM WIRE IGNITER 250 INCLUDED WITH PILOT BURNER ASSEMBLY GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE zi THK INSULATION 200C SENSING PROBE WIRE JOHNSON YS7AH 36 L2 GND POWER SUPPLY 120 60
18. a copy of which is printed on the back of this manual It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete USA boilers built for installation at altitudes greater than 2 000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1 000 feet above sea level per the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 8 1 2 and Appendix F Canadian boilers orifice sizing is indicated on the rating label Table of Contents I II lt lt s Pre Installati ti oce tret 6 Boiler Assembly iere 8 Gas Control System Assembly 15 Knockdown Boilers Water Trim and Piping 27 DIDIDB 31 33 Electrical aet aatia te eni ets 36 System Start up uie ete 59 DEVICE ETT 68 Repair Parts 75 2 5 1cm PIPING SHOWN IN HIDDEN LINES NOT SUPPLIED BY MANUFACTURER VENT DAMPER IF USED SAFETY RELIEF VALVE 11g 2 MPT SUPPLY 28 9 P 6 7 TEMPERATURE PRESSURE MANUAL GAS TOP VIEW SHUT OFF VALVE 323 82 6cm 112 4 6cm LEFT SIDE VIEW FRONT VIEW Figure 1 Dimensional Data Table 1 Dimensional Data A 20 35
19. installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME No CSD 1 Provide clearance between combustible material and boiler Jacket following clearances are minimums USA 805B 807B listed for Alcove installation WARNING Appliance is design certified for installation on noncombustible flooring only For a Front 18 b Top 36 c Draft hood rear sides and flue connector 6 2 USA 808B 810B for installation in room which is large in comparison with size of boiler a Front 18 b Top 517 c Draft hood rear sides and flue connector 6 3 Canada 805B 810B a Topand front 18 45 7cm b Flue rearand sides 6 15 2 Provide clearance for servicing and proper operation following clearances are recommended and may be reduced to minimum clearances shown above 1 Singleboiler 805B 807B Front Top 24 61cm 2 Single boiler 808B 810B Front Top 48 122 3 Multiple modular boiler USA Canada Sides 1 2 5cm Install boiler on level floor as close to chimney as possible For basement installation provide a solid base such as concrete or masonry construction if floor is not level or if water may be encountered on floor around boiler Protect gas ignition system components from water dripping spraying rain etc during boiler operation and service circulator replacement control replacement etc Pro
20. interrupts main burner operation if a pilot flame is not detected during the four or ten second pilot flame establishing period The RM7890A will lockout or recycle based on jumper settings Alarm light will be illuminated Refer to instructions supplied with RM7890A for additional control information SUPPLY 120 60 1 e GND 6 ITEMS SUPPLIED BY INSTALLER 24V THERMOSTAT 9 OTHERS X3 x4 HONEYWELL Eh gid OPTIONAL 24V THERMOSTAT WIRING xe Lwco IF USED LIMIT IF USED RI LIMIT BLOCKED VENT SWITCH BVS SOLENOID GAS VALVE CODE BLACK BLUE GREEN GRAY GRAY WITH WHITE TRACE POWER SUPPLY 120 60 1 FUSED SWITCH IGNITION TRANSFORMER NOTES IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ALL CSD 1 BOILERS SUPPLIED WITH SECOND LIMIT ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULE IGNITER T H BURNHAM EP PANEL E 19 GR GROUNDING LUG CIRCULATOR BY OTHERS B SOS TERMINAL STRIP PILOT BURNER ASSEMBLY SOVA TRANSFORMER JUNCTION BOX JUNCTION BOX IGNITION TRANSFORMER id
21. see diagram below panel flip the main power rocker switch to I position on The POWER status indicator will light Turn gas control knob counterclockwise to ON POSITION On the electronic control panel flip the main gas valve INDICATOR rocker switch to I position on The MAIN gas valve status indicator will light Main burners will operate MAIN gas valve indicator will cycle on and off at the same time GAS 2 as the thermostat or operating control and the main INLET burners GAS CONTROL KNOB If pilot failure occurs the ALARM status indicator will SHOWN IN OFF POSITION light Repeat steps 1 thru 16 Replace the front door 8 Push in gas control knob slightly and turn clockwise to 16 If the appliance will not operate follow the instructions OFF NOTE Knob cannot be turned from PILOT to OFF TURN OFF GAS TO APPLIANCE and call your unless knob is pushed in slightly Do not force service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set the thermostat to the lowest setting 4 Push in gas control knob slightly and turn clockwise 2 Turn off all electric power to the appliance if service is to OFF Do not force to be performed 5 Replace front door 3 Remove front door Figure 51 Lighting Instructions OP 62 FOR YOUR SAFETY READ BEFORE OPERATING WARNING you do not follow these instructions exactly a fire or explosion
22. the pilot by hand B BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some C Use only your hand to turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician gas is heavier than air and will settle on the floor Force or attempted repair may result in a fire or WHAT TO DO IF YOU SMELL GAS explosion Do not try to light any appliance D Do not use this appliance if any part has been under Do not touch any electric switch do not use any water Immediately call a qualified service technician phone in your building to inspect the appliance and to replace any part of the control system and any gas control which has been lier fr ighbor e Immediately call your gas supplier from a neighbor s ande water phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS 1 STOP Read the safety information above on this label 7 Rotate gas control knob clockwise from ON 2 Set the thermostat to lowest setting position to OFF Make sure knob rests against stop 3 Turn off all electric power to the appliance 8 Wait five 5 minutes to clear out any gas Then smell ane for gas including near the floor If you smell gas 4 This appliance is equipped with an ignition device STOP Follow B in the safety information above on which
23. 15490 X 1 LG CARRIAGE BOLT CANOPY 1t 20 x 14 LG CARRIAGE BOLTS GAS MANIFOLD BASE FRONT PANEL 17 FLAT WASHER 17 20 HEX NUT JACKET ATTACHMENT BRACKET 8 1 SHEET 18 5 METAL SCREWS BURNER ACCESS PANEL Figure 5 General Assembly Knockdown Boilers on three sides alcove while maintaining clearances shown in Figure 4 F Move boiler to permanent location by sliding or walking DO NOT DROP For Packaged Boiler proceed to Section IV Trim and Piping G Install Canopy on section assembly See Figure 5 Canopy and hardware are located in Combination Boiler Parts and Control Carton 1 Position Canopy on top of Section Assembly Locate between end sections and sealing ledge on front and back of each section 2 Fasten each end with 20 x 1 carriage bolts washers and nuts 3 Seal between Canopy and Section Assembly with furnace cement H Inspect joints between sections They were factory sealed If any openings resulted during shipment or handling reseal with furnace cement Confirm tie rods are only hand tight to allow for thermal expansion 10 Install Base Front Panel See Figure 5 Panel and hardware located in Combination Boiler Parts and Control Carton 1 Attach Base Front Panel to Section Assembly using 1 4 20 1 4 carriage bolts washers and nuts 2 Seal between top of Base Front Panel and Section Assembly with furnace cement shipped in Combina
24. J SEE NOTE 5 LADDER DIAGRAM LEGEND 24V WIRING gt 5 2 J S77 LESS VENT DAMPER 5 FRS BVS 2 VENT EE exe pAMPER L 1 a 9 HONEYWELL E Le D ROBERTSHAW GAS VALVE IGNITION MODULE 120V WIRING NOTES 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER U S A VENT DAMPER REQUIRED ON MODEL 8058 OPTIONAL ON MODELS 8068 THROUGH 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG ALLIANCE WATER HEATER CONTROLS SUPPLIED BY INSTALLER SHOWN FOR DOMESTIC WATER PRIORITY AND CIRCULATOR ZONING Figure 36 Wiring Diagram Honeywell El USA Intermittent Circulation 46 24 THERMOSTAT OR OPERATING Y CONTROL 5 7 SECTON BY OTHERS p TO VENT DAMPER RECEPTACLE TO TRANSFORMER Py TERMINAL R THERMOSTAT OR OPERATING CONTROL BY OTHERS JUNCTION BOX SOVA VENT DAMPER TRANSFORMER RECEPTACLE VENT DAMPER WIRING HARNESS POWER 11 0 SUPPLY 1120 60 1 FUSED SERVICE DISCONNECT SWITCH SWITCH ITEMS SUPPLIED BY INSTALLER CIRCULATOR BURNER BY OTHERS ASSEMBLY FLAME SWITCH LOR
25. Only EM Pipe 80660105 _ Pine Pwo teea 80888108 73 Lm Natural Gas Brass Compression Adapter 14 OD Tube x 1 8 822630 808B 810B Natural Gas 806B 810B LP Gas PILOT TAPPING GAS VALVE TO PILOT BURNER 7 E PILOT FIRING VALVE ASSEMBLY REQUIRED ON 8088 8108 CANADA ONLY ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 12 Pilot Assembly and Piping Standing Pilot OP CSD 1 USA Only 8 10 Section LP Gas Only Thermocouple Honeywell 130941996 w 36 Lg Lead Brass Compression Union OD Tube Regulator Maxitrol RV12LT Nat LP Gas Pilot Switch Johnson L62 GB 3C ConBraCo Leak Test Shut Off Valve 1 8 x 1 8 Brass Compression Adapter 1 4 OD Tube x 1 8 NPT S LL 4 x C N FROM EXTERNAL MAIN GAS SUPPLY ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 13 Pilot Assembly and Piping Intermittent Ignition EP USA amp Canada 6 10 Section Natural Gas Only s rame Leag Konene R1268020 71982567 D Leas rneyermoswimsR ig 7196247 Brass Compression Coupling OD Tube 8236008 Shut off Valve Essex P2L 822645 Pipe Tee 1 8 NPT Malleable 806601005 Canada Only Pipe Plug 1 8 NPT Sq Head 806603508 806B amp 807B Canada Only Brass Compression A
26. POWER BOTTOM VIEW SUPPLY 1120 60 1 11 FUSED DISCONNECT SWITCH 12 9 SERVICE SWITCH puse Al JUNCTION BOX THERMOSTAT OR OPERATING CONTROL BY OTHERS 8 10 SECT OPTIONAL 5 7 sect BURNER ASSEMBLY LIMIT USED TRANSFORMER TOP VIEW VENT DAMPER RECEPTACLE LIMIT VENT DAMPER WIRING ROLL O HARNESS SEE NOTE 5 UT T SWITCH FRS T WIRE 1 BLOCKED VENT BR SWITCH GR BVS GY WH OR RD WH YE CODE BLACK BLUE BROWN GREEN GRAY GRAY WITH WHITE TRACE ORANGE RED WHITE YELLOW IGNITION MODULE pe ___81 GAS VALVE SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105C LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE HONEYWELL IGNITER SENSOR CABLE 250C GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE THK INSULATION POWER SUPPLY 120 60 1 FUSED DISCONNECT SWITCH SERVICE SWITCH REVERSE ACTING CIRCULATOR CONTROL O sO o p SEE NOTE 3 ALLIANCE RELAY CIRCULATOR PRIMARY SEE 9 IGNITER SENSOR LwCO LIMIT IF USED IF USED LIMIT s 6 4 5 ALLIANCE RELAY SEE NOTE 6
27. S3ATVA 140 1 5 S3NOZ 1N3A IV 30 V Gas Piping 4 Specific gravity of gas Gas piping systems for gas WARNING with a specific gravity of 0 70 or less can be sized directly from Table 6 unless authority having Failure to properly pipe gas supply to jurisdiction specifies a gravity factor be applied For boiler may result in improper operation and specific gravity greater than 0 70 apply gravity damage to the boiler or structure Always factor from Table 8 If exact specific gravity is not assure gas piping is absolutely leak free shown choose next higher value and of the proper size and type for the i connected load For materials or conditions other than those listed An additional gas pressure regulator may above refer to the National Fuel Gas Code NFPA be needed Consult gas supplier 54 ANSIZ223 1 and or CAN CGA B149 Installation Codes or size system using standard engineering methods acceptable to authority having jurisdiction A Size gas Piping Design system to provide adequate gas supply to boiler Consider these factors B Connect boiler gas valve to gas supply system 1 Allowable pressure drop from point of delivery to boiler Maximum allowable system pressure is 2 psig Actual point of delivery pressure may be less contact gas supplier for additional information Minimum allowable gas valve inlet pressure is indicated on rating label WARNING
28. WHITE TRACE LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105 C ORANGE LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE RED LINE VOLTAGE SIZE 18 AWG TW OR TEW AWM WIRE HONEYWELL IGNITER SENSOR CABLE 250 C WHITE 7 YELLOW GROUND SIZE 18 AWG TYPE 5 2 5 2 STRANDED WIRE 55 THK INSUL 200 C L2 GND POWER SUPPLY 120 60 1 FUSED DISCONNECT SWITCH IT REVERSE ACTING SWITCH CIRCULATOR CIRCULATOR CONTROL l SEE NOTE 3 PRIMARY IGNITER SENSOR AUX LWCO LIMIT IF USFD IF USED LIMIT 5 r VENT Bu ae lt lt DAMPER THERMOSTAT HONEYWELL 4 SEE NOTE 5 IGNITION Less vent gt MODULE DAMPER 5 2 ROBERTSHAW LADDER DIAGRAM LEGEND GAS VALVE 24V WIRING 120V WIRING NOTES IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER U S A VENT DAMPER REQUIRED ON MODEL 8058 OPTIONAL ON MODELS 8068 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPFR PLUG Figure 35 Wiring Diagram Honeywell El USA Continuous Circulation 45 CIRCULATOR BY OT HONEYWELL R8285D CONTROL CENTER ITEMS SUPPLIED BY INSTALLER RB222U RELAY
29. and replace flame roll out switch Thermocouple Senses pilot flame and causes gas valves to turn off main burner and pilot burner gas flow should pilot burner flame extinguish Circulator continues to operate and Vent Damper if used remains open with call for heat 24 THERMOSTAT OR OPERATING CONTROL 1 5 7 SECTION 7 a BY OTHERS 4 5 r LIMIT TO VENT DAMPER RECEPTACLE BLI I U LWCO OPTIONAL 5 7 f m B 8 TO TRANSFORMER 24V TERMINAL THERMOSTAT OR OPERATING CONTROL BY OTHERS 7 SOVA TRANSFORMER VENT DAMPER RECEPTACLE VENT DAMPER WIRING HARNESS SEE NOTE 5 Wai POWER 11 SUPPLY 120 60 1 FUSED SERVICE DISCONNECT SWITCH SWITCH ITEMS SUPPLIED BY INSTALLER JUNCTION BOX CIRCULATOR P BY OTHERS SEE NOTE 6 FLAME ROBERTSHAW ROLL OUT GAS VALVE SWITCH FRS xs SC CODE BK BLACK BLUE SOLENOID GAS VALVE GREEN GRAY GRAY W NHTE TRACE SCHEMATIC DIAGRAM LEGEND ORANGI LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C RED OW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105 WHITE LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE YELLOW LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE L2 POWER SUPPLY OH 120 60 1 FUSED DISCONNECT S
30. cannot reach your gas supplier call the hand When lighting the pilot follow these instructions fire department exactly C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS result in a fire or explosion Do not try to light any appliance D Do not use this appliance if any part has been under e Do not touch any electric switch do not use any water Immediately call a qualified service technician phone in your building to inspect the appliance and to replace any part of the control system and any gas control which has been diately call lier fi Immediately call your gas supplier from a neighbor s uqa phone Follow the gas supplier s instructions INSTRUCTIONS wa 1 STOP Read the safety information above on this label 9 Wait five 5 minutes to clear out any gas Then smell 2 Read the lighting instructions all the way through for gas including near the floor If you smell gas STOP before starting the procedure Follow B in the safety information above on this label 3 Set the room thermostat to lowest setting If you do
31. connector should run downward or have dips or sags Vent connector must be securely supported Use thimble where vent connector enters masonry chimney keep vent connector flush with inside of flue liner Donotinstall Non listed AGA CGA CSA ETL or UL vent damper or other obstruction in vent pipe Locate Boiler as close to Chimney as possible consistent with necessary clearances See Section I Pre Installation VENT DAMPER POSITION INDICATOR BLOCKED VENT SWITCH LEF FRONT VIEW Figure 28 Vent Damper Installation 34 10 11 Design vent system for sea level input Provide adequate ventilation of Boiler Room See Section I Pre Installation Never pass any portion of vent system through a circulating air duct or plenum Ifan Existing Boiler is Removed At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system WARNING 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 fireplace dampers Place in operation the appliance being inspected Follow the Lighting or Operating Instructions Adjust thermos
