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Burnham 5B Installation Operating Instructions

Contents

1. IN LINE LIMI Dang CANADA ONLY FUSE 5 wae TO PILOT PILOT OPTIONAL IGNITER 4 CANADA ONLY TO PILOT TO PILOT OPERATING CONTROL NITER GND SPARK BNR GND 24V 24V GND SPARK BNR GND 77 PV 24V 24V GND 1 HONEYWELL E f ry 58610 see HONEYWELL EN V88A 58610 di 4 0 GAS VALVES PILOT VALVE V88A J Gas VALVES LADDER DIAGRAM LEGEND ee SUAE INTERNA WIRING LEFT GAS TRAIN RIGHT GAS TRAIN 24V EXTERNAL WIRING WIRING WIRING 120V INTERNAL WIRING 120V EXTERNAL WIRING FIG 43 LADDER WIRING DIAGRAM 5015B THRU 5026B SECTION BOILERS El CONTROL SYSTEM 50 SECTION IV OPERATION continued TROUBLE SHOOTING GUIDE BOILERS EQUIPPED WITH 58610 INTERMITTENT ELECTRIC IGNITION START BEFORE TROUBLESHOOTING FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES TURN GAS SUPPLY OFF TURN THERMOSTAT CONTROLLER TO CALL FOR HEAT NOTE 24 VAC CALL FOR HEAT IS ALWAYS CONNECTED TO THE TH W TERMINAL ON THE MODULE CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING NO ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE END SWITCH IF USED IS MAD
2. BOOED S 5 Sizes One to Three Per Boiler e 1 s 5 Sizes One 4 ui gt s d ab 26 E 224 411 51 8 880 11 8 4114 4114 Boo 4114 1111 8 111 11 BURG o 1 18 s 79 SECTION 1 EQUIPMENT CHECK LIST continued CANADIAN EQUIPMENT CHECK LIST CI 7S Steam Trim Carton Steam Boilers Only Includes PA404 Pressure Limit Control 4 Sizes One Per Boiler 25 ees 2 2 151517 2 esa e sa spese ese ae sie asas 5 s asss e Eee Sep c oe ea EB CLESIA 67 2 Low Water Cut off Carton Steam Boilers Only One Per Boiler Water Trim Carton Water Boilers Only Includes L4006A Temp Limit Control 3 Sizes One Per Boiler Low Water Cut off Carton Boilers One Per Boiler u Complete Jacket Carton Assembly One Per Boiler Gas Train Cartons By Gas 2 Sizes One or Two Per Boiler THERM Controls Carton s Manual Ignition 100 Shutoff 24V 1 Size One or Two Per Boiler ui HCP Plain Heater Cover Plate Not furni
3. OLNI S ON3 X30108 INIOd WO34 34015 S NIVN 14405 WV3IS W3lSAS 83108 5014 100 Nv319 JAWA 8 HUM 234 33108 OL NMOQ HOlld 13 WALSAS O 9Nidid 034 34384 gt ONidid_SLYNYALTY AE 30 418084 NOILO3NNOO 138 OF 9 JAYA 31 9 331 30014 AINO 31ddlN 42 1 12 43Q1n0HS MOO1J 40 9 NIHLIM MO 35019 01 39NVHOSIG TWN 319NV 6 V YO 30 401 440 38 OL S NIVW 14405 TWWMON OL 037114 83108 433 N31VM IWNYON 08 76 WONININ 254 6 16 NOILVTIVLSNI Ill NOLLO3S 19 LINN 831108 NST LS38 31VSN3dNOO 544104 LN3 AHONVHWV 9NIdld WWALS TVWOIdAL S 213 JAVA Nivad 01 NOLLVH3dO TIYWHON 404 035013 JO 3 440 1nHS M SSv19 39nv9 N31VM NOLLVH3dO 80 404 435012 TVOIdAL 93H9 310N 335 431108 31VSN30NO2 MO W3lSAS 31VSN3QNOO AlddnS 3 4 AllOvdvo Qd1nQ3H2S 404 Galva 31VSN3Q0NOO
4. 598 89209 SSOLWSSOGA d1 ZH09 eui 28g 89509 8001 VZ9OvA OT IH 01 7 09 9 Buruedo 298 89206 7001 VSSOrA 07 SOA EA JO SJOJenjov 0LOLSSSOSA ZOOLESSOSA SED 19MOg 109 86005 88009 89009 8215 108 VOVNVO SNIVH L SVO CINTA S Ls Vd MIVd33 NOILOAS 029208 69228 Sv9cc8 9 9228 819228 0109228 9 8 21092428 11098228 109228 9009228 v6009918 88009918 vL009918 81009918 21009918 11009918 01009918 LHVd 96 WALSAS 1OH LNOO 1499 LYOddNS 9 WOL98S 3 IY1GOIN S HII 534425 X 26 01 NN WLAN 133 5 E X 9 JINGOW NDILINDI L332V88 JINGOW JINVAW uoniub 6006 101986 Ajquiessy uoddng ainpoy piojiue uonduoseq 089600 _____ ONIMVd penunuoo 5 IA NOLLOAS 97 WALSAS 1OH LNOO 3 1d1090WH3H L 43 423 8 LYOddNS 9 9997 1V1S 10 ld YOUMS A q
5. e 1 11 11 5452 3585 U Tapped NPT Heater Cover Plate Not Furnished on Water Boiler Ordered With Tankless Heater s One Per Boiler 2 L i j i i 14 pest eec ec poste INSPECT SHIPMENT carefully for any signs of damage All equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of Boiler to carrier in good condition Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within sixty 60 days after receipt of equipment Carton 9 or 9 on sizes 5006B thru 5009B is standard on all systems except EI and may be optional on 5006B thru 5009B EI Carton 9 is standard on sizes 5006B thru 5009B for EI systems This Series 5B 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 Fitter SECTION 1 EQUIPMENT CHECK LIST continued CANADIAN EQUIPMENT CHECK LIST This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered It covers standard equipment for both steam and water boilers without Tankless Heaters Heaters o
6. oL A LADDER DIAGRAM LEGEND GROUND 8 8 E x BK R 24V EXTERNAL WIRING INTERNAL WIRING WIRE CODE 120V INTERNAL WIRING _ L O 1411 2221 120V EXTERNAL WIRING 2 ae 5568530 BK R BLACK RIBBED LETTERING PILOT SAFETY SWITCH PILOT SAFETY SWITCH 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 LEFT GAS TRAIN WIRING RIGHT GAS TRAIN WIRING 2 ALL WIRING INCLUDING GROUNDING CONNECTIONS MUST COMPLY WITH NATIONAL ELECTRIC CODE AND APPLICABLE LOCAL CODES SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C VOLTAGE SIZE 18 2 AWG POWER LIMITED CIRCUIT CABLE 105 C LINE VOLTAGE SIZE 14 AWG WIRE TYPE TW OR TEW AWN WIRE LINE VOLTAGE SIZE 18 AWG WIRE TYPE TEW AWM 105 C STRANDED WIRING DIAGRAM 5015B THRU 5024B SECTION BOILERS THERMOCOUPLE CONTROL SYSTEM CANADA ONLY 59 SECTION IV OPERATION continued 10 CHECK GAS INPUT RATE TO BOILER 1 Input Rate and Maximum Inlet Pressure shown on Rating Plate must not be exceeded Inlet pressure must not be lower than minimum inlet pressure shown on Rating Plate All Rate checks and all adjustments are to be made while boiler is firing all other appliances connected to the same meter
7. 55233 N3NMhB MIYOS ONiddvl 4 35 wi amp xo 91 Gv3H SINN M 503425 we x oz 4 438 3 98 1509915 T3NVd Dit 31VIQ3WH31NI M3M01 oO duoc m 03345 92 55 NOLLVINSNI 7T3NVd QN3 3598 T3Nvd ONI Eu 35 8 G NOUVINSNI 35 8 SLYVd MI Vd33 IA NOILOAS 75 SECTION VI REPAIR PARTS continued TABLE 2A SERIES 5B BASE PARTS 5006B thru 5014B Number in in Table Relates to Corresponding Number in in Figure 60 PART BOILER SIZE NUMBER ee 5006B 50078 50088 50098 5010 5011 5012 50138 50148 7181301 High Base End Panel 12 1 2 x 25 3 4 1 1 1 1 1 1 1 1 1 7201319 High Base End Panel Insul 1 Supertemp 12 x 21 1 2 2 2 2 2 2 2 2 2 2 80861551 Head Pin CL 10 x 1 5 8 3 3 3 3 3 3 3 3 3 80861503 Speed Clip 1 1 4 x 1 1 8 SS Type 304 4 4 4 4 4 4 4 4 4 61813061 5006B Base Front and Rear Frame Assembly 12 1 2 x 27 3 16 5 5 amp 6 5 61813071 5007B Base Front and Rear Frame Assembly 12 1 2 x 32 5 8 5 6 5 amp 6 5 61813081 5008B Base Front and Rear Frame Assembly 12 1 2 x 38 1 16 5 61813091 5009B Base Front and Rear Frame Assembly 12 1 2 x 43 1 2 5 6181
8. seo 06S9z st oW euoH Ajquiessy 9291 V99A 8191 V99A llewAeuoH seg 1 WALI VSN SNIVH L SVO V88A M3ldvQ0v NOISS3HdWOO 55 48 8 1 38n1 00 SLYVd MIVd33 NOILOAS Sv9cc8 19 9228 819228 0109228 9 8 21092428 11098228 109228 9009c28 409228 60009918 80009918 89209 82109 scs N 89109 89109 109 86005 4215 431108 88009 89005 V 7 1002 UeNIIIA UEUMSN 7 WOO Ue N UeuuMeN pejeouqn 9 EA 101 VL0 98S 0S 8 8 6 2 X ab 10 449 04 8 9A EA gyojnus 18 18 p VZL J297 19 18 JOJIIXe N 18 11 IOJIXEIA b Xab JOJMIXE A OM 0 9 X 0 Buds ped pis seo 06992 9291 V89A 8191 V99A seg 1 SV9 WYN VOVNVO SNIVH L SVO V88A 2 SLYWd MIVd33 NOILOAS 029228 619228 Sv9cc8 9 9228 819228 0109228 vL9Cc8 109228 9009228 409228 60009918 80009918 LHVd 92 1 1 4 1 9 9 9