32. gas supply piping For testing at CAP psig or less isolate boiler from gas supply piping by closing boiler s individual manual shut off valve FRONT VIEW 2 Locate leaks using approved combustible gas detector soap and water or similar nonflammable Figure 26 Recommended Gas Piping solution 32 VI Venting A Install ventsystem in accordance with local building codes or local authority having jurisdiction or National Fuel Gas Code ANSI Z223 1 NFPA 54 Part 7 Venting of Equipment and or CAN CGA B149 Installation Codes Part 5 Venting Systems and Air Supply for Appliances Install any of the following for this Series 8B Category I draft hood equipped appliance 1 Type B or Type L gas vent Install in accordance with listing and manufacturer s instructions 2 Masonry or metal chimney Build and install in accordance with local building codes or local authority having jurisdiction or Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 and or National Building Code of Canada Masonry chimney must be lined with approved clay flue lining or listed chimney lining system except as provided in ANSI Z223 1 NFPA 54 Paragraph 7 5 4 a Exception Where permitted by the authority having jurisdiction existing chimneys shall be permitted to have their use continued when an appliance is replaced by an appliance of similar type in
33. gas valve pressure regulator as necessary turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure If pressure can not be attained check gas valve inlet pressure If less than minimum gas supply pressure listed on rating label contact gas supplier for assistance 3 Clock gas meter for at least 30 seconds Use Table 12 to determine gas flow rate in Cubic Feet per Hour 4 Determine Input Rate Multiply gas flow rate by gas heating value WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance Improper and unsafe boiler operation may result 5 Compare measured input rate to input rate stated on rating label a Boiler must not be overfired Reduce input rate by decreasing manifold pressure Do not reduce more than 0 3 inch w c If boiler is still overfired contact your Burnham distributor or Regional Office for replacement Gas Orifices b Increase input rate if less than 98 of rating plate input Increase manifold gas pressure no more than 0 3 inch w c If measured input rate is still less than 98 of rated input i Remove Main Burners per procedure in Section IX Service Remove gas orifices Drill one 1 drill size larger drill size is stamped on orifice or see Key No 4E iii Reinstall gas orifices and main burners Measure input rate 6 Recheck Main Burner Flame 7 Return other
34. i USA See Figure 12 ii Canada See Figure 13 b Johnson EI i USA See Figure 14 ii Canada See Figure 15 3 Install Ignition Module a Attach Ignition Control Mounting Bracket to Jacket Vestibule Panel using two 2 8 x sheet metal screws b Attach Johnson Ignition Module to Mounting Bracket using two 2 6 x sheet metal screws or attach Honeywell Ignition Module to Mounting Bracket using two 2 8 x sheet metal screws c Connect pilot ground wire and ignitor sensor lead s to ignition module Refer to Section VII Electrical for connection details 4 Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box SeeFigure 8 a Canada only loop 4 nylon cable tie between junction box and transformer control center b Attach transformer control center to junction box C OP Control System Install Gas Control System All components are located in Combination Boiler Parts and Control Carton 1 Install Gas Control Assembly on Manifold See Figure 16 Use thread joint compound pipe dope resistant to action of liquefied petroleum gas 2 Install pilot burner piping and controls See Figure 16 3 Connect Thermocouple Lead to Gas Valve 4 Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box a Canadaonly loop 4 nylon cable tie between junction box and transformer control center
35. liabilities of any kind whatsoever except as set forth herein EXCEPT AS SET FORTH IN THESE WARRAN TIES BURNHAM MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE AND OTHER IMPLIED WARRANTY ARISING OUT OF A COURSE OF DEALING OR PERFORMANCE CUSTOM USAGE OF TRADE OR OTHERWISE 8 No Authority to Expand Warranty No sales representative agent or distributor or has authority to expand or otherwise modity in any way the Scope of these warranties or the obligations of Burnham hereunder No such modification shall be binding unless set forth In a written document signed by a duly authorized officer of Burnham 9 Effective Date This statement of warranties is effactive as to all Boilers sold on or after July 17 2000 and supersedes all prior warranty statements CBurnham AMERICA S BOILER COMPANY Burnham Corporation Lancaster PA 17604
36. the gas valve Honeywell EI Disconnect ignitor sensor cable from Terminal 9 of ignition module Gas valve must close and pilot and main burners extinguish If not measure voltage across gas valve terminals TH and TR a If voltage is not present replace gas valve b If voltage 15 present replace ignition module Johnson EI Disconnect sensor cable from Terminal 4 SENSE Gas valve must close and pilot and main burner extinguish If not measure voltage across gas valve terminals TH and TR a If voltage is not present replace gas valve b If voltage is present replace ignition module EP and OP Refer to instructions supplied with the Honeywell RM7890 Burner Control L Check Limit s l 2 Adjust thermostat to highest setting Observe temperature gauge When temperature exceeds limit set point main burners should extinguish 66 INCANDESCENT OUTER MANTLE BLUE WITH OCCASIONAL ORANGE FLASHING OUTER CONE DARKER TRANSPARENT BLUE INNER CONE SHARPLY OUTLINED WITH BRIGHT LIGHT BLUE PARTIALLY LIFTED FROM BURNER Figure 59 Main Burner Flame 3 Adjust limit to setting above observed reading Main burners should reignite 4 Adjust thermostat to lowest setting Adjust limit to desired setting M Adjust gas input rate to boiler Natural Gas 1 Adjust thermostat to highest setting 2 Check manifold gas pressure Manifold pressure is listed on rating label Adjust
37. to accept at the option of Burnham repair or replacement of the non conforming Boiler cast iron section or other component part These warranties do not cover labor and other costs and expenses associated with the removal and replacement of a non conforming Boiler cast iron section or other componant part which costs and expenses shall ba te sole responsibility of Owner 8 Limitation Damages Under no circumstances shall Burnham liable to Owner or to any other person for any indirect incidental special consequential or punitive damages of any kind whatsoever under these warranties or otherwisa including without limitation injury or damage to persons or property loss of time or labor expense Involved in repairing or replacing a non conforming Boiler loss of the use of the Boiler and loss of profits revanues or business even if Burnham has been advised of the possibility of such damages whether such damages are sought based upon breach of warranty breach of contract negligence strict liability or any other legal theory Burnham s liability under these warranties shall under no circumstances exceed the purchase price paid by the Owner for the Boiler involved Exclusivity and Disclalmer These warranties are given in lieu of all other express warranties and set forth the entire obligation of Burnham with respect to any defective or otherwise non conforming Boiler and Burnham shall have no obligations responsibilities or
38. x ao M31dvav NOISS3NdWOO SSvu8 AINO 579 IYYNLYN MOIVIn938 SVD 10114 AINO 8018 8808 NO Q33InO038 XTANASSV x 4 NOISS3MdWOO SSvu8 S3NSO8 1014 OL 144 3553 5202 101 318v3T VW Qv3H 95 8 F 131 4 IVNIWH3L 5 O68 VWM 01 dva1 05 35 SNIGNL 10114 3NIVA SV9 OL JIdNOOOWYSHL 9 TYNINYIL 3svaans 0684 4 OL AINOOOWYSAHL 10114 19313 06210 TI3MA3NOH 23 9018 8808 5 6 5 062 4 seo 25 941614 33n 10VJnNVN GSHSINYN4 LON 5 9 5 579 IVNH3IX3 WOMJ ONIENL 10114 abl TWNINYSL 06849 OL avs 008 15 214 VNINM3L 06824 OL 3MIM QNnOMO HOLIMS AL33VS 1014 OL AIdNOSOWYSHL JIdNOOSOWYSHL 10114 OINONIO313 06 10 TI3MA3NOH JOlvino938 SVD 10114 3902 9f ld 9NIBQL 1074 NOISS3HdWOO 55 8 x Yaldvdv NOISS3HdWOO SSVH8 HOLIMS 1 5 1079 2 89 291 51051405 5 24 8018 8908 Ajuo sed jeunjewN 6 5 sec 8
39. 1 FUSED DISCONNECT SWITCH REVERSE ACTING LLIANCE CIRCULATOR CONTROL RELAY CIRCULATOR SEE NOTE 8 LWCO LIMIT IF USED IF USED LIMIT 5 2 m xc t I EU 1 SENSING 2 LADDER DIAGRAM LEGEND SEE NOTES PILOT SOLENOID 24V WIRING JOHNSON VALVE 120V WIRING VA LESS VENT IGNITION s DAMPER MODULE NOTES 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER VENT DAMPER REQUIRED ON 8058 VENT DAMPER OPTIONAL 8068 AND 8078 VENT DAMPER MUST USED ON MODELS 8088 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULE Figure 42 Wiring Diagram Johnson El Canada Intermittent Circulation 53 6 Electronically Supervised Intermittent Ignition EP EP CSD 1 Sequence of Operation a Normal Operation ii i iii Thermostat or operating control calls for heat Terminal 6 of RM7890A Burner Control is energized initiating amicrocomputer monitored circuit test The pilot valve terminal 8 and ignition tr
40. 1 8 NPT Malleable 806601005 Pipe Plug 1 8 NPT Sq Head 806603508 805B 807B Natural 2 Gas Brass Compression Adapter 1 4 OD Tube x 1 8 NPT 822630 808B 810B Natural 3 Gas 805B 807B LP Gas 1 Solenoid Gas Valve Johnson H91WG 6 822666 Junction Box 4 Sq x 1 Deep 8136259 Rigid Conduit Nipple x 12 Lg 8136019 1 1 1 Conduit Locknut 8136220 Plastic Insulating Bushing 1 2 8136034 Regulator Maxitrol RV12LT Natural Gas 8226005 5055 6105 1 Natural Gas Only EE E P SOLENOID VALVE PILOT GAS SOLENOID VALVE ASSEMBLY DETAIL quee E PILOT i TAPPING TO PILOT VALVE TO 7 BURNER PILOT FIRING VALVE ASSEMBLY REQUIRED ON 808B 810B ONLY ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 11 Pilot Assembly and Piping Standing Pilot OP USA amp Canada a 10 Section Natural and LP Gas Pilot Burner Honeywell Q179D1008 Natural Gas 8236025 A Pilot Burner Honeywell Q179D1008 w 388146KD 6236039 Orifice LP Gas G Honeywell Q309A1996 w 36 Lg 8236004 806 810 Flame Rod Lead Honeywell R1298020 4 ft Lg 71362561 D Rajah Connector Honeywell 37356 8236021 Ground Wire Assembly 6136259 2 USA 806B 810B Brass Compression Union OD Tube 8236008 Canada 806B amp 807B Canada 806B 810B Regulator Maxitrol RV12LT Natural Gas 8226005 Natural Gas
41. ARNESS REPLACED WITH JUMPER PLUG CANADA ONLY ATTACH GREEN GROUND WIRE FROM CONTROL CENTER TERMINAL C TO JACKET SCREW IN VESTIBULE ALLIANCE WATER HEATER CONTROLS SUPPLIED BY INSTALLER SHOWN FOR DOMESTIC WATER PRIORITY AND CIRCULATOR ZONING Figure 32 Wiring Diagram Standing Pilot 24V USA and Canada Intermittent Circulation 40 2 Electronically Supervised Standing Pilot OP Sequence of Operation a NormalOperation i iii Thermostat or operating control calls for heat Terminal 6 ofRM7890C Burner Controlis energized initiating a microcomputer monitored circuit test Pilot Flame Establishing Period PFEP begins After pilot flame is proven terminal 9 of RM7890C isenergized allowing main gas flow and ignition of main burners Main gas light will be illuminated Call for heat ends Terminal 6 of RM7890C is de energized in turn de energizing gas valves and extinguishing main flame Main gas light is de energized b Safety Shutdown 1 iii Limit Automatically interrupts main burner operation when water temperature exceeds setpoint Maximum allowable temperature is 250 F Circulator continues to operate with call for heat Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive flue gas spillage occurs Circulator continues to operate with call for heat If blocked vent switch is acti
42. Brass Compression Union OD Tbe Union OD Tube 8236008 ___ 8078 1 Canada 806B amp 807B Regulator Maxitrol RV12LT Natural Gas 8226005 Natural Gas Only s Canada 806B amp 807B Brass Compression Adapter 14 OD Tube x 1 8 NPT 822630 Natural Gas Only PILOT TAPPING PILOT TUBING ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 7 Pilot Assembly and Piping Intermittent Ignition Honeywell El USA 5 10 Section Natural and LP Gas Pilot Burner Honeywell Q348A1002 Natural Gas A Pilot Burner Honeywell Q348A1010 LP Gas Igniter Sensor Cable 36 Lg Honeywell 394803 2 8236072U 8236081 8236121 805B 810B Ground Wire Assembly 6136054 Brass Compression Union OD Tube 1 0 0 ALUMINUM PILOT TUBING 86 1 O D ALUMINUM PILOT TUBING PILOT TAPPING ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 8 Pilot Assembly and Piping Intermittent Ignition Honeywell El Canada 5 10 Section Natural Gas 5 7 Section LP Gas 1 Brass Compression Union OD Tube O Shut off Valve Essex P2L 822645 Pipe Tee 1 8 NPT Malleable 806601005 808B 810B Pipe Plug 1 8 NPT Sq Head 806603508 1 1 1 805B 807B Natural Gas 2 Brass Compression Adapter 14 OD Tube x 1 8 822630 808B 810B Natural Gas 3 1 1 2 1 1 Junction Box 4 Sq x 1 Deep Rigid Conduit Nipple NPT x 1 Lg A Conduit Locknut 1 2 Plastic Insulating Bushing
43. CONTROL od ALLIANCE RELAY CIRCULATOR oro SEE NOTE 6 SEE NOTE 3 IGNITER SENSOR LwCO LIMIT 1 IF USED IF USED lt 20 1 ALLIANCE REY 04 ro 4 SEE NOTE 6 LlI SEE NOTE 5 IGNITION MODULE LADDER DIAGRAM LEGEND 24V WIRING 120V WIRING 5 2 Km LESS VENT DAMPER PO NOTES 2 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST REPLACED IT MUST REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER VENT DAMPER REQUIRED ON 8058 VENT DAMPER OPTIONAL 8068 AND 8078 VENT DAMPER MUST NOT BE USED ON MODELS 8088 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULF Figure 38 Wiring Diagram Honeywell El Canada Intermittent Circulation 48 5 Johnson EI Sequence of Operation a NormalOperation i iii Thermostat or operating control calls for heat Vent Damper if used opens Ignition Module Terminals 1 GND and the Ignition Terminal are energized Terminals 1 iii and GND power the Pilot Valve in the Gas Valve supplying as to the Pilot The Ignition
44. D LINE VOLTAGE SIZE 1 wre THK INSUL pu SCHEMATIC DIAGRAM LEGEND VOLTAGE SIZE 18 AWG TYPE TEW TYPE ANG OR TERA LINE VOLTAGE SIZE 18 AWG TW OR GROU SIZE 18 AWG TYPE SF 2 SEW 2 THERMOSTAT WIRING EP PANEL COMPONENT LEGEND AM STRA STRANDED WIRE 105C F1 PANEL FUSE IDED WIRE 1050 S1 POWER SWITCH AWM WIRE S2 GAS VALVE SWITCH ANM WIRE L1 POWER INDICATOR LAMP GREEN STRANDED L2 GAS VALVE INDICATOR LAMP GREEN L3 FLAME FAILURE LAMP RED FLAME ROD LEAD HONEYWELL R1298020 IGNITION LEAD HONEYWELL R1061012 POWER SUPPLY 120 60 1 REVERSE ACTING CIRCULATOR CONTROL IF USED sez 3 AUX LIMIT a Wise USED LMT IGNITION SENSI TRANSFORMER SENSING CIRCULATOR 120V THERMOSTAT OR OPERATING CONTROL PILOT SOLENOID GAS VALVE 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT 2 SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ALL CSD 1 BOILERS SUPPLIED WITH SECOND LIMIT 3 ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER 4 CANADA ONLY AITACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW IN VESTIBULE 56 LADDER DIAGRAM LEGEND 24V WIRING 120V WIRING 97800 SUB BASE TERMINAL 182850 CONTROL CENTER TERMINAL EP TERMINA
45. D POWER SUPPLY 120 60 1 FUSED DISCONNECT SWITCH SERVICE SWITCH REVERSE ACTING ALLIANCE CIRCULATOR CONTROL RELAY CIRCULATOR 04 ro 0 0 0 3 SEE NOTE 6 Lwco IF USED IF USED LIMIT FRS BVS EA peng i cu EA 20 cir SENSING ROD LADDER DIAGRAM LEGEND E 5 24V WIRING 5 2 JOHNSON 120V WIRING e gt LESS VENT IGNITION 7 DAMPER MODULE SEE NOTE 6 NOTES IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER U S A VENT DAMPER REQUIRED ON MODEL 8058 OPTIONAL ON MODELS 8068 THROUGH 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG ALLIANCE WATER HEATER CONTROLS SUPPLIED BY INSTALLER SHOWN FOR DOMESTIC WATER PRIORITY AND CIRCULATOR ZONING Figure 40 Wiring Diagram Johnson El USA Intermittent Circulation 51 24V THERMOSTAT OR OPERATING CONTROL 5 7 SECTION BY OTHERS 1 TO VENT DAMPER ES RECEPTACLE BL TO TRANSFORMER 320 RMF TERMINAL R THERMOSTAT OR OPERATING 5 7 SECTION CONTROL VENT DAMPER RECEPTACLE VENT DAMPER WIRING HARNESS SEE NOTE 5 SUPPLY SE
46. D BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER U S A VENT DAMPER REQUIRED ON MODEL 8058 OPTIONAL ON MODELS 8068 8108 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG Figure 39 Wiring Diagram Johnson El USA Continuous Circulation 50 HONEYWELL 82850 CONTROL CENTER ITEMS SUPPLIED BY INSTALLER L E HONEYWELL 2 R8222U RELAY POWER 12 8 BOTTOM VIEW SUPPLY 1120 60 41 H FUSED SERVICE m DISCONNECT SWITCH SWITCH 1 24V THERMOSTAT OR OPERATING CONTROL BY OTHERS SOVA Sor TRANSFORMER LWCO TOP VIEW BURNER ASSEMBLY 8 10 SECT OPTIONAL 5 7 SECT VENT DAMPER RECEPTACLE AUX LIMIT IF USED DAMPER SEE NOTE 4 VENT DAMPER WIRING HARNESS SEE NOTE 5 SWITCH 1 CODE pM BLACK BLUE BLOCKED BLUE GREEN GRAY GRAY WITH WHITE TRACE ORANGE RED JUMPER WHITE IGNITION GAS VALVE YELLOW SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105 LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE IGNITER 250 C INCLUDED WITH PILOT BURNER ASSEMBLY GROUND SIZE 18 AWG TYPE gt SIRANDED WIRE i THK INSULATION 200C SENSING PROBE WIRE JOHNSON Y57AH 36 L2 GN
47. DUST COVER CAPTIVE SECURING pee E SCREWS gt CLIP JR2 2 RESISTOR WIRE RM7890 WITH LEADS AND FLAME DUST COVER AMPLIFIER REMOVED DISCARD HONEYWELL RM7890 HEAT SHIELD CONTROL P N 70116003 HONEYWELL HEP Q7800 CONTROL CABINET COVER SUB BASE 8 x LG CONTROL CABINET SHEET METAL SCREWS TYPE B Figure 9 EP OP Control Installation 14 Ill Gas Control System Assembly Knockdown Boilers 24V Standing Pilot Control System Install Gas Control System All components are located in Combination Boiler Parts and Control Carton 1 Install Gas Control Assembly on Manifold See Figure 10 Use thread joint compound pipe dope resistant to action of liquefied petroleum gas 2 Install pilot burner piping and controls See Figure 10 3 Connect Thermocouple Lead to Gas Valve 4 Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box a Canada only loop 4 nylon cable tie between junction box and transformer control center b Attach transformer control center to junction box EI Intermittent Ignition Install Gas Control System All components are located in Combination Boiler Parts and Control Carton 1 Install Gas Control Assembly on Manifold See Figure 11 Use thread joint compound pipe dope resistant to action of liquefied petroleum gas 2 Install pilot burner piping and controls a Honeywell EI
48. Dimensions Inches Approx Recommended Water Gall Carada 27 18 vasa o ie amos 159 9 Fee ss vo seme 15 raz ist 1 Special base required for installations on combustible flooring adds 4 3 4 to boiler height floor to jacket top panel is 37 1 4 2 Gas connection size 1 3 Maximum Allowable Working Pressure 50 psi Water Only 4 Items shown in hidden lines supplied by installer 5 Pre Installation WARNING Carefully read all instructions before installing boiler Failure to follow all instructions in proper order can cause personal injury or death A a Inspect shipment carefully for any signs of damage equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of boiler to carrier in good condition Any claim for damage or shortage in shipment must be filed immediately against carrier by consignee No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within sixty 60 days after receipt of equipment Installation must conform to the requirements of the authority having jurisdiction In the absence of such requirements installation must conform to the National Fuel Gas Code 54 ANSI Z223 1 and or CAN CGA 8149 Installation Codes Where required by the authority having jurisdiction the
49. End Section Tapping G See Figure 21 Components are located in Water Trim Carton Install Temperature Pressure Gauge Components are located in Water Trim Carton 1 Standard Temperature Pressure Gauge Piping See Figure22 a Install 2 NPT x 10 lg nipple with gauge tapping into Supply Tapping A See Figure 3 Gauge tapping should face forward b Insert Temperature Pressure Gauge Tighten by applying pressure to square shank on back of gauge DONOT APPLY PRESSUREON GAUGE CASE since this may ruin gauge calibration 2 Alternate Temperature Pressure Gauge Piping See Figure23 a Install 2 NPT x 10 Nipple into Supply Tapping A See Figure 3 b Install 2 NPT x 2 NPT Tee provided or 2NPT 2 Tee installer furnished 32 NPT leg should face forward c Install Bushing d Insert Temperature Pressure Gauge Tighten by applying pressure to square shank on back of gauge DO NOT APPLY PRESSURE ON GAUGE CASE since this may ruin gauge calibration Connect system supply and return piping to boiler See Figure 25 Also consult I B R Installation and Piping Guides Maintain minimum inch clearance from hot water piping to combustible materials 1 Ifboiler is used in connection with refrigeration systems boiler must be installed with chilled medium piped in parallel with heating boiler using appropriate valves to prevent chilled medium from entering b
50. Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas 2 Maximum gas demand Table 5 lists boiler input rate Also consider existing and expected future gas utilization equipment 1 e water heater cooking WARNING equipment Gas supply to boiler and system must be 3 Length of piping and number of fittings Refer to absolutely shut off prior to installing or Table 6 for maximum capacity of Schedule 40 pipe servicing boiler gas piping Table 7 lists equivalent length for standard fittings 1 Use methods and materials in accordance with local Table 5 Rated Input plumbing codes and requirements of gas supplier In absence of such requirements follow the National Rated Capacity Gas Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN cubic feet per hour Connection CGA B149 Installation Codes LP Propane Size 2 Use thread joint compound pipe dope resistant to 105 5 action of liquefied petroleum gas dd 2 shut off valve upstream of boiler gas valve and 807B outside jacket See Figure 26 808B 4 above ground gas piping upstream from manual 805B 3 Install sediment trap ground joint union and manual 809B 211 25 gas valve must be electrically continuous and bonded to a grounding electrode Do not use gas 810B 237 5 piping as a grounding electrode Refer to the National Electrical Code ANSI NFPA 70 and or CSA C22 1 Electrical Code NOTICE USA boilers built fo
51. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 8B GAS FIRED BOILER For service or repairs to boiler call your heating contractor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number Heating Contractor Phone Number BURNHAM COMMERCIAL AMERICA S BOILER COMPANY Price 5 00 8141602R14 1 04 IMPORTANT INFORMATION PLEASE READ THIS PAGE CAREFULLY NOTE The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made These regulations shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and or local regulations wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and or local regulations This Series 8B Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters Approval No G1 0202 11A The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER CAUTION Indicates an immin
52. Id SOLV 0938 Sv9 10114 JAVA GION31OS 5 9 1014 9 9ML6H 510 1 02 5 JAYA 010 3105 Sv9 10114 wel X YlddlN 1IndNOO 1nN 201 ONILWINSNI 5 20 VSN 13 4 WNINS3L 31000090 OL QV31 5 35 41415 GNNOYD JINON OL jMIM QNnO39 JINGOW NOILIN9I OL QV31 NOILIN9I JAIV SV9 SNIddVL 10114 SV9 OL 10114 193NNOO aE NOISS3SHdWOO SSVHg ONIGAL 1074 O O Qv31 3l1ViVd3S ONIGNL 1014 OL 031 QInOHS 3 0 SNISN3S QNV ONIEGNL 1014 OL 135001 JIL OL 0931 N31SV4 LON OQ 10114 10114 NOILINS LNALLINYSLNI MA1L66f NOSNHOP 8 08 8908 529 d7 8018 9608 sed uosuuor 6 9 1614 Qv31 WO N4 3lViVd3S 10114 OL 031 38 100 5 3MIM 38044 5 35 ANY 1014 OL 5001 311 Q IOJINVA 2 Ts ONIddVL 1 SV9 JVNIA331 31000N OL 0 31 MOSN3S AINGOW 01 QY31
53. L STRIP TERMINAL Figure 44 Wiring Diagram EP EP CSD 1 Ignition System USA Intermittent Circulation NOTICE REMOVE JUMPER BETWEEN 1 AND 120 VAC SUPPLY NEUTRAL 24V THERMOSTAT ALARM IF USED TO 24V LIMIT TO TERMINAL R OF CIRCUIT TRANSFORMER AL TO TERMINAL C OF BOILER TRANSFORMER CONTINUOUS CIRCULATION NOTICE REMOVE JUMPER BETWEEN 1 AND 3 120 VAC SUPPLY NEUTRAL TO TERMINAL Y OF R8285D ALARM IF USED TO TERMINAL OF RB285D TO 24V LIMIT CURCUIT INTERMITTENT CIRCULATION Figure 45 McDonnell amp Miller PS 851 120V L W C O Wiring for Boilers with 24V Limit Circuits NOTICE REMOVE JUMPER BETWEEN 1 AND 3 120 VAC HOT SUPPLY NEUTRAL TO TERMINAL 3 ON TERMINAL STRIP OR SUB BASE 24V THERMOSTAT TO 120V LIMIT CURCUIT CONTINUOUS CIRCULATION NOTICE REMOVE JUMPER BETWEEN 1 AND 3 HOT 120 VAC NEUTRAL TO DISCONNECT IN R8239 CONTROL CENTER JUNCTION BOX ALARM IF USED TO 120V LIMIT CURCUIT INTERMITTENT CIRCULATION Figure 46 McDonnell amp Miller PS 851 120V L W C O Wiring for Boilers with 120V Limit Circuits OP amp EP 57 120 VAC NEUTRAL SUPPLY HOT TO TERMINAL R OF BOILER TRANSFORMER TO 24V 24V LIMIT CIRCUIT THERMOSTAT TO TERMINAL C OF BOILER TRANSFORMER CONTINUOUS CIRCULATION Pg 120
54. LY 5 RD 1120 60 1 12 a VENT YE DAMPER FUSED SERVICE DISCONNECT SWITCH SEE NOTE 4 SWITCH PILOT ITEMS SUPPLIED BY INSTALLER JUNCTION BURNER B ASSEMBLY 4 CIRCULATOR BY OTHERS TRANSFORMER FLAME ROLL OUT SWITCH FRS BLOCKED VENT mj SWITCH IGNITION u evs MODULE JUMPER GAS VALVE SCHEMATIC DIAGRAM LEGEND BLUE LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C GREEN LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105 GRAY LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE GRAY WITH WHITE TRACE LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE ORANGE IGNITER 250 C INCLUDED WITH PILOT BURNER ASSEMBLY RED GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE qh THK INSUL 200 C SENSING PROBE WIRE JOHNSON 57 36 L2 GND POWER SUPPLY 120 60 1 FUSED CIRCULATOR CONTROL CIRCULATOR DISCONNECT SWITCH SERVICE SWITCH REVERSE ACTING R LWCO LIMIT IF USED IF USED LIMIT FRS BS 4 Y fo d THERMOSTAT rc SEE NOTE 5 SENSING r e LESS VENT x gt DAMPER 5 2 LADDER DIAGRAM LEGEND JOHNSON 24V WIRING IGNITION E 120V WIRING MODULE GAS VALVE NOTES 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGE
55. Milliken 200M 1 NPT 822619 5085 8105 Canada Only 1 D Hex Bushing 1 NPT NPT 806600501 8068 amp 8078 1 E Nipple x 2 Lg 806600003 806B amp 807B 1 E 1 USA Nipple 1 NPT x 2 Lg 806600004 808B 810B Street Elbow 1 NPT x 34 NPT 806601512 806B amp 807B Street Elbow 1 4 NPT x 1 NPT 806601513 808B 810B NO DESCRIPTION PART NUMBER QUANTITY 5 2 Gas Train Standing Pilot OP CSD 1 OP CSD 1 USA Only 10 Section LP Gas Only 8 Solenoid Gas Vae Honeywell enesA oso 1680238 1 Lubricated Manual Shut Off Valve ConBraCo 50 403 02 1 NPT Nipple 1 x 2 Long Street Elbow 90 x 1 Close Nipple 1 Malleable Coupling 1 1 4 x 1 Wiring Harness Gas Valve to Solenoid Valve Pilot Outlet Plug Honeywell 4394424 ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 3 Gas Train Intermittent Ignition El USA 5 10 Section Natural and LP Gas Canada 5 10 Section Natural Gas 5 7 Section LP Gas Gas Valve Robertshaw 7000DERHC Natural Gas 1 NPT 81660151 805B 810B 1 USA 805B 810B Gas Valve Robertshaw 7000DERHC LP LP Gas 1 NPT 81660158 Canada 805B 807B Lubricated Manual Shut Off Valve Newman Milliken 200M 1 NPT 822619 808B 810B Canada Only 1 Nipple 1 NPT x 2 Lg 806600004 Street Elbow 1 NPT 806601514 805B 807B 1 Street Elbow 1 4 NPT x 1 NPT 806601513 808B 810B ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 4 Gas Train Intermittent Igniti
56. NTROL 0410 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT LADDER DIAGRAM LEGEND SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR 24V WIRING KNOCKDOWN BOILER ALL 50 1 BOILERS SUPPLIED WITH SECOND LIMIT 125 MIRNO ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET Q7800 SUB BASE TERMINAL SCREW IN VESTIBULE R826585 CONTROL CENTER TERMINAL PILOT SAFETY SWITCH REQUIRED ON CSD 1 BUILDS ONLY OP TERMINAL STRIP TERMINAL Figure 34 Wiring Diagram OP OP CSD 1 Ignition System Intermittent Circulation 43 4 Honeywell EI Sequence of Operation a NormalOperation i iii Thermostat or operating control calls for heat Vent Damper if used opens Ignition Module Terminals PV MV PV and the Ignition Terminal are energized Terminals PV and MV PV power the Pilot iii Valve in the Gas Valve supplying gas to the Pilot The Ignition Terminal supplies voltage to the Ignition Electrode creating an electric spark to ignite the Pilot The sensing Circuit between the Q348 Pilot Burner and the IGNITION MODULE proves the presence of the Pilot Flame Electronically and the Ignition Terminal is de energized Terminals MV and MV PV of the iv IGNITION MODULE are energized and E supply po
57. RVICE DISCONNECT SWITCH g SWITCH PILOT 120 80 1 12 BURNER CIRCULATOR BY OTHERS 1 SEE NOTE 6 PILOT SOLENOID VALVE FLAME ROLL OUT SWITCH FRS 1 BLOCKED VENT SWITCH IGNITION evs MODULE JUMPER GAS VALVE SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105C ERAY WITH WHITE TRACE _________ VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE m IGNITER 250 C INCLUDED WITH PILOT BURNER ASSEMBLY m GROUND SIZE 18 AWG TYPE SF 2 SEW 2 STRANDED WIRE THK INSUL 200 C sw SENSING PROBE WIRE JOHNSON Y57AH 36 L2 GND SUPPLY 120 60 1 FUSED DISCONNECT SWITCH EX REVERSE ACTING CIRCULATOR CONTROL CIRCULATOR 0 AUX IGNITER LWCO LIMIT IF USED IF USED LIMIT BVS 6 6 THERMOSTAT L SEE NOTE 5 SED a LESS VENT gt T BiLDT DAMPER 5 2 LADDER DIAGRAM LEGEND 73 24V WIRING MODULE NOTES 120V WIRING 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER VENT DAMPER REQUIRED ON 805B VENT DAMPER OPTIONAL ON 806B AND 807B VENT DAMPER MUST NOT
58. S JAIM QNnONS SVD 1014 6 JAYA GION310S S1OMINO9 NOSNHOP Sv9 1079 OL 2 41 X LON uf 0 31 SLE af 10N3201 iia ANOA MOlV1n93M 599 lOd 26 19 ONIHSNG ONLLWINSNI 5 NOLLYTIVISNI GIONXIOS SVD IV Water Trim and Piping WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure Burnham s Warranty does not cover problems caused by oxygen contamination of boiler water or scale lime build up caused by frequent addition of water A Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions WARNING 1 There are many possible causes of oxygen contamination such as Pressure relief valve discharge piping must be piped such that the potential of severe burns is eliminated DO NOT pipe in any area where freezing could occur DO NOT b Absorption through open tanks and fittings install any shut off valves plugs or caps c Oxygen permeable materials in the distribution Consult Local Codes for proper discharge system piping arrangement 2 Install safety relief valve on NPT nipple a Addition of excessiv