9. SONIN3dO 1dN 0 034 NOILVENDIANOD 3 MH3AI3034 13315 1385 8 43108 M3NIVMIS I31NI 334 Alddns 4001 Wv3ls MO71483A 0 JHL OL 358 JHL 3AOOM3AO OL 3 8 LSAW 21 15 3511 3dld 83 1N3A 143191545415 138 9 SI 31VSN3QNOO 4 01 310N 4001 OL SNOILONYLSNI NOILVTIVLSNI III NOLLO3S 20 89208 8020S 54218 SNOILO3NNOO 13 6 9 SNOLLO3NNOO H3 1 08 84 991 Sls 4 139 1545 SNINV319 5 3014 OL 553338 d ST3NVd 13863 30 VAOW3M M pd 3834H31NI LON GINOHS 83 08 40 IV 4 8 8 13 H109 6108 NYHL 99009 54215 NOI LO3NNOO NOLLO3NNOO AlddNs L SNIdld Q3ON3WINOO3H V9L Sls WALSAS Alddns SNOILONYLSNI NOILVTIVLSNI 9345 21 SECTION INSTALLATION INSTRUCTIONS continued 1 Repairing system leaks to eliminate the need for WATER T CHILLER addition of make up water 2 Eliminating open tanks from the system HEATING 3 Eliminating and or repairing fittings which allow
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11. 599 38 NULLVNISWDO V 37199 NIHA 440 LAHS 001 11114 134 5 LNGLLINWSGINI JA WA 590 STLYWOLNY 80 3 0813313 8 1 938 38 58284 599 440 LNHS Y 1409 081138 LOTId NUILVOU 19 41 SVO 31 831 V y 053931 SWH IIOH AO LNONA 30IS 1437 3015 1437 NIVSL SYD 07 1031 6106 O4INVW v10S 590 GIOSINVW 4106 8005 NI 1006 1008 008 1006 9006 30 828 105 etos 206 SWWIIOH 40 SATIO AO HIIS 1108 0105 070 6005 Adis LATI 1 5005 5005 843708 ei 5 COJINVN 319NIS 1 106 0106 6006 01 8005 X IDHINYW 2008 ID3INVA 9005 7 1 4 e 800S 2006 9005 83 8 8 40 38 544 40 8389801803 FOIANAS NOLLO IS 68 SNOIIV2OT LO Tld 5 SWWIIOH 40 1 4 G ID dINVN 6108 G IDJINVN 2106 C ID3INVN 6106 G IDJINVW 105 2006 4005 2006 5005 3A WA WANN ANY 804 938 52 SV 09 DAL 399 1d392 TIM 3JA NA 599 4 38 NOILVNIGWOD V NIHA JA IVA SSD
12. 89005 99009 5 97009 Jeueg 1uBr4 Jeued 11014 9 86009 30014 190 88009 8 8411 043 82005 8 8411 044 190 89009 Jeueg 14014 98009 14014 J9 01 87009 Wall 00809808 92609808 0 CLELvOL LLELvOL OLELvOl 60619021 80 1 04 21061901 806709 10619802 09 c Lv09 L Lr09 LLOLELYO9 11606109 LL80 L709 11061909 902 709 LLSOELVO9 LLVOELVO9 OLOLELTOO 01 6081 709 OL80EL 709 017061709 07902 709 015061709 01706 709 5061709 O Lv09 9602 709 9802 709 92061709 9902 709 9902 709 98051 09 YIJANWNN 87 SECTION VI REPAIR PARTS continued TABLE 4F Water Trim Water Trim Carton Number 7W2 7WA Description 5006B 5011B 5012B 5022B 5024B 5026B PART NO Temperature Control Honeywell L4006A2015 1 1 1 80160400 Immersion Well Honeywell 123871A 3 4 1 1 1 80160452 Temperature Pressure Gauge 100 PSI 80 320 F 1 2 NPT 1 1 1 8056028 Relief Valve Piping Nipple 3 4 x 2 1 1 806600003 Nipple 1 x 2 1 806600004 Nipple 1 1 2 x 3 1 1 1 806600006 Bushing Hex 1 1 2 x 3 4 1 1 1 806600507 Elbow Reducing 1 1 2 x 3 4 x 90 1 1 806601506 Elbow Reducing 1 1 2 x 1 x 90 1 806601507 Relief Valve ConBraCo 10 303 10 3 4 x 3 4 50 psi
13. 1 vSOELVOL LZOELvO9 662 709 06 09 101709 80161909 86061909 802 709 61061909 2902 709 2902 709 2012 709 26061909 28061 09 cLOELvO9 2902 Lv09 9051809 87 709 21061709 9L Lv0Z 6011709 660 1709 68061 709 620 1709 69061 709 6908 09 8 84 29 99 8 27 LL 22 Lv 91 81 86 8 26 99109 49 Zp LL 22 81 Lv 41 91 81 82 46 97109 17 99 cv 21 Lb 22 9 8 9 61 81 19 21 91 81 82 9 22 86108 Zp LL 9 s 61 81 Lv 91 81 86 46 82108 49 zv 99 8 cv Zp 21 LL 22 s 9 8 s 81 61 8 81 19 21 41 91 91 91 81 46 12 8 81009 80109 3215 Y41104 49 LL s 81 91 81 46 86008 17 zv 99 LL LL g g 81 81 41 41 91 91 81 81 46 46 9800 82008 zv LL 81 41 91 81 46 88009 penois 91 2 10 9 91 6 06 91 11 84 1 09 L 8 6 66 91 8
14. INNYM 9NNOOli DAINO 523908 315 Hvid 1343 WOM TGNNYHO 19081 53440 138041 gt t PRES 153403 1 0 3 8324 1 9 7 M 5 1 8333 ROE AVIS ev NOLI 13wowr 7 dyt Tava 1330990 401 14081 921 305 INGNOSHA 083 45431 12 LIHI AK aor oo 834 SNOLLWOO 38 H TVL UNYA 3n8u53 TCGNW 538 2 ava wwo 20 335 9 53 5083 1292708 18404405 6 ONS RAW 01 gt gt JOS nnam RONY T9NYd 243 Hadar 7 38205 x 0 Ben NOUYTINGA 308 Eu NOuShneno S INIT PUSANI N umo wwwo NOUYYYISNI men 30 3 Bird LO 501 30S 1331 201 INOU T3Nvd 3 3 401 3025 TGN d SNOILONYLSNI NOILVTIVLSNI Ill NOLLO3S 24 SECTION INSTALLATION INSTRUCTIO
15. SNOLLVD07 1389 5 13 8 1382 401 WIS TIIV LAG 831833 LINT 401 3015 141 men 0 3 83108 13x5v 401 31 SNOLLONYLSNI 3IVIQ3WH3INI 1NON 138 1 3 8 SNI1IV83d0 E 13 4138 3 dOl 1 084 NOUSNENOD 3ivno30v P 0013 39NvHv310 378 5 8 63 JANIS AINO VOVNY2 13891 NOLIVTIVISNI NYIQYNYO AINO VOVNY2 138 1 39v110 TBNYd 13823 401 3015 49 8 6 16 NOILVTIVLSNI III NOLLO3S 3 8 401 3IVIQ3AH31NI 73Nvd 1332vr 401 29 1935 89205 ANY 09 Il3MOVf dO uonsnquioo 913 pue 40 jo eq 10 19 IOq JO 49 0 2091919 Nd 138Y1 SNINSVM ONINOO14 318 508 suoneJojied 088 3 9 TA d 1331 HINON 5 03438 1 4 M3MO1 1NONJ N3ddn 25 3 aun 0901 WYHNYNG AINO 583708 0 315 13X2v88 3i1vid 13A31 T3NVd LIOV 18044015 T3NVd 3185584433 153 01 31VIO3WH3INI 14084 AINO 583708 W3viS ome 13881 3 TANYA LINOVI
16. o NI UN ii 33 835 WAWININ AINO YVOYNY2 138 1 IMNOA o 13 LIH 7 3 SNOILONYLSNI 401 1NOMj SN PS M 9 8320 gt TBNVd 1 D 401 3015 1H9hi 508 31vn030v 13 312 318uSn8WO2 XINO 138 1 NOLVTVISNI NVIOVNYO 13 4 43 3 401 D TBNYd 139v 3 1331 83401 2 2081718 Nd 138 1 9NINNVM 2 9NINOO14 318uSn8W09 INO 583708 5 3ivid T3A31 H31VM TISISSINY3d 153 01 AINO 583108 Wv3ls 38 331VM 18300384 f 13 1431 43348 1404405 3 I 13 2 XIMON T3NVd 43838 2 638 N3MO1 ros M3NOS 3NIHOVN 48 x ze oid 3 1383 31VI03WH31NI 333 TaNVd 43 3 401 3015 1331 13 4 43 3 401 31VIQ3WH31NI 31 33 T3NVd 138 3 31VIQ3WH31NI AVIY 6 16 NOILVTIVLSNI Ill NOLLO3S 27 SECTION INSTALLATION INSTRUCTIONS continued 22 INSTALLATION OF TOP FRONT JACKET PANEL a Remove knockout for supply piping right or left for water boilers both knockouts for steam boilers refer to recommended boiler piping diagrams in this manual
17. 9 9 9 m 9 G G gr gr gr 23 8 8 Vy 9t e i L em 89209 82109 89109 89109 109 86005 8215 108 10 JA X SAL 0 989 06 ub 589 06 1 6 18 48 pepnjour vez Jeyur xee1 19 48 pepnjour OYZ Li 04 Jeyur xee1 ALX AL LAY ab X ab LOAM OM 0 ZL Buds enig LOH 101ejnBes seo ALX AL LAX OXE ab X ab LOAM IODIXelN OM 0 9 X O E Buds ped pis sed ZLLVEM U99 LLI AL ZOSVEM USD LLI ab 585 05 7 09 9 296 89206 990199067 Bune npoy 7 09 9 598 99209 8001 VZ90vA 01 2409 9 Buruedo 598 89209 LOOLWSSOPA SOAJ E A SJOJenjov OLOLESSOSA ZOOLESSOSA JoMOg 88009 89005 984 seo 1 20 9884 VSN SNIVH L SVO CINTA SLYWd MIVd33 NOILOAS 99958 9 9228 819268 0109228 9208 21092428 110
18. Ze 8 2 16 8 02 9 9 y 2 9 9709 01 21 22 92 8 2 ve 22 zz 12 02 61 81 2 62 91 91 v1 1 sod z LI sod z 11 6 8 2 06 y 2 0 82008 01 1 22 62 91 91 sodz 11 sod 2 LL 4 06 9 9 y 2 9 81208 01 21 22 92 8 95 vc 22 zz 12 02 61 81 2 62 91 91 v1 1 sod z LL sod z LL 6 2 06 9 8 s y 6 2 gozos 3ZIS 43 108 ui JOQUINN sejejes 81 u ur jequinN 89206 1441 89109 ST Vd 35 8 86 531835 S Vd MIVd33 NOILO3S 01 92 8 sc vc 22 zz 12 02 61 81 62 8 21 91 91 vi sod z LL 26 8 6 8 9 8 9 2 86108 01 92 sz 72 22 22 LZ 02 61 81 62 91 1 sod z LL sod 2 11 6 6 8 9 9 y 6 2 88109 01 21 01 01 zi 2 92 8 sc 92 82 ez 92 9 90 82 sz pz 72 22 22 22 22 12 02 02 61 61 81 8 62 21 62 91
19. peo pis J0je nDes sec U99 1 11 AL p 9 96 111 PlousjOS L 018 68 L SED 01 01 gros 86005 89006 89005 4218 Y41109 SVO VIVNVO NIVH L SVO JAVA INDVtHdVIG S LzIVd MIVd33 IA NOILOAS 029268 6192c8 Sv9cc8 9 9228 9 8 0109228 vL9Cc8 21092428 09208 21092428 9009c28 v6009918 18009918 08109918 6v 109918 LHVd 95 89209 82109 Ww av 89109 89109 8 JV WOOZ 8 7 INOOZ 9 1 1 HOINYS 10lld 9 JAM X AL 0 989 06 oOe1guoo 9 ab X ab 589 06 5 gyojnus 9 18 48 reve Ls lonixeN Jeyur xee1 9 19 48 pepnjour vOVZ Ls xee1 av AV X AL V8 Az av ab X ab LO AY IXEN OM O Z enig LOH seo 47 V8 Az Ionixe lN ab X ab LO AY IXEN OM 0 9 X O E Buds ped pis sed ZLLVEM U99 111 2 1 gt ZOSVEM USD LLI 1 7 09