59. SHAW DAMPER GAS VALVE SEE NOTE 4 Em VENT DAMPER WIRING H SWITCH FRS HARNESS SEE NOTE 5 1 SOLENOID GAS CODE VALVE BLOCKED Black VENT a BROWN Um CREN SCHEMATIC DIAGRAM LEGEND RAY GRAY WITH WHITE TRACE LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 1050 ORANGE LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105C RED LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE WHITE LINE VOLTAGE SIZE 18 AWG TW OR TEW AWM WIRE YELLOW POWER SUPPLY 120 60 1 FUSED DISCONNECT SWITCH SERVICE SWITCH REVERSE ACTING CIRCULATOR CONTROL ALLIANCE CIRCULATOR FOo Ae SEE NOTE 3 SEE NOTE 6 LIMIT 4 IF M s USED LIMIT 5 pues ps gt ALLIANCE SOLE OID GAS L RELAY 1 O rom SEE NOTE 5 SEE NOTE 7 4 La gt LESS VENT 5 2 DAMPER LADDER DIAGRAM LEGEND gt 24V WIRING 120V WIRING NOTES 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER USA VENT DAMPER OPTIONAL CANADA VENT DAMPER OPTIONAL ON MODELS 806B AND 807B VENT DAMPER MUST NOT BE USED ON MODELS 808B 810B 5 FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING H
60. Terminal supplies voltage to the Ignition Electrode creating an electric spark to ignite the Pilot The sensing Circuit between the J991 Pilot Burnerandthe IGNITION MODULE proves the presence ofthe Pilot Flame electronically and the Ignition Terminal is de energized Terminals3 and GND ofthe IGNITION iv MODULE are energized and supply power to the Main Gas Valve The Gas Valve is energized allowing main gas flow and ignition of Main Burners Call for heat ends Ignition module is de energized de energizing gas valve and extinguishing pilot and main flame Vent Damper ifused closes b Safety Shutdown l Limit Automatically interrupts power to the Ignition Module and Gas Valve s extinguishing pilot and main flame when water temperature exceeds set point Maximum allowable temperature is 250 F Circulator continues to operate with call for heat Vent Damper ifused closes Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when 49 excessive flue gas spillage occurs Circulator continues to operate Vent Damper if used remains open with call for heat If blocked vent switch is activated do not attempt to place boiler in operation Correct cause of spillage and reset blocked vent switch FlameRoll outswitch automatically interrupts main burner operation when flames or excessive heat are present in vestibule Circulat
61. VE WILL NOT COME ON Does spark stay on for more than 15 START seconds after pilot lights YES NO Is sensor cable securely attached to Is 25V available between terminals ignition control and flame sensing probe 3 and ground terminal YES NO YES NO 15 sensor probe ceramic cracked Is gas pressure in excess of recommended limits Secure Replace G775 module Replace flame Are main valve connections tight sensor probe Check for continuity of flame sensing probe cable and state of insulation Reduce pressure OK Not OK Disconnect sensor probe Replace sensor wire from terminal 4 cable Connect DC microammeter Secure connections to terminals 3 and ground terminal Replace valve assembly between terminal 4 and terminal on wire to sensor probe Is DC microamp current greater than 0 2 microamp NO YES Pilot orifice size should be changed Replace G775 to obtain a probe current module SITUATION B WHEN BOILER IS RESET SPARK IS PRESENT BUT PILOT WILL NOT LIGHT r Are pilot valve connections correct START and securely fastened NO YES MEM Connect securely to terminal 1 Is 25V available between terminal and ground terminal 1 and ground terminal Replace G775 Is gas pressure per manufacturer s module specifications Correct ga
62. WITCH REVERSE ACTING CIRCULATOR CONTROL CIRCULATOR SEE NOTE 6 OBERTSHAW LIMIT oS VANE I IF USED IF USED LIMIT THERMOSTAT SOLENOID GAS VALVE SEE NOTE 5 L 1 4 x gt 4 LESS VENT LADDER DIAGRAM LEGEND 22 2 0 DAMPER 6 2 24V WIRING d 120V WIRING NOTES 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT SECOND LIMIT INCLUDED WITH PACKAGED BOILER INSTALLER SUPPLIED FOR KNOCKDOWN BOILER ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER USA VENT DAMPER OPTIONAL CANADA VENT DAMPER OPTIONAL ON MODELS 806 AND 807B VENT DAMPER MUST NOT BE USED ON MODELS 808B 810B FOR BOILER LESS VENT DAMPER ONLY VENT DAMPER WIRING HARNESS REPLACED WITH JUMPER PLUG 6 CANADA ONLY ATTACH GREEN GROUND WIRE FROM TRANSFORMER TERMINAL C TO JACKET SCREW VESTIBULE Figure 31 Wiring Diagram Standing Pilot 24 USA and Canada Continuous Circulation 39 CIRCULATOR HONEYWELL R8285D BY OTHERS ye CONTROL CENTER F ITEMS SUPPLIED BY INSTALLER HONEYWELL R8222U RELAY BOTTOM VIEW ES SUPPLY I120 60 1 i THERMOSTAT FUSED SERVICE OR OPERATING DISCONNECT SWITCH CONTROL SWITCH BY OTHERS JUNCTION BOX 50VA TRANSFORMER nm VIEW px SECT 5 7 SECT OPTIONAL AUX IH VENT DAMPER IF USED RECEPTACLE LIMIT ROBERT
63. ach opening must be 1 square inch per 4 000 Btu per hour input of all equipment in space ii Vertical ducts Minimum free area of each opening must be 1 square inch per 4 000 Btu per hour input of all equipment in space Duct cross sectional area shall be same as opening free area iii Horizontal ducts Minimum free area of each opening must be 1 square inch per 2 000 Btu per hour input of all equipment in space Duct cross sectional area shall be same as opening free area b One permanent opening shall be permitted where the boiler has clearances ofat least 1 2 5cm from the sides and rear and 6 15 2cm from the front Locate the opening within 12 30 5cm of top of space Size opening per following i Minimum free area of square inch per 3 000 Btu per hour input of all equipment in space ii Free area shall not be less than the sum of the areas of all vent connectors in the confined space Alternate method for boiler located within confined space Use indoor air if two permanent openings communicate directly with additional space s of sufficient volume such that combined volume of all spaces meet criteria for unconfined space Size each opening for minimum free area of square inch per 1 000 Btu per hour input of all equipment in spaces but not less than 100 square inches 7 Ventilation Duct Louvers and Grilles Equip outside openings with louvers to prevent entrance of rain and snow and screens to prevent
64. all your service tech nician or gas supplier 8 Push in gas control knob slightly and turn clockwise to OFF NOTE Knob cannot be turned from PILOT to OFF 14 Replace burner access panel P unless knob is pushed in slightly Do not force 15 Turn gas control knob counterclockwise to ON position 9 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP 16 Replace front door Follow B in the safety information above on this label 17 Turn on all electric power to the appliance I you do not smell gas go to the next step 18 Set room thermostat to desired setting NOTE Vent damper must be open during this five 5 minute wait period TURN OFF GAS APPLIANCE 1 Set thermostat to the lowest setting 4 Push in gas control knob slightly and turn clockwise 2 Turn off all electric power to the appliance if service is to OFF Do not force to be performed 5 Replace front door 3 Remove front door Figure 49 Lighting Instructions 24V Standing Pilot 60 FOR YOUR SAFETY READ BEFORE OPERATING WARNING you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device e If you cannot reach your gas supplier call the which automatically lights the pilot Do not try to light fire department
65. anel holes with projections on Base Front Panel See Figure 6 Install Immersion Well s 1 Remove Immersion Well s from Combination Boiler Parts and Control Carton 2 Insert Immersion Well in Tapping D See Figure 3 3 If second limit or operating control is used insert immersion well in Tapping E If vertical gas piping is to be installed inside of boiler jacket it is recommended that second limit be installed in system piping Install Jacket See Figure 8 1 Locate four 4 Jacket Attachment Brackets in Combination Boiler Parts and Control Carton Attach to Front Base Panel and Rear Base Panels with 8 sheet metal screws See Figure 5 2 Hang Left Side Panel and Right Side Panel onto Jacket Attachment Brackets 3 Attach Lower Rear Panel to Left and Right Side Panels Do not tighten sheet metal screws 4 Attach Upper Rear Panel to Lower Rear Panel Do not install three 3 upper screws 5 Remove Rating Label and Combustible Clearance Label from Combination Boiler Parts and Control Carton Attach to Vestibule Panel in locations shown 6 Attach Vestibule Panel to Left Side and Right Side Panels 12 7 Attach Lower Front Tie Bar to Left Side and Right Side Panels 8 Engage Upper Front Panel in slots on Left Side and Right Side Panels Place Top Panel in position Attach Top Panel to Left Side Right Side and Upper Rear Panels 9 Tighten all jacket screws 10 Affix Lighting Operating Instructions La
66. ansformer terminal 10 are energized The pilot valve opens and the ignition electrode sparks igniting the pilot After the pilot flame is proven the ignition terminal 10 is de energized and the main valve terminal 9 is energized allowing main gas flow and ignition of main burners Main gas light will be illuminated When the call for heat ends terminal 6 is de energized extinguishing the pilot and main flames Main gas light is de energized b Safety Shutdown 1 Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature 15 250 F Circulator continues to operate with 54 iii call for heat Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive flue gas spillage occurs Circulator continues to operate with call for heat If blocked vent switch is activated do not attempt to place boiler in operation Correct cause of spillage and reset blocked vent switch Flame Roll out Switch Automatically interrupts main burner operation when flames or excessive heat are present in vestibule Circulator continues to operate with call for heat Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct cause of spillage and replace flame roll out switch 7890 Burner Control Automatically
67. automatically lights the pilot Do not try to this label If you do not smell gas go to the next step light the pilot by hand POSITION 9 Rotate gas control knob counterclockwise from 5 Remove front door INDICATOR OFF to Make sure knob rests against stop Do not force 6 Locate the gas control valve at the end of the gas 10 Replace front door ON supply pipe going into the 11 Turn on all electric power to the appliance boiler The gas control GAS 297 knob is the gray or brown INLET 12 Set thermostat to desired setting plastic knob located on top of the gas control valve GAS CONTROL KNOB 13 If the appliance will not operate follow the SHOWN OFF POSITION instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier TURN OFF GAS TO APPLIANCE SSS 1 Set the thermostat to the lowest setting 4 Rotate gas control knob clockwise from ON 2 Turn off all electric power to the appliance if service is position to OFF Make sure knob rests against stop to be performed 5 Replace front door 3 Remove front door Figure 50 Operating Instructions El 61 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which must be lighted by e f you
68. b Attach transformer control center to junction box OP CSD 1 Control System Install Gas Control System All components are located in Combination Boiler Parts and Control Carton 1 Install Gas Control Assembly on Manifold See Figure 17 Use thread joint compound pipe dope resistant to action of liquefied petroleum gas 2 Mount pilot switch 3 Install pilot burner piping and controls See Figure 17 4 Connect Thermocouple lead to pilot switch 5 Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box 6 Attach transformer control center to junction box EP Control System Install Gas Control System All components are located in Combination Boiler Parts and Control Carton 1 Install Gas Control Assembly on Manifold See Figure 18 2 Install pilot burner piping and controls See Figure 18 3 Install Ignition Transformer a Attach Ignition Transformer to Jacket Vestibule Panel using four 4 8 x lg sheet metal screws b Connect Ignition Lead from Pilot to Ignition Transformer 4 Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box a Canada only loop 4 nylon cable tie between junction box and transformer control center b Attach transformer control center to junction box EP CSD 1 Control System Install Gas Control System All components are located in Combination Boiler Parts a
69. bel and Wiring Diagram Label to inside of Front Removable Door Labels are located in Combination Boiler Parts and Control Carton Install Junction Box See Figure 8 Attach junction box to inside of Left Side Panel with 20 x 12 machine screw located in Combination Boiler Parts and Control Carton Install Limit Control Locate limit in Combination Boiler Parts and Control Carton Insert limit probe into left immersion well as far as possible Tighten set screw Install Auxiliary Limit or operating control if used Insert control probe into right immersion well as far as possible Tighten set screw Install Gas Control Assembly Refer to Section III Gas Control System Assembly Knockdown Boilers EP and OP System See Figure 9 1 Install pre wired EP OP Control Cabinet Assembly to right front corner of jacket top panel 2 Install Honeywell RM7890 Control located in RM7890 Control Carton 3 Remove RM7890 s Dust Cover With a pair of side cutters carefully snip both wire leads to the brown resistor labelled JR2 and discard it Replace Dust Cover 4 Install Honeywell R7847 Flame Amplifier 5 Install heat shield T3NVd 3015 quiessy 3exoer 8 911614 T3NVd 31n8lLS3 1NO34 43MOT1 13871 SNOILONYLSNI SNILVH3dO 9NILHOIT1 138 1 138 1 19 318l1Sn8ACO 3 18VAOW3H 138 1 13
70. boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when the boiler is operating Do not touch any components unless they are cool Boiler materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance Failure to follow all instructions in the proper order can cause personal injury or death Read all instructions including all those contained in component manufacturers manuals which are provided with the boiler before installing starting up operating maintaining or servicing Keep boiler area clear and free from combustible materials gasoline and other flammable vapors or liquids Do not operate boiler with control which has been subject to water cover plates enclosures and guards must be in place at all times NOTICE This boiler has a limited warranty
71. ch control system requirements Refer to Table 9 D Wirethermostat Provide Class II circuit between thermostat and boiler Refer to appropriate wiring diagram for control system being used 4 PIN POLARIZED CONNECTOR 6 PIN POLARIZED CONNECTOR VENT DAMPER HARNESS INTERMITTENT 24V TO DAMPER FROM LIMIT GROUND INTERMITTENT 24V FROM DAMPER TO FRS CONSTANT 24V TO DAMPER FROM TRANSFORMER BOILER WIRING DAMPER WIRING Figure 30 Vent Damper Schematic Wiring Diagram 36 E Alliance Water Heater if used May be used with through Terminal 2 and the damper motor is de Intermittent Circulation only energized Refer to Alliance Installation Operating and 5 When the call for heat is satisfied the damper relay Service Instructions for wiring piping and coil is de energized closing contacts which additional information energize the damper motor This causes the damper to close When the damper blade reaches the fully Vent Damper Sequence of Operation Figure 30 for closed position the damper motor is de energized schematic wiring diagram POWER FAILURE The damper blade will stop in 1 The Vent Damper is continuously powered at the position it was in when power failed Terminal 1 Combustion can never take place unless the 2 When there is a call for heat the damper relay coil damper blade is in the fully open position is energized through Terminal 5 if all limits ahead Sequenc