20. 39 3 35 8 ATONIS SH3 108 gStL0S 1 89009 5311903587 4 3 4 35 8 8S 531935 9 318 1 119161819 116061819 19161819 691 21819 17911819 16081819 12601819 286061819 89109 19901819 119061819 59061819 7902 1819 89009 118161819 188061819 18161819 68161819 17911819 2802 1819 11802 1819 29802 1819 99109 SLYWd 43 NOILOAS A SSV ldnooouu u sseqng eseg 9 SSY ejdnooouueu A sseqns eseg 14674 svo SSY d3 sseqng eseg ejdnooouueu sseqng eseg 9 SSY A sseqns eseg SSY d3 Asseqns eseg 14614 ejdnooouueu M sseqns eseg 1uBr4 SSY 0 sseqns eseg yyy svo TWYNLVN 55 ejdnooouueu M Assy eseg svo SSY d3 M eseg ejdnooouueu M Ssy eseg 55 3 M Assy eseg l lduuoo svo TWYNLVN 82 SECTION VI REPAIR PARTS continued RIGHT SIDE TOP FRONT TOP JACKET PANEL JACKET PANEL CENTER INTERMEDIATE TOP JACKET PANEL FRONT INTERMEDIATE TOP JACKET PANEL REAR TOP JACKET PANEL e f 3 INTERMEDIATE VESTIBULE PANEL UPPER RIGHT END JACKET PANEL UPPER REAR JACKET PANEL
21. 552 229 25 lt gt gt gt 25 5900 5 Pat lt gt lt gt SXRD 25969 25 25 CX Q2 2 52552 lt lt 55 555525 55259 WASHER amp JAMNUT SECURE BOLT TO SECTION 55555205506 2500550 2525 555 552 CARRIAGE BOLT 2 2555 gt CARRIAGE BOLT Q 5 Remove material placed over burners and vacuum the FRONT OF BOILER following with care so as not to disturb base insulation SECTION MACHINE SCREW floor top of burners primary air opening in burners PANEL and primary air openings in pilot This will remove any FLUE COVER PLATE FLUE TO BOILER dust or lint that may have accumulated as well as any PLATE foreign matter that may have been dislodged during the FIG 52 cleaning of the flues ATTACHMENT OF FLUE COVERS CANOPY DRAFTHOOD VESTIBULE PANEL SIDE TOP JACKET PANELS REAR TOP JACKET PANEL FLUE COVER PLATE H Li y FLUE COVER PLATE 2 2 2 2 BURNER ACCESS PANEL 1 SOFT BRISTLE BRUSH STEEL BURNER FIG 53 66 CLEANING OF FLUEWAYS THIS PAGE LEFT BLANK INTENTIONALLY 67 SNOIIV2OT LO Tld L vS Sls ONY DLv 0932 3015 18918 NO Q3TWISNI 3 5 9 211 1 DAL JHL NIVAL 590 31 1 0 gt 33 438 TIM
22. ee FIG 48 V8944B COMBINATION VALVE b MINIMUM INPUT ADJUSTMENTS Lo Hi Lo MOTORIZED ACTUATOR V4062A On boilers equipped with Fluid Power Valves that have Lo Hi Lo Actuator Low Fire Adjustment should not be less than Minimum Input shown on Rating Plate 1 3 of full rated input Fig 49 shows the Limit Switch Cam and Scales to indicate direction to rotate cam for increasing or decreasing low fire input on the Honeywell V4062A Lo Hi Lo Actuator To adjust the low fire setting after the burners are the following procedure should be used 1 With power to actuator off remove the wiring compartment cover 2 Check to be sure the low fire adjustment is set at MAX to insure a safe light off Low fire adjustment is preset at factory in the MAX position 3 Disconnect the controller lead from terminal 4 on the actuator to keep the valve in the low fire position 4 Start the system and establish the main burner flame 5 Loosen the setscrew in the cam Fig 49 with the special wrench taped to inside of actuator cover Keep the wrench seated in the setscrew Rotate the cam slightly downward by moving the wrench toward the base of actuator to open bleed valve Actuator will start to close 6 When valve reaches desired low fire position quickly tighten setscrew and remove wrench If the desire low fire setting is missed merely lo
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24. GAS exert 2 8 4 s Nan WH SUPPLY ip HONEYWELL vasa OR a MAIN GAS VALVES 9 Al 4 Bulg Dw JUNCTION BOX T IGNITION amp kl e ME p o PK Y TRANSFORMER BK WH g maspas uu ass FAEERE 1 PILOT GAS x 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 2 ADDITIONAL LIMITS TEMPERATURE LOW WATER CUT OFF ETC SUPPLIED BY INSTALLER 3 ALL WIRING INCLUDING GROUNDING CONNECTIONS MUST COMPLY WITH NATIONAL ELECTRICAL CODE AND APPLICABLE LOCAL CODES GROUND CANADA ONLY WIRE CODE EP PANEL BK 5 BMGK SCHEMATIC DIAGRAM LEGEND COMPONENT GR GREEN 2 2 LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C 51 POWER SWITCH GY GRY LOW VOLTAGE SIZE 18 2 AWG TYPE CL2X STRANDED WIRE 105 C 52 GAS VALVE SWITCH GY WH GRAY WITH WHITE TRACE _ LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE PI PINK LINE VOLTAGE SIZE 18 AWG TYPE TW OR TEW AWM WIRE OR ORANGE GROUND SIZE 18 AWG SF 2 SEW 2 STRANDED CONTINENTAL SRGX600 200 C WIRE OR EQUAL FLAME ROD LEAD HONEYWELL 81298020 WIRE BKR BLACK RIBBED LETTERED DO NOT RUN CONDUIT WITH LINE VOLTAGE WIRING FIG 44 WIRING DIAGRAM 5006B THRU 5014B SECTION BOILERS 54 EP CONTROL SYSTEM YINWYOJSNYYL NOI
25. OFF E T We VALVE 2 TEE COMP MAXITROL REGULATOR ADAPTER HONEYWELL V88A b GAS VALVES NJ MANIFOLD DAAR COMPRESSION UNIONS MALE COMPRESSION ADAPTER lt gt BLEED VALVE ASSY 2 9 CANADA MANUAL REDLACES PILOT FIRING VALUE SHUT OFF VALVE MAL IRON TEE REMOVE FOR CANADA MALE COMP ADAPTER LUBRICATED PLUG COCK _REPLACES_ FIG 35 PILOT PIPING EP CONTROL SYSTEM 38 COMPRESSION NUT NOTE PILOT PIPING DUPLICATED ON WA ATTACHED SLEME 15 SECT AND LARGER BOILERS Ce SE 7 CANADA 5 COMPRESSION NUT W ATTACHED SLEEVE SECTION INSTALLATION INSTRUCTIONS continued 23 INSTALLATION OF IGNITION TRANSFORMER AND WIRING OF PILOT If space permits mount the ignition transformer on the Jacket above the Gas Train using four 8 x gt SMS Holes will have to be drilled for this purpose If space does not permit mounting the Ignition Transformer on the Jacket install the Ignition Transformer on a nearby wall Connect the two wires from the Q179C pilot to the RM7890 sub base as follows a Ground Wire 200 C to the 12 terminal b Flame detector wire Honeywell 1298020 to 11 terminal c Ignition Cable Honeywell 1061012 to the Secondary High Voltage terminal of the Ignition Transformer Run these wires to outside of Jacket on underside of manifold and secure in this pos
26. SEQUENCE OF OPERATION EP See Fig 45 b NORMAL OPERATION 5015B thru 5026B 1 When the operating control calls for heat terminal 6 of each RM7890A is energized 2 Acomponent check circuit in each RM7890A is activated which checks the electronic network of the relay 3 Terminals 8 and 10 of each RM7890A relay are energized Terminal 8 opens the pilot line solenoid valve supplying gas to the Q179C pilot Terminal 10 energizes ignition transformer creating electric spark ignition at the Q179C pilot 4 Flame rod circuit between each Q179C pilot and terminal 11 on its respective RM7890A proves presence of flame electronically at its Q179C pilot 5 Terminal 10 of each RM7890A and the ignition transformer connected to it is de energized 6 Terminal 9 on each RM7890A is energized supplying power to its respective main gas valves 7 Main gas valves open and main burners are ignited by the pilot flames 8 When the operating control is satisfied terminals 6 and all other terminals on both RM7890A relays are de energized The main gas valves and pilot valve for each gas train are closed and main burners and pilot burner flames are extinguished c SAFETY SHUTDOWN 1 SAFETY SWITCH CIRCUIT If limit control low water cut off or any other electrical safety switch opens power to terminal 6 and all other terminals on both RM7890A relays are interrupted de energizing the main gas valves and pilot va
27. VALVE COILS LIMIT OPERATING PILOT SAFETY LWCO CONTROL CONTROL SWITCH ur XM j i LADDER DIAGRAM LEGEND 24V INTERNAL WIRING 24V EXTERNAL WIRING 120 EXTERNAL 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 2 ALL WIRING INCLUDING GROUNDING CONNECTIONS MUST COMPLY WITH NATIONAL ELECTRIC CODE AND APPLICABLE LOCAL CODES WIRE CODE BK BLACK BK R BLACK RIBBED LETTERED BL BLUE WH WHITE YE YELLOW WIRING DIAGRAM 5006B THRU 5014B SECT BOILERS THERMOCOUPLE CONTROL SYSTEM CANADA ONLY SECTION IV OPERATION continued ITEMS SUPPLIED BY INSTALLER When the operating control A calls for heat it energizes the main gas valves B in both gas trains starting burner operation The burners will operate until the operating control is satisfied The high limit control C will stop burner operation in case of excessive steam pressure steam boiler or excessive boiler water temperature water boil er The low water cut off D will stop burner operation if the water level in the boiler drops below the low est safe level Should one of the pilot flames become extinguished the pilot safety switch E to which it is connected would shut off the gas supply to that pilot and to the main gas valves and burners it is serving 10096 shut off Operat
28. connected to main gas valve B prevents operation of the main burners in case the pilot flame becomes extinguished Pilot safety switch E provide for 100 shut off of gas supply L1 12 POWER 9 SUPPLY E z 120 60 1 Uu 2 gt 7 FUSED DISCONNECT 8 SWITCH 9 9 a amp BK WH 5 2 P e 4 2 SERVICE SWITCH HONEYWELL BK R E MAIN GAS VALVES 9 9 lt 2 JUNCTION BOX L Hod gt 16268 3 OPERATING CONTROL PILOT SAFETY SWITCH NOT FURN AS STD EQUIP 1 STEAM L404F 08 Eaua WATER L4006A BK wH BK BK R WATER CUT OFF 40VA STEAM M amp M 67 2 TRANSFORMER 11 WATER B4 BK V 55 L 8 8 iTo LIMIT CONTROL MANUAL RESET STEAM L4079B WATER L4006E IF USED SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE 105 C VOLTAGE SIZE 18 2 AWG POWER LIMITED CIRCUIT CABLE 105 LINE VOLTAGE SIZE 14 AWG TYPE TW OR TEW AWM WIRE 58 L1 12 120 60 1 SUPPLY FUSED DISCONNECT SWITCH PRIMARY 076 SERVICE TRANSFORMER SECONDARY b MAIN GAS
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30. 10 10 10 10 8201303 Low Base End to Right Section Fiberglass Rope 3 4 X 25 3 4 89208 89109 SLYYd 3Sv8 09 914 3 02 310H 2580 3935 WIIN L33HS ieiuna d p W s SM3HSVM SINN M SMIYIS 078 91 xo 1382 48 18404405 T3NVd DAP 31VIT3WH31NI 1NONJ 105 7BNYVd ON3 35 2 7 AIEMGSSY QIO3INYM SVD L3 0vu8 1014 260 XINYANG Tas 51081 403 433 03 33 13X9V 8 1014 6 0 HUM 3 8 6 0 13 1074 6 68 HUM N3NNnB 13315 13 3 88 1074 3 8 13315 5402 03345 92 55 JL x 1339V88 1804405 T3NVd Dit 31VIG3W3H3INI N3M01 SH3HSVW SINN M 583805 91 X 02 35 8 7BNVd 35 penunuoo SLYVd 3I Vd3sl IA NOILO3S 9 MAYIS 9NIddYl 3135 we PED TT 01 2 92 82 8 22 80 91 1 sod z LL sod z LL 6 Ze 8 2 9 Le 8 02 9 y 2 9 89208 01 1 82 9 22 92 vc 22 22 02 61 81 62 91 91 1 sodz 11 sod 2 11
31. 1VO 14 INZ9 V ANY 091 HO 5 ONILNNOW 82 2513 ONiddVL 1418 4015 LAAI U Ore 4131 Q3dld 38 GINOHS 138 31IVSN3QONOO 310N SM3HLIO Q3llddns NMOQMO18 OL HSN 44 1 NYNLIY 440 1002 YSLVM MOT M3TIOMINOO 29 MO 051 YITIW TIJNNOGON ON ONIddVL dOL l NYNL S3SSO Y l 5 E Ls am lt ONILSVO 1084144 55444 gt sons 3m 17071 114 NOILVTIVLSNI NOILO3S 32 SECTION INSTALLATION INSTRUCTIONS continued A Bottom Blowoff using a valve must also be connected to one of the return tappings The 52 Drain Valve may be used for Bottom Blowoff for 5009B or smaller boilers since any Bottom Blowoff piping or valves for 5009B or smaller boilers must be at least 4 Bottom Blowoff piping and valves for Boilers 5010B through 5021B must be at least 1 Bottom Blowoff piping and valves for 5022B Boilers and larger must be at least 174 g If boiler has been ordered with 3 8 try valve tapping install try cock h Install Lowest Permissible Water Level Plate and Frequent Water Addition Caution Label on upper left end jacket panel 1 Proceed directly to Paragraph 36 FIG 29 WATER TRIM AND CONTROLS 34 INST
32. 5010B THRU 5026B NAT GAS CANADA 5006B THRU 5026B NAT GAS 4 COMPLETION OF WIRING Connect power supply fused disconnect switch service switch primary side of transformer gas valves and remaining controls see Fig 40 41 or 42 for wire type and connections to be made All wiring must be adequately supported and strain relief provided All wiring including ground connections must comply with the requirements of the authority having jurisdiction and in the absence of such to the National Electrical Code ANSI NFPA No 70 2005 or the Canadian Electrical Code C22 1 whichever is applicable EP Control System 1 INSTALLATION OF EP PANEL Attach the EP Control Panel with RM7890 control see Fig 34 to the front top jacket panel preferably on the closest jacket panel to the gas train installed There are 3 three KO s and 4 four fastening holes provided for this purpose use 4 four 8 SMS to fasten the Control Panel to the front top jacket panel If Foot Mounted Transformer connect to J box using straight connector BX straight connector and 4 pipe nipple Drill holes in Jacket and fasten Transformer using SMS Install Honeywell RM7890 Control located in RM7890 Control Carton onto prewired sub base 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 Install Honeywell R7847 Flame Amplifier Ins
33. 54 2 69 Pilot Locations Fig 55 70 Main Burner Flame Adjustment Fig 56 70 Pilot Flame Honeywell Q3481B Fig 57 71 Pilot Flame Honeywell Q179C Pilot Fig 58 71 Pilot Flame Honeywell 27 Pilot w Thermocouple Section VI Repair Parts Fig 59 75 Base Parts 5006B Thru 5014B Fig 60 77 Base Parts 5015B Thru 5026B Fig 61 79 Integral Canopy Draft Hoods and Sections Fig 62 83 Jackets Robertshaw 90 7000DERHC Gas Train El 5006B Thru 5009B USA Gas Train 2 91 V88A Gas Train USA 92 V88A Gas Train Canada Natural Gas Only Gas Train oo 93 Fluid Power Gas Train USA Honeywell 94 Diaphragm Valve LO HI LO Gas Train USA Natural Gas Only Gas Train Honeywell 95 Diaphragm Valve LO HI LO Gas Train Canada Natural Gas Only Gas Train 96 Fluid Power Gas Train Canada APPENDIX A FIGURES continued APPENDIX A FIGURES continued Figure Number Page Number Description Section VI Repair Parts continued Honeywell Ignition Module Penn Johnson Control System Penn Pilot Solenoid Valve Ass y Maxitrol Pilot Reg Ass y Penn Pilot Solenoid Valve Ass y EP Control Ass y Honeywell Q3481 Pilot Ass y Honeywell Q179C Pilot Ass y Miscellaneous Figures 97 98 99 100 101 102 103 104 105 107 Ignition Module 58610 and Support Bracket Control System Pilotstat L62GB amp Support Bracket Thermocouple Control System Transformer
34. Fig 56 1 Use a round wire gauge to check spark gap 2 Spark gap should be 0 1 for optimum performance 090 MIN 140 MAX 3 8 E HEIGHT IGNITER SENSOR FIG 56 PILOT FLAME HONEYWELL Q3481B SECTION SERVICE continued The EP Control Systems utilize a Honeywell Q179C Flame Rectification Pilot Adjust pilot line regulator 5 5 WC in pilot line so that a medium hard center flame envelops flame rod see Fig 57 If flame is yellow primary air opening may be covered with dirt or lint This can be removed with a soft brush or by vacuuming The Thermocouple Control System utilizes a Honeywell Q327A non primary aerated pilot with a Q309A thermocouple Adjust pilot line regulator to give a steady flame enveloping 3 8 to 1 2 of the tip of the thermocouple see Fig 58 FLAME ROD CENTER FLAME PRIMARY AIR OPENING IGNITION ELECTRODE FIG 57 PILOT FLAME HONEYWELL Q179C PILOT 7 LOW WATER CUT OFF a Float Type Low Water Cut off During the heating season if an external low water cut off is on the boiler the blow off valve should be opened once a month use greater frequency where conditions warrant to flush out the sediment chamber so the device will be free to function properly Low water fuel cut offs and water feeders should be dismantled annually by qualified personnel to the extent necessary to insure freedom from obstructions and proper