72. cross PV MV PV Terminals on module if voltage is OK replace gas control if not replace module Note If module goes into lockout reset system or wait 6 minutes for retry Check continuity of ignition cable and ground wire Clean flame rod Check electrical connections between flame rod and module Check for cracked ceramic flame rod insulator Check that pilot flame covers electrode Adjust pilot flame If checks are OK replace module Check for 24 Across MV MV PV terminals If no voltage replace module Check electrical connections between module and gas control OK replace gas control operator Note If module goes into lockout reset system or wait 6 minutes for retry Check continuity of ignition cable and ground wire Note If ground is poor or erratic shutdowns may occur occasionally even though operation is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue If checks are OK replace module Check for proper thermostat controller operation Remove MV lead at module If valve closes replace module If not replace gas control Repeat procedure until trouble free operation is obtained Minimum pilot signal should be 1 0 microamps Disconnect pilot ground wire from module and connect DC microammeter between ground terminal and pilot ground wire 71 Johnson El Trouble Shooting Guide SITUATION A PILOT LIGHTS BUT MAIN VAL
73. d any gas control which has been phone Follow the gas supplier s instructions under water LIGHTING INSTRUCTIONS 1 STOP Read the safety information above on this label 10 Remove burner access panel Pilot Burner 2 Read the lighting instructions all the way through 11 Find the pilot by following Thermocouple before starting the procedure the aluminum tube from the gas control valve to the pilot 3 If equipped with vent damper set the room thermo located between the steel stat to highest setting and wait two 2 minutes for tube burners ine damper 12 Turn gas control knob counterclockwise P to 4 Turn off all electric power to the appliance PILOT position POSITION 5 Set the room thermostat to lowest setting INDICATOR 13 Push in control knob all the way d hold in Immed 1 iately light the pilot with a match Continue to hold 6 Remove front door the control knob for about one 1 minute after the 7 Locate the gas control pilot is lit Release knob and it will pop back up Pilot valve at the end of the gas ON OFF should remain lit If it goes out repeat steps 8 13 PILOT s GAS 297 If knob does not pop up when released stop and knob is the gray or brown INLET immediately call your service technician or gas supplier E gis ces GAS CONTROL KNOB If the pilot will not stay lit after several tries turn SHOWN IN OFF POSITION gas control knob to OFF and c
74. dapter 7 OD Tube x 1 8 822630 Canada Only M Junction Box 4 Sq x 1 Deep N Conduit Nipple x 17 Lg 806B 810B Conduit Locknut v2 Plastic Insulating Bushing V2 1 Regulator Maxitrol RV12LT Natural Gas 8226005 6065 6105 1 Canada Only 806B amp 807B USA amp Canada 808B 810B USA Only BN M EUN PILOT GAS SOLENOID VALVE PILOT GAS SOLENOID VALVE ASSEMBLY DETAIL 4 S G I GAS VALVE c N N BURNER 7 0 n d PILOT FIRING VALVE ASSEMBLY REQUIRED ON 8088 8108 CANADA ONLY PART NO DESCRIPTION NUMBER SIZE QUANTITY 5 14 Pilot Assembly and Piping Intermittent Ignition EP CSD 1 USA Only 10 Section Natural Gas Only A Pilot Burner Honeywell Q179C1009 Natural Gas 8236017 Flame Rod Lead Honeywell R1298020 4 Ft Lg 71362561 C Rajah Connector Honeywell 37356 8236021 Ignition Lead Honeywell R1061012 3 Ft Lg 7136247 Brass Compression Coupling 1 4 OD Tube 8236008 808 810B Brass Compression Adapter OD Tube x 1 8 NPT Gas Solenoid Valve Johnson H91WG 4 Junction Box 4 Sq x 1 Deep Rigid Conduit Nipple x 1 Lg Conduit Locknut 1 2 Plastic Insulating Bushing 72 Ez NE SOLENOID VALVE PILOT GAS SOLENOID VALVE ASSEMBLY DETAIL TO EXTERNAL MAIN GAS SUPPLY
75. ds the desired cold fill pressure Close fill valve Note If make up water line is equipped with pressure reducing valve adjust pressure reducing valve to desired cold fill pressure Follow fill valve manufacturer s instructions 10 Open isolation valve in boiler supply piping 11 Remove hose from purge valve F Confirm that the boiler and system have no water leaks G Prepare to check operation 1 Obtain gas heating value in Btu per cubic foot from gas supplier 2 Connect manometer to pressure tap on gas valve Use 1 8 NPT tapping provided 3 Temporarily turn off all other gas fired appliances 4 Turn on gas supply to the boiler gas piping 5 Confirm that the supply pressure to the gas valve 15 14 in w c or less 6 Open the field installed manual gas shut off valve located upstream of the gas valve on the boiler 7 Using soap solution or similar non combustible solution electronic leak detector or other approved method Check that boiler gas piping valves and all other components are leak free Eliminate any leaks 8 Purge gas line of air DANGER Do not use matches candles open flames or other ignition source to check for leaks H Follow Lighting or Operating Instructions to place boiler in operation Refer to label on inside of Front Removable Panel or appropriate Figure as listed in Table 11 Table 11 Lighting and Operating Instructions Lighting or Operating Instructions Standi
76. e Gauge Figure 23 Alternate Temperature Pressure Installation Gauge Installation HEATING BOILER R CUSHION TANK CIRCULATOR 3 SUPPLY MAIN RETURN MAIN FROM COMBINED HEATING COMBINED HEATING amp COOLING SYSTEM amp COOLING SYSTEM Figure 24 Recommended Piping for Combination Heating amp Cooling Refrigeration System 29 AlddNS 0109 31 3ATVA 40 W31SAS SANOZ IWNOLLIQQV OL SATA 1051409 MOTH 3ATVA 3JO 1nHS 3NOZ 01 5 6 peuoz Buidig 62 N 1 4 5 M3lV3H M3lVM 3ONVITIV OL 440 LAHS MATA 30074 30 9 83108 30 1 3ATVA 340 34 40035 5 WALSAS NOISNVdX3 3ATVA 5 1404 1104 JAVA TIVE Q t 1350 5 40005 31 NIN 81 3ONVITIV WO 3NOZ HIS 4441 JAVA NIVXQ 440M079 Nei 38 W31SAS 3ATVA 39134 3410 34 X JAVA SSVdAg bd 0 440 LNO 3ATNA
77. e and main burner flames through observation port 1 Check pilot flame Refer to Table 11 for appropriate pilot detail 2 Adjust thermostat to highest setting 3 Check main burner flames See Figure 59 Flame should have clearly defined inner cones with no yellow tipping Orange yellow streaks caused by dust should not be confused with true yellow tipping Figure 56 Johnson J991 Pilot Flame 24V Electronic Ignition 65 CAUTION Avoid operating this boiler in an environment where saw dust loose insulation fibers dry wall dust etc are present If boiler is operated under these conditions the burner interior and ports must be cleaned and inspected daily to insure proper operation Yellow tipping indicates lack of primary air Improper FLAME RETENTION INNER CONE burner alignment on Main Burner Orifice will also affect primary air injection Adjust primary air as follows a Loosen lock screw b Close air adjustment until yellow tips appear on flames c Slowly open air adjustment until clearly defined inner cones are visible d Tighten lock screw 4 Adjust thermostat to normal setting J Check thermostat or operating control operation Raise and lower temperature setting to start and stop boiler operation K Check ignition system shut off Standing Pilot 24 Disconnect thermocouple lead at Gas Valve Gas Valve must close and pilot and main burners extinguish If not replace
78. e make up water as a result of system leaks 2 In order to insure long product life oxygen sources must be eliminated This can be accomplished by Table 4 Flow Rate Temperature Rise and taking the following measures Pressure Drop a Repairing system leaks to eliminate the need for TEMP BOILER addition of make up water BOILER RISE PRESSURE M SIZE THRU b Eliminating open tanks from the system BOILER c Eliminating and or repairing fittings which allow oxygen absorption 805B d Use of non permeable materials in the distribution system e Isolating the boiler from the system water by 806B installing a heat exchanger f Use properly designed and operating air elimination devices in water piping 807B B Design system to obtain a 20 F temperature rise through the boiler see Table 4 If a temperature rise greater 2 than 40 F is desired consult Burnham 808B e 1 24 C InstallSafety Relief Valve See Figure 20 Components are located in Water Trim Carton Safety Relief Valve 809B must be installed with spindle in vertical position 1 Install NPT x 3 lg nipple in tapping C See Figure3 810B 27 PT X 34 LG E NIPPLE Figure 20 Safety Relief Valve Installation DRAIN VALVE i NPT PIPE d COUPLING NPT X 59 PIPE NIP Figure 21 Drain Piping Installation D Install Drain Valve in rear of Left
79. e of Operation and Wiring Refer to Table 10 of the damper are satisfied for the appropriate control system 3 The relay coil closes contacts which energize the Optional Low Water Cut Off Wiring See Figures 45 damper motor causing the damper to open through 48 4 When the damper blade reaches the fully open position power is sent back to the ignition circuit Table 9 Heat Anticipator Settings Heat Anticipator Setting Control System Continuous Circulation Intermittent Circulation 0 3 USA 0 9 Canada 12 i 24V Standing Pilot 24V Electronic Ignition El Canada 1 2 room is heated above thermostat temperature setting reduce heat anticipator setting by 0 1 or 0 2 amps If boiler short cylces without room reaching desired temperature increase heat anticipator setting by 0 1 or 0 2 amps 37 Table 10 Sequence of Operation and Wiring Diagrams Ignition System Standing Pilot 24V Standing Pilot OP 120V Natural Natural Natural Natural Wiring Diagram Figure Country Fuel Boiler Sizes Intermittent USA amp USA amp Sequence of Operation Standing Pilot Intermittent Ignition Honeywell El 24V Intermittent Ignition Johnson 24 Intermittent Ignition EP 120V Natural Natural Gas Natural Gas USA Canada LP iPGas 1 Standing Pilot 24 Sequence of Operation a NormalOperation i iii Thermostat o
80. e of indicating 50 psi 3 Insert 2 NPT NPT bushing in Supply Tapping A Install purge valve with a hose that runs to a drain 4 Connect fill valve and piping to Drain Tapping G WARNING Do not use air to leak test boiler Fill boiler completely with water by venting air through purge valve Close purge valve and apply water pressure of at least 10 psi but less than 50 psi gauge pressure Examine boiler for leaks or damage due to shipment or handling Remove plugs from Return Tapping B Tapping C and Tapping E if second limit or operating control is used Also remove fill valve and piping purge valve and piping and pressure gauge Install special base if installation is on combustible flooring See Figure 4 Floor shield adds 434 to boiler height 1 Place special base on combustible floor with surface marked FRONT in upward position Locate special base with spacing to combustible materials as shown in Figure 4 Place boiler on special base Boiler must rest inside locating brackets Boiler jacket panels will overhang special base Do not enclose boiler including special base on all four sides Models 805B 807B may be enclosed COMBUSTIBLE WALLS Figure 4 Installation of Special Base for Combustible Flooring 9 20 HEX NUT i FLAT WASHER 17 80 X 1 LG CARRIAGE BOLT JACKET ATTACHMENT BRACKET DM AS 48 1 suEET METAL SCREWS
81. ead and understand the entire manual before attempting installation start up operation or service Installation and service must be performed only by a knowledgeable experienced and skilled installer or service agency This boiler must be properly vented This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions A clean and unobstructed vent system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency Installation is not complete unless a pressure relief valve is installed into the tapping located on the top of boiler See the Water Piping and Trim Section of this manual for details This boiler is supplied with safety devices which may cause the boiler to shut down and not re start without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this
82. ehind Upper Front Panel 2 Swing lower portion of door toward boiler 3 Lower door to engage bottom flange behind Lower Front Tie Bar 67 Table 12 Input Rate emm Revolution Cu Ft Cu Ft Cu Ft Cu Ft 30 120 240 600 56 225 56 40 45 90 180 45 42 43 172 40 52 35 6 138 346 60 120 300 6 29 54 109 2 Combustion Chamber 1 The mineral wool combustion chamber panels contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation 2 Ventilate the boiler room set the high limit to its maximum setting set the thermostat to call for heat 3 Allow the boiler to fire for at least an hour or until the odor from the cornstarch has dissipated 4 Return the high limit and thermostat to their desired settings S Review User s Information Manualandsystem operation with owner or operator IX Service WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency Inspections should be performed at intervals specified in this manual Maintain manual in a legible condition Keep boiler area clear and free of combustible materials gasoline and other flammable vapors and liquids Do not place any obstructions in boiler room that will hinder fl
83. ently hazardous situation Indicates a potentially hazardous situation which if not avoided will result in death which if not avoided may result in serious injury or substantial property moderate or minor injury or property damage damage WARNING NOTICE Indicates a potentially hazardous situation Indicates special instructions on which if not avoided could result in death installation operation or maintenance serious injury or substantial property which are important but not related to damage personal injury hazards DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance If you smell gas vapors DO NOT try to operate any appliance DO NOT touch any electrical switch or use any phone in the building Immediately call the gas supplier from a remotely located phone Follow the gas supplier s instructions or if the supplier is unavailable contact the fire department DO NOT install this boiler on combustible flooring carpet concrete over combustible flooring or wood nor on concrete over any heat affected material such as plastic piping or wiring without a properly installed combustible floor shield WARNING This boiler requires regular maintenance and service to operate safely Follow the instructions contained in this manual Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life R
84. entrance of insects and rodents Louvers and grilles must be fixed in open position or interlocked with equipment to open automatically before burner operation Screens must not be smaller than 1 4 inch mesh Consider the blocking effect of louvers grilles and screens when calculating the opening size to provide the required free area If free area of louver or grille is not known assume wood louvers have 20 25 percent free area and metal louvers and grilles have 60 75 percent free area 8 For Specially Engineered Installations The above requirements shall be permitted to be waived where special engineering consistent with good engineering practice and approved by the authority having jurisdiction provides an adequate supply of air for combustion ventilation and dilution of flue gases WARNING Do not install boiler where gasoline or other flammable vapors or liquids or sources of hydrocarbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used or stored NOTICE Mis sizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure Burnham DOES NOT warrant failures caused by mis sized boiler applications DO NOT oversize the boiler to the system Modular multiple boilers greatly reduce the likelihood of boiler oversizing Il Boiler Assembly A Remove Crate Semi Pak and Packaged Only 1 Remove all fa