35. Penn H91WG 5 Pilot Solenoid Valve and Pilot Line Regulator El Control System USA 5010B 5026B Natural Gas Canada 5006B 5026B Natural Gas Transformer and Pilot Line Regulator Thermocouple Control System Canada Transformer Penn H91WA 4 Pilot Solenoid Valve and Pilot Line Regulator EP Control System Control Assembly and Mounting Bracket EP Control Systems Control System Honeywell 03481 Pilot Assembly EP Control System Pilot Assembly Appendix A Figures 107 Number Number APPENDIX B TABLES Description Section Equipment Check List Section General Information Reference 10 Clearances for Boiler Room Space Section Ill Installation Instructions Table 34 Natural Gas Maximum Capacity of Piping in Cubic Feet of Gas Per Hour Table 34 Multipliers to be Used with Table when Pressure Drop is Not 0 3 WC Table III 34 Multipliers to be Used with Table when Specific Gravity Other than 0 60 Par 38 35 Installation of The Remainder of The Gas Controls Section IV Operation Par 1c 43 Reference Should Next be Made to The Applicable Control System Table IV 44 Water Content Gallons 5006B Thru 5026B Models Par 3 45 Control Variations Flow Chart 51 Trouble Shooting Guide Boilers Equipped With S8610M Intermittent Electronic Ignition Par 5b 60 Additional Check on Input Section V Service RCF 65 Important Product Safety Information Refractory Ceramic Fiber Product Form 73 Se
36. Regulators EP Control Panel ta ee teca eie e ced 102 Pilot ASSernblies 103 104 All Series 5B 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 888 791 3790 or Fax 717 293 5803 97109 89009 61 3Sv8 6S Old NOLIVAH3SBO 63 35 9NIddVL 35 x oz 4 A1BW3SSV Q104INYW SVD NGYOS 138 133 5 X ih Algwmassv 3 653229 3 8 S10M1NOO 31d4n000WN3HI 1338 1014 860 N3NHn8 Ras 51081 2 433 33 1383 8 2 10114 6 10 HUM N3NNh8 73315 Wo S10M1NOO 13 13 8 1014 GD L66n N3NNnB 13315 13 3 8 1014 791 Nid dno 3835 3135 13 4 QN3 35 8 NOLLVINSN T3NVd ONI 35 8 H9IH 03345 vo SS fl x 14004405 T3NVd 1 084 SM3HSVM SINN SMIYIS INIH VW oH 91 8 x oz A18W3SSV 33 45 35 8 MGMOS 9NIHOVLIV
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38. 16 16 16 16 16 16 16 16 16 8221306 50068 Manifold 1 Pd E 1 07 8221307 5007B Manifold 17 8221308 5008 Manifold 17 8221309 5009B Manifold 17 8221310 5010 Manifold 17 8221311 5011B Manifold 17 8221312 50128 Manifold 17 8821313 5013B Manifold 17 8221314 5014B Manifold 17 8231301 Main Burners without Pilot Bracket 18 18 18 18 18 18 18 18 18 8231302 Or Main Burners w J991 Pilot Bracket El Controls 19 19 19 19 19 19 19 19 19 8231303 Or Main Burners w Q179 Pilot Bkt EP Controls 20 20 20 20 20 20 20 20 20 8231304 Or Main Burners w Q327 Pilot Bkt Thermocouple Controls 21 21 21 21 21 21 21 21 21 822628 Main Gas Orifices Nat Gas 40 Drill 22 22 22 22 22 22 22 22 22 822629 Or Main Gas Orifices LP 55 Drill 23 23 23 23 23 23 23 23 23 822604 Hitch Pin Clip 24 24 24 24 24 24 24 24 24 61813062 5006B Burner Access Panel Assembly 7 1 4 x 26 15 16 25 25 amp 26 25 61813072 5007B Burner Access Panel Assembly 7 1 4 x 32 3 8 25 26 25 amp 26 25 61813082 5008B Burner Access Panel Assembly 7 1 4 x 37 13 16 25 26 61813092 5009B Burner Access Panel Assembly 7 1 4 x 43 1 4 25 61813102 5010B Burner Access Panel Assembly 7 1 4 48 11 16 25 7186001 Observation Hole Cover 12 12 12 12 12 12 12 12 12 80860900 1 4 20 Wing Nut 10 10 10 10 10
39. 331VM 18300384 1 083 GNYd 138 3 1431 18044 5 13 4 yos SIVIISPRIUNI SV38 N3MO1 ST3NVd ONY 1NON3 30 NOILVTWISNI T3Nvd x V TIVLAG 1NOMN4 34 2 T3NYd 1383 P I3NNVHO 33M01 Es BON Gd 221 T3NYd 8301 3 a 1NON3 83801 X ed Ense d 13382 v ON3 H108 T 1342v88 LNOddhs 3 3 QN3 09 J9v8 13NOVT N34O1 4315 5 28 4315 3825 3NIHOVM S x ze oid BNYd 1342 TGNVd 834 083 83 3NNVH2 T3NVd T3NNVH 16 25 83001 324 8 1 335 7T3NYd 13 13 2w 8333 13 13 2wn ONJ N3ddh 7GNYd 413 2 13 13 9vr 1395vr dOl 1NOMJ 901 305 401 5 0 138v1 TIVLAG TaNVd DINGUSIA 31V1033 31NI LDV 401 3015 1331 138 1 43708 73Nvd 3 13 4383 401 31VIQ3A831NI 1NONJ3 o REGLA EE 5 0815 1 T3NVd 13 3 401 3IN32 TaNvd 13 3 NOLLSNENOD SOL 3NVd 13999 34
40. 4 Note if High Base End Panel is at right end of Base section assembly must start with Right End Section Left end sections are identified by LEH cast on section Right End Sections are identified by REH cast on section CLEAN NIPPLES AND NIPPLE PORTS thoroughly with a de greasing solvent Use the Loctite 592 supplied to lubricate the nipples and nipple ports Apply the lubricant to the nipples and nipple ports then use a brush to disperse it evenly around the nipples and the nipple ports Use approximately 25 ml of Loctite 592 per flueway 1 7 and 2 3 nipples and their 6 corresponding nipple ports Use Nipple Gauge furnished follow instructions included with gauge to set nipples USE ALL PRECAUTIONS TO AVOID COCKED NIPPLES PAINT ALL GROUND SURFACES of each section with the Sealer Compound furnished ASSEMBLE CENTER SECTIONS Refer to Fig 6 for proper location of Tapped and sometimes plugged 11 SECTION INSTALLATION INSTRUCTIONS continued UPPER SHIPPING STRIP LOWER REAR INTERMEDIATE JACKET PANEL SUPPORT BRACKET RIGHT LOWER SHIPPING SUBASSEMBLY ANGLE FRONT INTERMEDIATE JACKET PANEL SUPPORT BRACKET 1 4 20 x 3 4 HEX HD MACH SCREWS WITH NUTS AND WASHERS FRONT INTERMEDIATE JACKET PANEL SUPPORT BRACKET 1 4 20 x 3 4 HEX HD MACH SCREWS WITH NUTS AND WASHERS LEFT SUBASSEMBLY REMOVE LOWER SHIPPING ANGLE AND UPPER SHIPPING STRIP FROM BOT
41. Adaptor 8136038 Heyco Strain Relief Bushing SR 6P 4 99 SECTION VI REPAIR PARTS continued 1 2 CONDUIT COUPLING 1 2 STRAIGHT 1 2 FLEXIBLE CONDUIT CONNECTORS 1 4 0 D ALUMINUM TUBING FROM PILOT VALVE 1 4 0 0 TUBE X 1 8 COMPRESSION ADAPTER 1 8 M P T X CLOSE PIPE NIPPLE 1 4 O D TUBE X 1 8 M P T COMPRESSION ADAPTER 1 4 O D ALUMINUM TUBING TO PILOT BURNER TRANSFORMER amp PILOT LINE REGULATOR THERMOCOUPLE CONTROL SYSTEM CANADA PART NO ITEM 1 J Box Mounting Bracket 24V 40 VA Transformer 120 60HZ Primary 80160039 2A USA Honeywell Plate Mounted AT140D1012 80160014 2B Canada Honeywell Foot Mounted AT72D1089 3 Pilot Line Regulator Nat Gas Maxitrol RV 12 LT w orange spring 4 to 8 WC 7016001 8226005 100 SECTION VI REPAIR PARTS continued bs 1 2 CONDUIT COUPLING 1 2 STRAIGHT CONNECTORS N 1 2 FLEXIBLE CONDUIT 1 2 CONDUIT LOCKNUT 4 X 4 JUNCTION BOX 1 2 INSULATING BUSHING 1 2 CONDUIT LOCKNUT me 2 2 PLACES 1 2 X 1 1 2 LG CONDUIT NIPPLE 1 4 O D ALUMINUM TUBING E 1 4 O D TUBE X 1 4 M P S BRASS COMPRESSION NUT W ATTACHED SLEEVE e Sete FROM PILOT VALVE 1 4 0 0 TUBE X 1 8 BRASS COMPRESSION ADAPTER NE 1 4 O D TUBE X 1 8 M P T BRASS COMPRESSION ADAPTER 3 s M P T PIP
42. INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF NECESSARY IF PROBLEM PERSISTS REPLACE MODULE CHECK FOR 24 VAC ACROSS PV MVIPV TERMINALS ON MODULE IF NO VOLTAGE REPLACE MODULE NO CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL IF OKAY REPLACE GAS CONTROL NOTE IF MODULE GOES INTO RETRY DELAY RESET THE CALL FOR HEAT 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 ADJUST PILOT FLAME IF CHECKS ARE OKAY REPLACE MODULE CALL FOR HEAT ENDS CHECK FOR PROPER THERMOSTAT CONTROLLER OPERATION REMOVE MV LEAD AT MODULE IF VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL REPEAT PROCEDURE UNTIL TROUBLE FREE OPERATION IS OBTAINED 52 SECTION IV OPERATION continued EP CONTROL SYSTEM 5006B thru 50148 The EP Control System utilizes an RM7890A Relay Module and a Q179C Rectification Pilot which in addition to a pilot burner and rectifying flame rod flame detector to prove pilot includes an ignition electrode for spark ignition of the pilot A Webster 612 6A7 Transformer supplies the high voltage spark potential Once pilot flame continues as long as there is a call for heat in