85. expiration of the applicable warranty period Owner must make the Boiler available for inspection by Burnham and if requasted to do so by Burnham must retum the Boiler cast Iron section or defective component part to Burnham at Owner s expense for inspection and or repair Owner must cooperate with Burnham and take all commercially reasonable efforts to resolve and settle any dispute arising in connection with warranty claim before resorting to legal remedies In court 3 Conditlons The foregoing warranties are subject to the following conditions 8 installation Location The Boller must be installed within the continen tal limits of the United States and Canada b Proper Installation The Boiler must be installed by qualified heating contractor whose principal business is the sale installation and mainte of commercial boilers and related equipment in strict accordance with tha Installation and Operating Instructions Manual furnished with the Boiler and must not have been damaged prior to or during installation Annual Service The Boiler including its related burner controls and other components and accessories must be serviced annually by a qualified heating contractor whose principal business is the sale Installation and maintenance of commercial bollers and related equipment and proof of Such service must be provided with each warranty claim The required annual service must include all service and mai
86. ffening rib 4 Secure bracket in position by tightening 10 sheet metal screw against outer surface of Draft Hood skirt 5 Insert excess power cord through Jacket Right Side Panel hole Remove slack 6 Position strain relief bushing around power cord Pinch bushing s two halves together and snap back into hole in Jacket Right Side Panel 7 Verify power cord mounting bracket and Blocked Vent Switch are secure and located as shown in Figure27 WARNING Do not operate boiler without Blocked Vent Switch properly installed DRAFT HOOD SKIRT DRAFT HOOD BLOCKED VENT SWITCH MOUNTING POWER CORD STRAIN RELIEF BOILER BUSHING BOILER JACKET SIDE PANEL VIEW ub RIB DRAFT HOOD SKIRT BOILER SIDE VIEW Figure 27 Blocked Vent Switch Installation E Boiler Equipped With Vent Damper SeeFigure28 1 Open Vent Damper Carton and remove Installation Instructions Read Installation Instructions thoroughly before proceeding CAUTION Do not use one vent damper to control two or more heating appliances 2 Vent damper must be same size as draft hood outlet See Figure 1 Unpack vent damper carefully Forcing vent damper open or closed may damage gear train and void warranty Vent damper assembly includes pre wired connection harness with polarized plug 3 Mount vent damper assembly on draft hood without modification to either Refer to in
87. gas fired appliances to previous conditions of use N Adjust gas input rate to boiler LP Propane 1 Set thermostat to highest setting 2 Adjust tank regulator for gas valve inlet pressure of 13 5 inches w c or less 3 Gas valve has step opening regulator which initially opens to 1 4 or 2 5 inch w c and steps to full pressure after approximately 30 seconds Check manifold pressure after step has occurred Adjust gas valve pressure regulator as necessary for 10 0 inches w c turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure If 10 0 inches w c can not be attained check gas valve inlet pressure If less than 11 0 inches w c contact gas supplier for assistance O Clean Heating System Oil grease and other foreign materials which accumulate in new hot water boilers and a new or reworked system should be boiled out and then thoroughly flushed A qualified water treatment chemical specialist should be consulted for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations P Check Damper Operation If boileris equipped with vent damper vent damper must be in open position when boiler main burners are operating Start boiler refer to instructions on damper to determine 1f damper is in full open position Install Front Removable Panel 1 Engage top flange longer of 2 flanges b
88. h flame roll out switch and blocked vent switch Is spark present now Replace ignition module Determine cause of flame roll out switch or blocked vent switch activation Correct condition Replace switch Is 0 1 gap at pilot electrode ves NO System OK YES NO PES Replace transformer Determine why primary Replace pilot burner Is igniter cable in good condition not cracked voltage is not present burned loose or brittle 7 Is power available to primary of transformer Is ceramic on pilot electrode cracked Set spark gap to 0 1 YES NO Replace ignition module Replace Pilot Burner 73 SERVICE RECORD DATE SERVICE PERFORMED 74 SERVICE RECORD DATE SERVICE PERFORMED X Repair Parts Series 8B Repair Parts may be obtained through your local Burnham Wholesale distributor Should you require assistance in locating a Burnham Distributor in your area or have questions regarding the availability of Burnham products or repair parts please contact Burnham Customer Service at 717 481 8400 or Fax 717 481 8408 75 Item v Quantity N Description Par
89. hutdown 1 iii Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature 15 250 F Circulator continues to operate with call for heat Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive flue gas spillage occurs Circulator continues to operate with call for heat If blocked vent switch is activated do not attempt to place boiler in operation Correct cause of spillage and reset blocked vent switch Flame Roll out Switch Automatically interrupts main burner operation when flames or excessive heat are present in vestibule Circulator continues to operate with call for heat Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct cause of spillage and replace flame roll out switch RM7890C Burner Control Automatically interrupts main burner operation if a pilot flame is not detected during the four or ten second pilot flame establishing period The RM7890C will lockout or recycle based on jumper settings Alarm light will be illuminated Refer to instructions supplied with RM7890C for additional control information Pilot Safety Switch Automatically de energizes main gas valve and interrupts pilot gas supply if pilot flame is not detected at any time CIRCULATOR OTHERS S T
90. ic Vent Damper MEO ames 2 Jp e wwe fe sw v e sw Automatic Vent Damper 7 Etikai RVaP KS 7 88646 1 Automatic Vent Damper 8 RVGPKS 8 11 Automatic Vent Damper 9 Erika RVGP KS 9 8868 1 Automatic Vent Damper 10 Etikai RVGP KS 10 __ 88649 All components for use both U S A and Canada unless marked with for U S A Only or for Canada Only 99 5382 235221554365 087085 01857 216 BURNHAM CORPORATION Cen Pear Limited Warranty COMMERCIAL CAST IRON BOILERS SERIES 5B 8B V9 and V11 4 Exclusions The foregoing warranties do not cover claims arising from or relating to any of the followlng a Burnham Corporation Burnham hareby warrants to the original owner Ownar of each Series 5B 8B V9 and V11 commercial cast iron boier manufactured by Burnham as follows Burnham warrants that each Boiler will comply at the time of manufacture with recognized hydronics industry regulatory standards and requirements then in effect and will be tree from defacts in material and workmanship under normal usage for a period of one year from the of orig
91. ilots Turn on main electric switch Reset safety switch on flame safeguard relay Immediately light constant burning rectification pilot s Q179D with a lighted match If pilot is not lighted in 15 seconds Step 7 must be repeated Electric pilot valve s are automatic opening after Step 7 OP System Intermittent electric ignition rectification pilot s Q179C light up automatically when thermostat or operating control calls for heat EP System Replace burner access panel s Open manual main shut ff valve s Adjust room thermostat and operating controls to desired setting Figure 53 Lighting Operating Instructions OP EP CSD 1 64 PILOT LAME ROD BURNER CENTER CENTER FLAME p THERMOCOUPLE PRIMARY AIR OPENING THERMOCOUPLE Figure 54 Honeywell Q314 Pilot Flame Figure 57 Honeywell Q179D Pilot Flame OP 24V Standing Pilot FLAME ROD COMBINATION IGNITION ELECTRODE SENSING CENTER FLAME PROBE PRIMARY AIRA OPENING IGNITION ELECTRODE Figure 55 Honeywell Q348 Pilot Flame Figure 58 Honeywell Q179C Pilot Flame EP 24V Electronic Ignition CENTER IGNITION ELECTRODE PRIMARY AIR OPENING TE Checkpilot burner flam
92. inal installation Subject to all of the terms and conditions set forth below I any Boiler cast iron section or component part covered by this warranty is found not to conform with this warranty during the one year warranty period Burnham wili at its option repair or replace the non conforming Boiler cast iron section or covered componant part Burnham warrants that the cast iron sections of each Boller will be free from detects material and workmanship under normal usage for period of ten years from the date of original installation Subject to all of the terms and conditlons set forth below If any cast iron section covered by this warranty is found not to conform with this warranty during the warranty period Burnham will at its option repair or replace the non conforming cast iron section The foregolng warranties are subject to the following terms and conditions 1 Applicabllity These warranties extend only to the original Owner at the original installation sita and may not be assigned or otherwise transferred or extended to any other parson or entity 2 Procedure Owner must contact the original installer and provide the installer with a detailed description of the claimed defect If the original installer unable to resolve the matter to Owner s satisfaction Owner must notify Burnham in writing at Burnham Corporation P O 3079 Lancaster 37604 which notice must be received by prior to the
93. ler Any pilot failure of the Q348 Electronic Pilot after ignition of pilot flame will close the main gas valve in 0 8 seconds For approximately 90 seconds after failure of the Q348 pilot the module through the ignition terminal will try to reestablish pilot flame If no pilot flame can be sensed by the flame rod circuit terminals PV and MV PV are de energized and the module will lock out on safety Five to six minutes after shutdown the IGNITION MODULE restarts the 1gnition sequence The ignition trial Shutdown and wait sequence continues until either the pilot lights or the Thermostat is set below room temperature to end the call for heat The ignition sequence can be reset by setting down the Thermostat for one minute c Trouble Shooting Guide See Page 71 44 2 x THERMOSTAT OR OPERATING CONTROL 5 7 SECTION BY OTHERS be TO VENT DAMPER I RECEPTACLE 29 TO TRANSFORMER 547 TERNS US THERMOSTAT OR OPERATING CONTROL BY OTHERS VENT DAMPER RECEPTACLE VENT DAMPER WIRING HARNESS POWER 11 SEE NOTE 5 SUPPLY Bs 20 12 DAMPER FUSED SERVICE SEE NOTE 4 DISCONNECT SWITCH SWITCH ITEMS SUPPLIED BY INSTALLER CIRCULATOR BY OTHERS FLAME ROLL OUT SWITCH FRS cv Aw H E MODULE SWITCH 5 D GAS VALVE CODE JUMPER BLUE SCHEMATIC DIAGRAM LEGEND GRAY LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C GRAY WITH
94. may result causing property damage personal injury or loss of life This appliance is equipped with an ignition device e If you cannot reach your gas supplier call the which automatically lights the pilot Do not try to light fire department the pilot by hand C Use only your hand to push in or turn the gas control B Pisis ni dc aie ede knob Never use tools If the knob will not push in or o qua uius o sme 99 th ris Some turn by hand don t try to repair it call a qualified gas Neavier Man WE On ie TOON service technician Force or attempted repair may WHAT TO DO IF YOU SMELL GAS result in a fire or explosion Do not try to light any appliance D Do not use this appliance if any part has been under e Do not touch any electric switch do not use any water Immediately call a qualified service technician phone in your building to inspect the appliance and to replace any part of the o Immediately call your gas supplier from neighbor s control system and any gas control which has been phone Follow the gas supplier s instructions under water EE OPERATING INSTRUCTIONS Ww 1 STOP Read the safety information above on this label 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance RESET SAFETY SWITCH BUTTON POSITION INDICATOR RM7890A ELECTRONIC INLET CONTROL GAS CONTROL KNOB PANEL SHOWN IN OFF POSITION
95. n unsafe condition 3 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 FIRECLAY TILE LINED CHIMNEY THIMBLE HORIZONTAL VENT CONNECTOR SLOPE SECTIONS UPWARD NOT LESS THAN ONE INCH IN FOUR FEET AIR VENT DAMPER DRAFT HOOD CLEANOUT BLOCKED VENT SWITCH Figure 29 Typical Vent System 35 VII Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building Lock out all electrical boxes with padlock once power is turned off WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm Electrical power may be from more than one source Make sure all power is off before attempting any electrical work Each boiler must be protected with a properly sized fused disconnect Never jump out or make inoperative any safety or operating controls The wiring diagrams contained in this manual are for reference purposes only Each boiler is ship
96. nd Control Carton l Install Gas Control Assembly on Manifold See Figure 19 Install pilot burner piping and controls See Figure 19 Install Ignition Transformer a Attach Ignition Transformer to Jacket Vestibule 16 Panel using four 4 8 x lg sheet metal Screws b Connect Ignition Lead from Pilot to Ignition Transformer Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box a Canada only loop 4 nylon cable tie between junction box and transformer control center b Attach transformer control center to junction box Q 104INVN A8 5 3 LON N3QGIH NMOHS NIdld L r AWA SV9 8408 9 8908 Buipue S sed 0 4 ao 21 NOINN NOISS3NdWOO 55788 3NIVA 5 9 01043105 101 4 M3ldvav NOISS3NdWOO SSVu8 AINO SVD WYNLYN MOIV1n93M 5 9 10114 lOlld Vr O TI3MA3NOH ANWA 5 9 OL Qv31 JIdNOOOWNSHL g AIGNOOOWYSHL TI3MA3NOH 17 Buidid seo 1 4 MO 14 133815 AINO 8018 8808 2 3202 9nd aaivoman H3JIIVISNI Q3HSINSOJ NI NMOHS 18 VSN 13
97. ng Pilot 24V Figure 49 Figure 54 Honeywell Figure 55 Figure 50 Pilot Flame Ignition System Illustration Johnson EI ___ __ Figure 51 Figure 57 Figure 52 Figure 58 Figure 56 OP CSD 1 Figure 57 Figure 53 EP CSD 1 Figure 58 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING if you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a pilot which must be lighted by you cannot reach your gas supplier call the hand When lighting the pilot follow these instruc fire department tions exactly C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS result in a fire or explosion Do not try to light any appliance D Do not use this appliance if any part has been under e Do not touch any electric switch do not use any water Immediately call a qualified service technician phone in your building to inspect the appliance and to replace any part of the Immediately call your gas supplier from a neighbor s control system an