43. MANIFOLD 5 5 50068 section thru 50148 section boilers require single base assembly see Fig 2 b 5015B section thru 5026B section boilers require a left and a right base subassembly see Fig 3 Remove Base Assembly s From Skid s c Remove bolts securing Base Assembly s to shipping skid s and place Base s in location where Boiler is to be installed d Join Base Sub assemblies together 15 section amp larger boilers by first removing upper shipping strip and lower shipping angles from subassemblies Use 4 27 20 x 34 MS nuts and washers to attach subassemblies see Fig 3 e Attach Front Intermediate Jacket Panel Support Bracket and Lower Rear Intermediate Panel Support Bracket to lower channel on Front Base Frame and Rear Base Frame respectively using 4 47 20 54 MSS nuts and washers f Base must be level in both directions and secure on the floor Shim and grout under Base if necessary g Place cardboard covering over the top of the burner assembly to protect them during the assembly of the boiler sections CLEAN BOILER SECTIONS inside and out to remove dirt due to shipment and handling Open Tie Rod Bundle s Open Draw up Rod Bundle s Open Boiler Assembly Carton s SET LEFT END SECTION ON BASE so that locating lugs on bottom of section go inside Front and Rear Base Frames Slide section on base until these lugs strike High Base End Panel at left end of Base see Fig
44. Since 8 terminal in the Relay Module is de energized at end of safety switch timing a solenoid valve in the pilot line will close and thus 100 shut off is achieved 53 SECTION IV OPERATION continued OMIT 24V TRANS amp V88A GAS VALVES HON V4055A GAS VALVE ACTUATOR 1 01 2 lt souenon VALVE Lo o TERMINALS IN TERMINAL STRIP EP PANEL BURNHAM EP PANEL EP NATURAL OPTIONAL USA amp CANADA oo 2 POWER FUSED OR 07800 SUPPLY DISCONNECT SERVICE SUB BASE 120 60 1 SWITCH SWITCH L1 63 2 9 69 GROUNDING ITEMS SUPPLIED LUG BY INSTALLER 62 8 of L W C O STEAM M amp M 67 BC 2 S warER 64 LIMIT CONTROL 9 BI MANUAL RESET STEAM 140798 WATER L4006E BK TERMINAL STRIP IF USED 003 ERMINAL S x FLAME ROD OPERATING CONTROL NOT FURNISHED AS STD EQUIP L IGNITION STEAM L404F i ELECTRODE WATER L4006A RD x HON Q179C 40VA PILOT TRANSFORMER X AS UD e ee TO PILOT
45. Supply Connections 5021B Thru 5026B Section Boilers Fig 15 20 Typical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit Fig 16A 21 Recommended Water Boiler Piping 1 Supply Connection and 1 Return Connection Sizes 5006B Thru 5019B Section Boilers Fig 168 21 Recommended Water Boiler Piping 3 Supply Connections and Two Return Connections Sizes 5020B Thru 5026B Section Boilers Fig 17 22 Recommended Boiler Piping for Combination Heating and Cooling Systems Fig 18 22 Installation of Jacket Support Brackets to Base End Panels Fig 19 23 Installation of Jacket End Panels Fig 20 23 Vestibule Attachment Diagram Fig 21 24 Exploded View of Jacket 5006B Thru 5010B Section Boilers Fig 22 25 Securing of Canopy Draft Hood Fig 23 26 Canopy Draft Hood Mounting Diagram Fig 24 27 Exploded View of Jacket 5011B Thru 5019B Section Boilers Fig 25 29 Exploded View of Jacket 5020B Thru 5022B Section Boilers Fig 26 30 Exploded View of Jacket 5024B and 5026B Section Boilers Fig 27 31 Steam Trim and Controls Fig 28 32 Mounting Elevations of M amp M 150 and a 67M Float Fig 29 33 Water Trim and Controls Fig 30 34 Recommended Piping to Built in Tankless Heaters Fig 31 36 Installation of S8610M Module Fig 32 36 Pilot Piping El Control System Robertshaw7000 USA 5006B Thru 50098 Fig 33 37 Pilot Piping El Control System V88A USA 5010B Thru 5026B Nat Gas Canada 5006B Thru 5026B Nat Gas Fig 34 38 Ins
46. V88 Gas Train only Using OD aluminum tubing connect the inlet of the pilot solenoid valve to the pilot valve installed in the manual shut off valve in the Gas Train Using 5 aluminum tubing complete installation to Pilot Burner see Fig 33 V88 Gas Train only INSTALLATION OF BLEED PIPING V88 Gas Train only Using 4 OD aluminum tubing install a bleed line on both diaphragm gas valves connect together and on USA boilers run tubing to bleed line protruding from inside base see Fig 33 On boilers installed in Canada run bleed line to outdoors INSTALLATION AND WIRING OF 58610 IGNITION CONTROL MODULE Using two 10 32 x 2 MS and nuts install the S8610M module bracket on the manifold just to the right of the main burner ROBERTSAW 7000DERHC GAS VALVE IGNITION ELECTRODE FLAME SENSING LEAD MANIFOLD MODULE SUPPORT BRACKET HONEYWELL IGNITION MODULE 6 X SHEET METAL SCREWS 10 32 X 2 MACHINE SCREWS WITH NUTS INSTALLATION OF 8610M MODULE with pilot see Fig 31 Using two 6 x SMS install the S8610M module on the bracket Connect the two wires from the Q3481B pilot to the S8610M module as shown on Fig 40 41 or 42 a Ground Wire 200 C to BNR GND terminal b Ignition Sensor Wire to Spark terminal Secure these wires to Pilot Piping with Wire Tie to provide strain relief Using wiring harness furnished connect leads with push on terminals
47. VESTIBULE PANEL JACKET PANEL UPPER REAR INTERMEDIATE LOWER JACKET END PANEL SUPPORT BRACKET BOTH ENDS LOWER RIGHT END JACKET PANEL FRONT INTERMEDIATE JACKET PANEL O UPPER FRONT JACKET PANEL TO LOWER FRONT JACKET PANEL LEFT TO RIGHT CHANNELS FRONT amp REAR LOWER LEFT ENO JACKET PANEL UPPER LEFT END JACKET PANEL LOWER REAR JACKET PANEL JACKET PANEL FIG 62 JACKETS 83 ve Le vc 9 62 01 Zp 6 89109 ve 1 ze 16 20 vc 01 22 6 9 9 109 ve 8 Ze Le 82 8 2 vc 8 22 OL 29 6 e 8 1 86109 ve v1 16 82 19 2 9 82108 66 ve 8 16 22 82 8 72 22 vc 8 22 OL 17 6 1 819 91109 90108 3215 108 84 814 ui Qu JequinN sejejes 9 46 1 ul Ul jequinN S L Vd MI Vd33 NOILOAS 22 22 9 86009 99 22 12 z 9 9 88009 82008 6 22 z 9 89008 S13MOVf 8S 531935 318v C L EG X X 8 9 X cl V vc 91 9 26 X VIE LE X
48. and open drain valve in return main Fill boiler to normal water level turn on burner and operate boiler A Steam Boilers 1 Oil greases amp sediments which accumulate in a new boiler and piping must be removed in order to prevent an unsteady water line and carry over of the water into the supply main above boiler Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler If the condensate can temporarily be at this water level for at least 30 minutes after the condensate begins to run hot then turn off burner Close all radiator valves Remove all supply main air valves and plug the openings in supply main 43 SECTION IV OPERATION continued b Draw about 5 gallons of hot water from same manner as litmus paper except that it gives boiler into a container and dissolve into it the specific readings A color chart on the side of appropriate amount of a recommended boilout the small hydrion dispenser gives the reading in compound Remove safety valve from boiler pH Hydrion paper is inexpensive and obtainable and pour this solution into boiler then reinstall from any chemical supply house or through your safety valve local druggist The pH should be in accordance c Turn on burner and keep operating while feeding to Minimum Water Quality Requirements chart water to boiler slowly This will raise water below Add some washout chemicals caustic soda level in b