98. not smell gas go to the next step 4 Turn off all electric power to the appliance 10 Remove bumer access panel Pilot Burner RESET SAFETY 11 Find the pilot by following Thermocouple SWITCH BUTTON the aluminum tube from the as control valve n the pilot ocated between the stee RM7890C tube burners 12 gas control knob counterclockwise J to ELECTRONIC PILOT position 13 Push in control knob all the way and hold in Immed iately light the pilot with a match Continue to hold the control knob for about one 1 minute after the pilot is lit Release knob and it will pop back up Pilot should remain lit If it goes out repeat steps 8 13 If knob does not pop up when released stop and MAIN GAS ROCKER immediately call your service technician or gas supplier 2 SWITCH If the pilot will not stay lit after several tries turn SWITCH gas control knob to OFF and call your service tech nician or gas supplier CONTROL LOCATION DIAGRAM 14 Replace burner access panel 2 15 SYSTEM 5 OP SYSTEM Flip both rocker switches to O position off Tum on all electric power to the appliance 6 Remove front door Set the thermostat or operating control to desired 7 Locate the gas control valve at the end of the gas supply pipe setting going into the boiler The gas control knob is the knob located See control location diagram On the electronic control on the top of the gas control valve
99. nst stop the main burners 9 Wait five 5 minutes to clear out any gas Then smell Replace front door for gas including near the floor If you smell gas 11 If the appliance will not operate follow the instructions STOP Follow B in the safety information above on TO TURN OFF GAS TO APPLIANCE and call your this label If you do not smell gas go to the next step service technician or gas supplier roruRNorrcAsTOAPPLIANCE 1 Set the thermostat to the lowest setting 4 Rotate gas control knob clockwise from ON 2 Turn off all electric power to the appliance if service is position to OFF Make sure knob rests against stop to be performed 5 Replace front door 3 Remove front door Figure 52 Operating Instructions EP 63 BOILER OPERATING INSTRUCTIONS IO SHUT DOWN 1 Close manual main shut off valve s and pilot valve s Turn off main electric switch IO START UP Make sure that both the main manual and the pilot valve s have been off for at least five minutes Turn room thermostat and all operating controls to lowest setting Remove burner access panel s Open manual pilot valve s Item 5 applies only to boilers with standing plot safety switch es Depress button on standing pilot safety switch and hold lighted match to pilot holding button in for at least one minute or until pilot remains lighted after button is released Repeat for remaining standing p
100. ntenance procedures specified in the Installation and Operating Instructions Manual furnished with the Boiler and all service and maintenance procedures specified in any instruction manual or similar document prepared by the manufacturer of the burner controls and other components and accessories Such annual service must also be performed in accordance with all applicable industry standards and procedures Proper Operation and Maintenance The Boiler must be operated and maintained in strict accordance with the Installation and Operating Instruc tions Manual furnished with the Boiler and all applicable industry standards and procedures No Alterations The Boiler must not have been modified altered or changed in any manner 1 Proper Application The Boiler must be used exclusively for purposes of cominercial space heating or domestic hot water generation through a heat exchanger or for a combination of such purposes Claims relating to component parts and accessories manufactured by others are not covered by these warranties and wil be subject only to the manufacturer s warranty if any b improper installation Claims arising from or relating to improper installation are not covered by these warranties c Natural Disasters Claims arising from or relating to damage caused by natural disasters including but not limited to lightening fire earthquake hurricane tornado or floods are not covered by these warrantias d
101. nts Remove all accumulations of soot with wire brush and vacuum Remove all obstructions Replace all deteriorated parts and support properly Seal all joints D Remove Main Burners for cleaning changing orifice plugs or repairs 1 Shut down gas boiler in accordance with Lighting Operating Instructions on inside of Front Removable Door Close Manual Shut off Valve 68 Remove Front Removable Door Raise Lower Front Tie Bar Disconnect ignition system Remove burner access panel s Marklocation of Main Burner with Pilot Bracket on manifold Removehitch pin clips from Main Burner Orifices Hold Main Burner on throat Lift slightly to raise rear of burner Push to rear of boiler until burner clears Main Burner Orifice Lift burners out Check burners to be sure they do not contain foreign matter or restrictions Clean burners with a soft bristle brush blow any dirt out with compressed air or use a vacuum cleaner See Figure 60 Clean Boiler Flueways l BW Shut down gas boiler in accordance with Lighting Operating Instructions on inside of Front Removable Door Close Manual Shut off Valve Disconnect vent system Remove Draft Hood Remove Jacket Top Panel Remove Canopy from top of boiler Thoroughly clean flueways with flue brush removing all scale and soot See Figure 60 Clean boiler heating surface accessible from combustion chamber with straight handle wire brush
102. o No 8058 8068 8078 8088 8098 8108 4 xr and Main Burners Burner 8231602 8231602 8 10 12 15 Main Burner with Pilot Bracket Standing Pilot 24V ETTET Main Burner with Pilot Bracket Honeywell El 8231604 Main Burner with Pilot Bracket Johnson EI Main Burner with Pilot Bracket OP 8231603 Main Burner with Pilot Bracket EP 82216051 6051 82241607 1 82216081 1 822160911 1 4D Pi Pipe Plug 1 8 Included with aC 1 1 os os Jon Main Burner Orifice 37 Natural Gas TUI 822601 11 13 16 18 20 Main Burner Orifice 452 LP Propane Only 822641 Main burner orifice sizes shown for normal altitude 0 2000 feet For High Altitude consult factory ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 1 Gas Train Standing Pilot 24V OP 24V USA amp Canada 6 amp 7 Section Natural amp LP Gas OP USA amp Canada 6 10 Section Natural amp LP Gas Gas Valve Robertshaw 7000 57 Natural Gas 1 NPT 81660156 A 806B 810B 1 Gas Valve Robertshaw 7000 1 57 LP Gas 1 NPT 81660157 Solenoid Gas Valve Honeywell V8295A1024 34 81660235 806B 807B 1 Solenoid Gas Valve Honeywell V8295A1032 1 NPT 81660236 808B 810B Lubricated Manual Shut Off Valve Newman
103. of obstructions E FILL ENTIRE HEATING SYSTEM WITH WATER and vent air from system Use following procedure on a Series Loop or multi zoned system installed as per Figure 25 to remove air from system when filling WARNING The maximum operating pressure of this boiler is 50 psig Never exceed this pressure Do not plug or modify pressure relief valve 1 Close full port ball valve in boiler supply piping 2 Isolate all zones by closing zone valves or shut off valves in supply and return of each zone s 3 Attach a hose to the vertical purge valve located prior to the full port ball valve in the system supply piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area 4 Starting with one circuit at a time open zone valve or shut off valve in system supply and return piping 5 Open purge valve 6 Open fill valve Make up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank 7 Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds 8 Close the open zone valve or shut off valve for the zone being purged of air then open the zone valve or shut off valve for the next zone to be purged Repeat this step until all zones have been purged At completion open all zone valves or shut off valves 9 Close purge valve continue filling the system until the pressure gauge rea
104. oiler See Figure 24 Also consult I B R Installation and Piping Guides 2 If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during cooling system operation 3 Use boiler bypass if boiler is operated in system which has a large volume or excessive radiation where low boiler water temperatures may be encountered i e converted gravity circulation system etc See Figure 25 4 A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of installation 5 Astart up strainer is recommended for practically all modular installations new and replacement alike to prevent system debris and sediment from ending up in the boilers where it will inhibit heat transfer and may eventually cause a cast iron section to crack from overheating Alliance Water Heater 1fused Referto Alliance Installation Operating and Service Instructions for additional information Install in same manner as space heating zone 2 NPT X 10 LG PIPE NIPPLE W i NPT GAUGE TAPPING TEMPERATURE HEX BUSHING PRESSURE GAUGE NPT x 1 NPT TEMPERATURE PRESSURE GAUGE REAR OF BOILER PIPE TEE 2 NPT X 10 LG PIPE NIPPLE Figure 22 Temperature Pressur
105. on EP USA amp Canada 6 10 Section Natural Gas Only Gas Valve Robertshaw 7000GVERHC S7C Natural Gas 1 NPT 81660168 806B 810B Solenoid Gas Valve Honeywell 8295 1024 54 NPT 81660235 806B 807B Solenoid Gas Valve Honeywell V8295A1032 1 NPT 81660236 808B 810B C Lubricated Manual Shut Off Valve Newman Milliken 200M 1 NPT 822619 8065 9105 1 Canada Only D Bushing 1 NPT x NPT 806600501 806B 8 8078 Nipple x 2 Lg 806600003 806B amp 807B i4 Nipple 1 NPT x 2 Lg 806600004 808B 810B Canada 2 Street Elbow 1 NPT x NPT 806601512 8068 amp 8078 1 Street Elbow 1 4 NPT x 1 NPT 806601513 808B 810B DESCRIPTION PART NUMBER QUANTITY 5 5 Gas Train Intermittent Ignition EP CSD 1 USA Only 8 10 Section Natural Gas Only Lubricated Manual Shut Off Valve ConBraCo 50 403 02 1 NPT D Leak Test Shut off Valve ConBraCo 56 221 01 1 8 x 1 8 82269 2 22111111 mese gt Hex Bushing 1 4 x 1 8 Street Elbow 90 x 1 Malleable Coupling 1 1 4 x 1 Wiring Harness Gas Valve to Solenoid Valve Pilot Outlet Plug Honeywell 394424 ITEM PART DESCRIPTION NUMBER SIZE QUANTITY 5 6 Pilot Assembly and Piping Standing Pilot 24V USA amp Canada 6 amp 7 Section Natural and LP Gas Pilot Burner Honeywell Q314A3687 Natural Gas 8236033 Pilot Burner Honeywell Q314A3828 LP Gas HI EDI MM C Brass
106. or continues to operate Vent Damper if used remains open with call for heat Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct cause of spillage and replace flame roll out switch Pilot Pilot failure can occur during the start up or the operating cycle of the boiler Any pilot failure of the 1991 Electronic Pilot after ignition of pilot flame will close the main gas valve For approximately 90 seconds after failure of the J991 pilot the module through the ignition terminal will try to reestablish pilot flame If no pilot flame can be sensed by the flame rod circuit terminals 1 and GND are de energized and the module will lock out on safety Five to six minutes after shutdown the IGNITION MODULE restarts the ignition sequence The ignition trial shutdown and wait sequence continues until either the pilot lights or the Thermostat is set below room temperature to end the call for heat The ignition sequence can be reset by setting down the Thermostat for one minute c Trouble Shooting Guide See Pages 72 and 73 Bus THERMOSTAT d OR OPERATING OPTIONAL CONTROL 5 7 SECTION 1 OTHERS I TO VENT DAMPER pass 1 RECEPTACLE BL TO TRANSFORMER LWCO TERMINAE THERMOSTAT OPTIONAL OR OPERATING 5 7 CONTROL BY OTHERS VENT DAMPER RECEPTACLE VENT DAMPER WIRING HARNESS POWER 11 9 SEE NOTE 5 SUPP
107. ow of combustion and ventilation air The service instructions contained in this manual are in addition to the instructions provided by the manufacturer of the boiler components Follow component manufacturer s instructions Component manufacturer s instructions were provided with the boiler Contact component manufacturer for replacement if instructions are missing Do not install start up operate maintain or service this boiler without reading and understanding all of the component instructions Do not allow the boiler to operate with altered disconnected or jumpered components Only use replacement components identical to those originally supplied by Burnham A General Inspection and service must be conducted annually Turn off electrical power and gas supply while conducting service or maintenance Follow instructions TO TURN OFF GAS TO APPLIANCE See Lighting Operating Instructions on inside of Front Removable Door WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing B Maintenance of Low Water Cut off if used Follow instructions provided with low water cut off C VentSystem Check 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 joi
108. ped with a wiring diagram attached to the front door Refer to this diagram and the wiring diagram of any controls used with the boiler Read understand and follow all wiring instructions supplied with the controls gt Install Boiler Wiring 2 Remove factory installed Jumper Plug from Vent Damper Receptacle on Vestibule Wiring Harness 1 Knock il ly Locate wiring h i ockdown boilers only Locate wiring harnesses in and discard Combination Boiler Parts and Control Carton Refer to Table 10 and connect wiring as shown on the 3 Plug Vent Damper Harness Plug into Vent Damper appropriate wiring diagram Receptacle See Figure 28 2 Connect supply wiring and electrically ground boiler C Installthermostat Locate on inside wall approximately in accordance with requirements of authority having 4 feet above floor Do not install on outside wall near jurisdiction or in absence of such requirements the fireplace or where influenced by drafts or restricted air National Electrical Code ANSI NFPA 70 and or flow hot or cold pipes lighting fixtures television or CSA C22 1 Electrical Code sunlight Allow free air movement by avoiding placement of furniture near thermostat B Wire Vent Damper if used required on 805 optional on 806 810 See Figure 28 1 Attach Vent Damper Harness to mounting hole in Jacket Left Side Panel Install Cable Clamp around flexible conduit and attach to Jacket Top Panel Set heat anticipator to mat
109. put rating and efficiency 3 Single wall metal vent Allowed by ANSI Z223 1 54 under very restrictive conditions B Inspect chimney and remove any obstructions or restrictions Clean chimney if previously used for solid or liquid fuel burning appliances or fireplaces DANGER Inspect existing chimney before installing boiler Failure to clean or replace perforated pipe or tile lining will cause severe injury or death C Install Draft Hood on canopy outlet Maintain height from Jacket Top Panel to Draft Hood skirt as shown in Figure 1 DO NOT ALTER CUT OR MODIFY DRAFT HOOD WARNING Do not alter boiler draft hood or place any obstruction or non approved damper in the breeching or vent system Flue gas spillage can occur Unsafe boiler operation will occur D Install Blocked Vent Switch The Blocked Vent Switch Assembly consists of a strain relief bushing power cord and switch attached to mounting bracket On Packaged boilers the assembly is shipped attached to top of boiler On Knocked Down boilers the assembly is located in Combination Boiler Parts and Control Carton 1 Uncoil power cord 2 Position mounting bracket onto lower edge of Draft Hood skirt Locate center tooth with 10 sheet metal screw on outside and other two teeth inside Draft Hood skirt See Figure 27 3 Slide mounting bracket tight against lower edge of Draft Hood skirt Position 10 sheet metal screw above skirt s sti