49. and return connections are tapped and plugged section is paint stencilled CXP CARTONS PACKAGES OR BUNDLES Base Burner Manifold Assembly By Gas and By Pilot System One Left amp One Right Req d on 5015B and Larger Boilers 1 1 1 1 1 1 1 9 10 11 12 13 14 L L L L L 15 15 15 15 15 15 16 17 19 R R R R R 15 15 15 15 15 8 9 9 10 zes One to Five Per Boiler ss eer poe 22 12 54 ICE RENT RI 2 res preset 3 Sizes One to Th 1 COMPLETE 6 7 8 1 L SUB BASE 18 A o Em N R SUB BASE EN o 10 Uu 2 NIN NIN 1 1 wo 79 1 5 c 2 374 497 674 3A Boiler Assembly Ca 3A6 7 3A8 3A9 3A10 3AM 2 EE o s 6 Sizes One to Five Per Boiler EE gt o 3 L A Uv W Q x Draft Hood C m Integ to rton s 5 Sizes One to Four P Boiler Natural amp LP SECTION 1 EQUIPMENT CHECK LIST c
50. and seated on Base a After section assembly is completed install 5 8 tie rods from tie rod bundle through the upper lug holes in the front of Boiler and Lower lug holes in the rear of Boiler sections and tighten until they are finger tight only to allow for expansion This is necessary in order to allow clearance for installation of Flue cover plates Finally remove 54 draw up rods from nipple ports FIG 7 PURPOSE OF TAPPINGS AND THEIR LOCATIONS PURPOSE OF TAPPINGS Steam Boilers Water Boilers Supply Supply J Return 4 4 2 Pressure Operating Control Temperature Operating Control less heater Bushed to 1 4 Bushed to 3 4 EMS with heater 1 12 7 PressreGage Tiy Cock Special Order __ lt 1 Cover Plate Cover Plate or Tankless Heater 4 1 2 Indirect Water Heater Supply or Return Indirect Water Heater Limit 1 Tappings on both end sections are identical Recommend trim be installed in left end section or on same end as gas train This tapping is used for safety valve and surface blowoff steam boilers and safety relief valve water boilers on end not equipped with trim 3 Temperature operating control location on tankless heater equipped boilers Also alternate operating control location tapped cover plate f using a float type LWCO feeder or pump controller on a steam boiler that does not use quick connect hook up fitt
51. as possible to c Determine type of space chimney so that vent connection is short and direct Divide Volume by Total Input of all appliances in space If the result is greater than or equal to ADANGER 50 82 1000 Btu per hour then it is considered an Boiler must not be installed directly on unconfined space combustible flooring A concrete pad is not If the result is less than 50 ft 1000 Btu per hour sufficient to protect combustible flooring then the space is considered a confined space The boiler shall be installed such that the gas ignition d For boiler located in an unconfined space of a system components are protected from water dripping conventionally constructed building the fresh spraying rain etc during boiler operation and service air infiltration through cracks around windows circulator replacement control replacement etc and doors normally provides adequate air for Do not install boiler where gasoline or other flammable vapors or liquids sources of hydrocarbons i e e For boiler located in a confined space or an bleachers cleaners chemicals sprays paint removers unconfined space in a building of unusually tight fabric softeners etc are used or stored construction provide outdoor air with the use of two permanent openings which communicate Refer to table below for minimum clearances service directly or by duct with the outdoors or spaces clearances and clearances
52. as the boiler must be off Water Manometer or water column gauge should be connected to a shut off valve installed in the 1 8 pipe tapping in each manifold boiler off By installing gas valve upstream of manometer gas pressure can be introduced gradually without shut off valve surge of pressure when boiler is turned on could blow liquid out of manometer LP Gas Input a Adjust Gas Train Regulator s so that manifold pressure 18 ten 10 inches water column Turning Regulator Adjusting Screw Clockwise increases pressure Counterclockwise rotation decreases pressure If boiler is equipped with two manifolds 5015B thru 5026B pressure in each must be equal 5 Natural Gas Input a Approximate Input Adjust Gas Train Regulator s so that manifold pressure is three and a half 352 inches from water column Turning Regulator Adjusting Screw Clockwise increases pressure Counterclockwise rotation decreases pressure If boiler is equipped with two manifolds pressure in each must be equal If more accurate check on input is necessary see b below For minor input changes readjust Gas Train Regulator s to increase or decrease manifold pressure to obtain corresponding increase or decrease in gas input If it is necessary to increase manifold pressure more than 0 3 of water to obtain rated input remove orifices and drill one size larger Reinstall and recheck input rate b wm Additional Check on Input
53. b Attach Top Front Jacket Panel to left and right end Jacket Panel and to Top Flange on the Vestibule Panel using 8 SMS See Fig 24 23 INSTALLATION OF LEFT AND RIGHT TOP SIDE JACKET PANEL a Remove knockout right or left only if needed See Fig 7 for purpose of tappings secure top side panels to upper end panels with 8 SMS 24 INSTALL KNOBS on the four remaining panels using 10 32 x 3 16 MS 25 INSTALL UPPER FRONT LOWER FRONT UPPER REAR AND LOWER REAR PANELS using procedure described in detail of Fig 25 CAUTION Panel with louvers must be at front of boiler for ventilation of vestibule Panel with perforations must be at front of boiler for ventilation and combustion air 26 TIGHTEN ALL SHEET METAL SCREWS 27 INSTALL THE FOLLOWING PLATES OR LABELS which are found in the Instruction Envelope See Fig 21 or 24 for location 1 Rating Label 2 Operating Instruction Plate 8 SMS required to fasten Combustible Clearance Flooring amp Adequate Combustion Plate G 4 Minimum Service Clearance Label self adhesive 5 Burnham Logo self adhesive Apply to Top Panel 6 Boiler Ventilation For Your Safety Label Apply to Top Panel 7 Proceed to Paragraph 33 Steam Boilers or Paragraph 34 Water Boilers COMPLETION OF JACKET INSTALLATION 5011B THRU 5026B SECTION BOILERS 28 PARAGRAPHS 1 THRU 4 HAVE ALREADY BEEN COMPLETED Refer to Paragraph 16 for installati
54. claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows Service Charge as a 96 of Retail Price 1 12131415161718191 10 __________ 100 Stainless Steel f No Charge 20 40 60 80 100 NOTE If the heat exchanger involved is no longer available due to product obsolescence or redesign the value used to establish the retail price will be the published price as set forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger whichever is greater ADDITIONAL TERMS AND CONDITIONS 1 Applicability The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to boilers parts or accessories designated as commercial grade by Burnham Commercial and installed and used exclusively for purposes of commercial space heating or domestic hot water generation through a heat exchanger or a combination for such purposes and do not apply to residential grade products or industrial uses 2 Components Manufactured by Others Upon expiration of the one year limited warranty on commercial grade boilers all boiler components other than