110. r installation at altitudes greater than 2 000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1 000 feet above sea level per the National Fuel Gas Code 54 ANSI 2223 1 Section 8 1 2 and Appendix F Canadian boilers orifice sizing is indicated on the rating label High altitude boiler models are identifiable by the model number s ninth digit on the rating label 4 2000 4500 5 2000 5000 Table 6 Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0 5 psig or Less 0 5 inch w c Pressure Drop Table 7 Lengths of Standard Pipe Fittings amp Valves Valves Fully Open Threaded Fittings Hg 1 D Swing 90 45 90 Tee Flow 90 Tee Flow Size Inches Gate Globe Angle Check Elbow Elbow Run Branch 9 3 4 3 Table 8 Specific Gravity Correction Factors Specific Correction Specific Correction Gravity Factor Gravity Factor WARNING Do not use matches candles open flames or other ignition source us o e ow Ls or C Pressure Test The boiler and its gas connection must be leak tested before placing boiler in operation MANUAL SHUT OFF VALVE UNION 1 Protect boiler gas valve For all testing over psig 3 MIN boiler and its individual shut off valve must be disconnected from
111. r operating control calls for heat Vent Damper if used opens Gas valves are energized allowing main gas flow and ignition of main burners iii Call or heat ends Gas valves are de energized extinguishing main flame Vent Damper ifused closes b Safety Shutdown Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature is 250 F Circulator continues to operate with call for heat Vent Damper if used closes Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive flue gas spillage occurs Circulator 38 USA 10 Sect Figure 35 Figure 36 Page 44 Figure 37 Figure 38 Page 49 Canada Figure 41 Figure 42 USA amp ES Gas 10 Sect Figure 43 Figure 44 Page 54 Not Available continues to operate and Vent Damper if used remains open with call for heat If blocked vent switch is activated do not attempt to place boiler in operation Correct cause of spillage and reset blocked vent switch Flame Roll out Switch Automatically interrupts main burner operation when flames or excessive heat are present in vestibule Circulator continues to operate and Vent Damper if used remains open with call for heat Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct cause of spillage
112. s 15 gas at pilot burner pressure CAUTION Do Not use match 1o test for gas presence YES NO Make sure lines are bled and pilot tubing is not blocked Is spark gap 0 1 and located in pilot gas stream NO YES Correct or replace pilot burner Check for drafts Shield as necessary Check for clean orifice If OK replace valve assembly 72 SITUATION C NO SPARK Is vent damper wiring harness securely connected in junction box and vent damper Wire components together securely Is 24 VAC available between THS 2 and ground Are thermostat relay limit and low water cutoff contacts closed YES NO Is jumper installed between terminal 5 and GR YES NO Install jumper Is vent damper if used rotated open 22 sA NO Check for proper thermostat thermostat relay limit and low Is 24 VAC available between PV1 and GR YES NO water cut off operation Lower thermostat setting to interrupt call for heat for 30 seconds Vent damper if used will rotate to closed position Raise thermostat setting to cause call for heat Vent damper if used will rotate to open position EE Is 24 available Between PV 1 and GR YES NO Check for proper wiring If OK replace vent damper Electrical continuity throug
113. s to lubricate cee Burners numbered left to right as viewed from front I Check operation Refer to Section VIII System Start of boiler up 70 Honeywell El Trouble Shooting Guide Tum thermostat controller to call for heat Turn gas supply off START Spark across igniter senser gap YES Turn gas supply on Does pilot burner light YES Spark stops when pilot is lit Main burner lights YES System runs until call for heat ends YES NO Call for heat ends Does system shut off ws Troubleshooting ends Power to module 25 VAC Nominal Note Before troubleshooting familiarize yourself with the startup and checkout procedure Check line voltage power low voltage transformer limit controller thermostat controller and wiring If so equipped check for proper operation of vent damper Pull ignition lead and check spark at module ignition stud Is spark OK ws so Replace ignition module Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protective action to shield cable and boot from excessive temperatures Check that all manual gas cocks are open supply tubing and pressures are good and pilot burner orifice is not blocked Check electrical connections between module and pilot operator on gas control Check for 24 VAC a
114. skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 69 FLUE BRUSH VENT DAMPER IF USED DRAFT HOOD BLOCKED VENT SWITCH JACKET TOP PAN a FLUE BRUSH FRONT REMOVABLE DOOR BURNER ACCESS PANEL S FLAME ROLL OUT SWITCH SOFT BRISTLE BRUSH 5 MAIN BURNER Figure 60 Boiler Flueway Cleaning 7777417777777777777777777777772 F Clean Combustion Chamber by vacuuming Exercise Table 13 Pilot Burner Location care to avoid damaging Base Insulation G Install Burners by reversing procedures used to Pilot Located Between Burners remove burners Verify Main Burners are properly located on support bracket in Base Rear Panel seated 4 amp 5 on Main Burner Orifices and secured with hitch pin 586 clips Verify Main Burner with Pilot Bracket is in proper location See Table 13 6 amp 7 H Lubrication Manufacturers Instruction should be 687 followed on all parts installed on boiler requiring 6 amp 7 lubrication This includes type of lubricant to be used frequency of lubrication and point
115. steners at crate skid 2 Lift outside container and remove with all other REAR DF BOILER WOODEN BLOCKS inside protective spacers and bracing B Remove boiler from skid See Figure 2 Exercise care to avoid dropping boiler FLOOR LINE _ SKID 3 4 PIPE ROLLER 1 Place boiler in approximate location Refer to END Section I Pre Installation Remove base hold down bolts 2 Using pry bar under rear corner of Base End Panel raise boiler and install 172 wood blocks under rear corners Install 94 pipe roller between Base and skid 3 Remove 1 wood blocks Place 3 pipe roller on floor behind skid 4 Roll boiler off skid Move skid out of way FLOOR LINE if TOP VIEW FRONT VIEW REAR VIEW Figure 3 Tapping Locations Table 3 Purpose of Tappings Tapping r 5 Roll boiler until 3 roller is located as shown Use pry bar to install wood blocks under front corners of base Remove 3 roller 6 Lift boiler with pry bar Remove wood blocks Lower boiler C For Packaged Boiler only proceed to Paragraph E D Test Section Assembly for leaks before connecting to system and installing controls trim and jacket Refer to Figure 3 and Table 3 1 Plug Tappings C amp and Return Tapping B 2 NPT 2 Insert 34 NPT x NPT bushing in Tapping D Install pressure gauge capabl
116. structions packed with vent damper for specific instructions Vent damper position indicator to be visible to users CAUTION Provide adequate clearance for servicing provide 6 minimum clearance between damper and combustible construction F Install Vent Connector from draft hood or vent damper to chimney See Figure 29 For modular or multiple boiler installations review Multiple Modular Manual for Series 8B Gas Boilers P N 8141615 VENT DAMPER LEFT SIDE VIEW VENT DAMPER WIRING HARNESS VESTIBULE WIRING HARNESS CONNECTION DETAIL Do not connect into same leg of chimney serving an open fireplace Where two or more appliances vent into a common vent the area of the common vent should at least equal the area of the largest vent plus 50 of the area of the additional vents Do not connect the vent of this appliance into any portion of mechanical draft system operating under positive pressure Vent connector should have the greatest possible initial rise above the draft hood consistent with the head room available and the required clearance from adjacent combustible building structure Install vent connector above bottom of chimney to prevent blockage inspect chimney for obstructions or restrictions and remove clean chimney if necessary Vent connector should slope upward from draft hood to chimney not less than one inch in four feet No portion of vent
117. t No 9 8058 8068 8078 8088 8098 8108 1 Heat Exchanger Assembly WT SERES ee EN 1 Complete ee eme EA 806032 1 8061083 1 ip Tera _ 1 eeose ES 80861085 EN 80861096 1 116 s 2 76 HEAT EXCHANGER ASSEMBLY SEE GROUP 1 SEE GROUP 4 Item D ipti PartN Quantity escription art No No 8058 8068 8078 8088 809B 8108 aaa WC 2 eases E eS eS Bolt Carriage 7 20 x 1 TT Item Quantity Description Part No 3 Base Assembly 21 1 1 1 1 2 _ _ 61816102 2 61816051 1 61816051 oes we Base Rear Panel Assembly E 80818081 ee EXER EE RC pu 4 25 as pa 81818083 o ee q s u 81818084 1 e uso 28 Burner Access Panel Assembly eS 81816105 2251 25125121 7041601 Bolt Carriage 14 20 x 1 78 Item D ipti Part Quantity escription art N
118. tat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or common venting system the common pipe venting system is likely to be too large for proper venting of the appliances remaining connected to it When an existing boiler is removed from a 6 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 fireplace dampers and any other gas burning appliance to their previous condition of use placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting 7 Any improper operation of the common venting system system should be corrected so the installation conforms with the National Fuel Gas Code NFPA 54 ANSI 7223 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 7 and Part 11 in the National Fuel Gas Code 54 ANSIZ223 1 2 Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion or other deficiencies which could cause a
119. tion Boiler Parts and Control Carton 3 Seal between top of Base Rear Panel and Section Assembly with furnace cement Install Pilot Main Burner Assembly See Figure 7 Assembly is located in Combination Boiler Parts and Control Carton Verify assembly is properly located on support bracket in Base Rear Panel seated on Main Burner Orifice and secured with hitch pin clip Attach Flame Roll out Switch to Burner Access Panel See Figure 6 Flame Roll out Switch and hardware are located in Combination Boiler Parts and Control Carton Flame Roll out Switch is a single use device do not test with heat switch cannot be reset CUT INSULATION FROM NOTCH BEFORE INSTALLING FLAME ROLL OUT SWITCH Figure 6 Flame Roll out Switch Installation BURNER ACCESS PANEL S FLAME ROLL OUT SWITCH MAIN BURNER 9 Figure 7 Burner Burner Access Panel Installation 11 2 1 Cut insulation from semicircular notch at right end of the burner access panel Models 808B 810B have two 2 burner access panels Remove insulation from notch of right side burner access panel only 2 Attach Flame Roll out Switch Mounting Bracket to burner access panel with 1 8 x lg sheet metal screw 3 Attach Flame Roll out Switch to mounting bracket with 1 8 x 32 lg sheet metal screw Install Burner Access Panel s Locate Burner Access Panel s in Combination Boiler Parts and Control Carton Engage Burner Access P
120. vated do not attempt to place boiler in operation Correct cause of spillage and reset blocked vent switch Flame Roll outSwitch Automatically interrupts main burner operation when flames or excessive heat are present in vestibule Circulator continues to operate with call for heat Control is single use device If roll out switch is activated do not attempt to place boiler in operation Correct cause of spillage and replace flame roll out switch RM7890C Burner Control Automatically interrupts main burner operation if a pilot flame is not detected during the four or ten second pilot flame establishing period The RM7890C will lockout or recycle based on jumper settings Alarm light will be illuminated Refer to instructions supplied with RM7890C for additional control information 41 3 Electronically Supervised Standing Pilot OP CSD 1 Sequence of Operation a NormalOperation iii Thermostat or operating control calls for heat Terminal 6 ofRM7890C Burner Control is energized initiating microcomputer monitored circuit test Pilot Flame Establishing Period PFEP begins After pilot flame is proven terminal 9 of RM7890C is energized allowing main gas flow and ignition of main burners Main gas light will be illuminated Call for heat ends Terminal 6 of RM7890C is de energized in turn de energizing gas valves and extinguishing main flame Main gas light is de energized b Safety S
121. vide combustion and ventilation air in accordance with applicable provisions of local building codes or the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 5 3 Air for Combustion and Ventilation or CAN CGA 8149 Installation Codes installation on combustible flooring only when installed on special base listed in Table 2 Boiler must not be installed on carpeting When boiler is installed on concrete which is over a material that is subject to melting PVC PEX radiant tubing etc the special base must be used A concrete pad is not sufficient to protect combustible flooring Part 5 Venting Systems and Air Supply for Appliances WARNING Adequate combustion and ventilation air must be provided to assure proper combustion The following guideline 15 based on the National Fuel Table 2 Special Base Required for Installation on Gas Code NFPA 54 ANSI Z223 1 Combustible Flooring 1 Boiler Model No 805B considered part of space 806B Volume 88 Length ft x Width ft x Height ft 2 Determine Total Input of all appliances in space Round result to nearest 1 000 Btu per hour Btuh 3 Determine type of space Divide Volume by Total Inge Determine volume of space boiler room Rooms communicating directly with space through permanent openings not furnished with doors are 807B 808B 809B 810B a Ifresult is greater than or equal to 50 ft per 1 000 Btuh space is considered an unconfined space b
122. wer to the Main Gas Valve The Gas Valve is energized allowing main gas flow and ignition of Main Burners Call for heat ends Ignition module is de energized de energizing gas valve and extinguishing pilot and main flame Vent Damper if used closes b Safety Shutdown 1 Limit Automatically interrupts power to the Ignition Module and Gas Valve s extinguishing pilot and main flame when water temperature exceeds set point Maximum allowable temperature is 250 F Circulator continues to operate with call for heat Vent Damper if used closes Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive flue gas spillage occurs Circulator continues to operate and Vent Damper if used remains open with call for heat If blocked vent switch is activated do not attempt to place boiler in operation Correct cause of spillage and reset blocked vent switch Flame Roll out switch Automatically interrupts main burner operation when flames or excessive heat are present in vestibule Circulator continues to operate Vent Damper if used remains open with call for heat Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct cause of spillage and replace flame roll out switch Pilot Pilot failure can occur during the start up or the operating cycle of the boi

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