55. for removal of Tankless Heaters crawl or attic freely communicating with the outdoors Locate one opening within 12 inches of 3 PROVIDE COMBUSTION AND VENTILATION top of space Locate remaining opening within 12 AIR inches of bottom of space Minimum dimension In the USA refer to National Fuel Gas Code NFPA of air opening is 3 inches Size each opening per 54 ANSI Z223 Section 5 3 Air for Combustion and following Ventilation In Canada refer to Natural Gas Installation 1 Direct communication with outdoors Minimum Code CAN CSA B149 1 latest edition or Propane free area of 1 square inch per 4 000 Btu per hour Installation Code CAN CSA B 149 2 latest edition input of all equipment in space Local code provisions may apply and should be 2 Vertical ducts Minimum free are of 1 square referenced inch per 4 000 Btu per hour input of all CLEARANCES From Table below and from dimensional data in Fig 1 determine BOILER ROOM space necessary for appropriate access to and servicing of Boiler Consideration should be given to other appliances installed in the same area Consult with local Building and Safety Codes for compliance MINIMUM CLEARANCE JACKET TO RECOMMENDED 202422 ee COMBUSTIBLE CONSTRUCTION SERVICE CLEARANCE TO TANKLESS HEATER NON COMBUSTIBLE CONSTRUCTION Left Side 24 61 18 Controls 32 Right Side 24 61 18 Controls 36 Cleaning Top 24 61 cm SECTION GENER
56. heat exchangers manufactured by others but furnished by Burnham Commercial such as oil burner circulator and controls will be subject only to tho manufacturer s warranty if any 3 Proper Installation The warranties extended by Burnham Commercial are conditioned upon the installation of the commercial grade boiler parts and accessories in strict compliance with Bumham Commercial installabon instructions Burnham Commercial specifically disclaims kability of any kind caused by or relating to improper installation 4 Proper Use and Maintenance The warranties extended by Burnham Commercial conditioned upon the use of the commercial grade boiler parts and accessories for its intended purposes and its maintenance accordance with Burnham Commercial recommendations and hydronics industry standards For proper installation use and maintenance soo all applicable sections of the Installation and Operating and Service Instructions Manual furnished with the unit 5 This warranty does not cover the foliowing a Expenses for removal or reinstallation The owner will be responsible for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from Burnham Commercial b Components that are part of the heating system but were not furnished by Burnham Commercial as part of the commercial boiler improper burner adjustment control settings care or
57. maintenance This warranty cannot be considered 85 a guarantee of workmanship of an installer connected with the installation of the Burnham Commercial boiler or imposing on Burnham Commercial liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed Pub BCL1109041 Boilers parts or accessories installed outside the 48 contiguous United States the State of Alaska and Canada f Damage to the boiler and or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction manual 0 Any damage or failure of the boiler resulting from hard water scale buildup or corrosion the heat exchanger h Any damage caused by improper fuels fuel additives or contaminated combustion air that may cause fireside corrosion and or clogging of the burner or heat exchanger i Any damage resulting from combustion air contaminated with particulate which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles dirt and dust particulate j Any damage defects or malfunctions resulting from improper operation maintenance misuse abuse accident negligence including but not limited to operation with insufficient water flow improper water level improper water chemistry or damage from freezing k Any damage cau
58. must be properly vented and connected to an approved vent system in good condition Do not operate boiler with the absence of an approved vent system This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting and air intake systems must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency This boiler is supplied with controls 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 is designed to burn natural and or LP gas only Do not use gasoline crankcase drainings or any oil containing gasoline Never burn garbage or paper in this boiler Do not convert to any solid fuel i e wood coal All flammable debris rags paper wood scraps etc should be kept clear of the boiler at all times Keep the boiler area clean and free of fire hazards Float type low water cutof
59. on S8610M module as shown in Fig 40 41 or 42 Run harness outside of jacket on underside of manifold and secure in this position with Wire Ties furnished Connect the six wires in the harness to the specified controls as shown in Fig 40 41 or 42 FLAME SENSING PROBE PILOT BURNER PILOT BRACKET IGNITION ELECTRODE LEAD MANIFOLC COMPRESSION UNION PILOT PIPING CONTROL SYSTEM Robertshaw7000 U S A 5006B THRU 5009B SECTION INSTALLATION INSTRUCTIONS continued COMPRESSION NUI W ATTACHED SLEEVE TUBING PILOT VALVE MANUAL SHUT OFF VALVE MAXITROL REGULATOR HONEYWELL V88A GAS VALVES MALE COMPRESSION ADAPTER BLEED VALVE ASSY MANUAL M SHUT OFF gt VALVE GENS 1 REPLACES M LUBRICATED PLUG COCK N P4 bac MALE COMPRESSION ADAPTERS 12 REGULATOR L REMOVE FOR CANADA COMP NUTS W ATTACHED SLEEVES BLEED LINE USA SHOWN CANADA VENT TO OUTDOORS IGNITION ELECTRODE SENSING PROBE PILOT BURNER PILOT BRACKET _ FLAME SENSING LEAD j _ IGNITION ELECTRODE LEAD 2 gt gt MANIFOLD COMPRESSION UNIONS COMPRESSION NUT W ATTACHED SLEEVE 1 PILOT FIRING VALUE MAL IRON TEE MALE COMP ADAPTER PILOT PIPING CONTROL SYSTEM V88A U S A
60. or by vacuuming b Loss of pilot gas may be due to faulty pilot solenoid valve improper wiring loose connections or low voltage c Loss of signal from sensing probe may be faulty probe improper or loose electrical connection or faulty Ignition Control CAUTION Be sure power is off when checking high voltage connections For S8610M Trouble Shooting Guide see Page 51 TWNINYSL 31000091 2 00 3MIM 81 3215 0098985 VIN3NIINOO MOSN3S M31IN9I 1 NO ML 3215 39 110 86009 NYHL 99009 77570 JAVA SVD 0002MVHS 1H380 WALSAS TOHLINOO I3 INVHOVIG O9ILVIN3HOS 9 2 501 318 2 Y3MOd 2 81 3ZIS 39VLIOA 2 501 030 15 WMV MAL 3dAL 81 3ZIS 39 1 0 89 OLLVWNHOS NMOHS SV Q3103NNOO Q3liddns 01314 AVi3H Q3MIM 38 LSNW SIVLSOWYSHL Q31VH3dO S ALIOVdVO 21 15 3 3AVH LSAW IVLSOWYSHL 3HL JONLNOD ONILVYSdO 40 NI 0350 SI LWLSOWYSHL LIOA 72 V 41 ANWA SV9 MVHS133803 ATIVN331NI Q3193NNOO 33V 310GON NI v SGNNOYD 11 753003 1 201 318 3 1 4 3003 21 19313 TWNOILVN A1dWOO 5 SNOLLOJNNOO ONIGNNOND ONISIM 4N
61. or its representative the parts claimed to be defective and if requested by Burnham Commercial to ship these parts prepaid to Burnham Commercial at the above address for inspection or repair In addition the owner agrees to make reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Commercial Boilers Burnham Commercial P O Box 3939 Lancaster PA 17604 Revised November 1 2009
62. peeH 99898 67 9 X 26 01 QL L BE X 8 G ZE X L 91 6 20 91 9 04 8 2 9 X 91 240 9 91 6 06 QL S L X 9 QL EL VL X 8 QL EL VL X 8 X B L 9 QL EL SS X v 8 0S X v X v C L GE X v QL L VE X 8 S 8C X v 91 6 60 X 91 11 48 X GZ v L 0S X Sc 9L b p X 95 8 6 66 X Sc 91 91 66 X SC 2 V 8c X X 55 21 01 X 9 92 x 95 9WV 8v X Z L 6 8 S CV X 211 6 QL LE X 2 1 6 VIE LE X 1 6 9 6 92 X 2 1 6 8 2 02 X 2 1 6 3ZIS 9198 ootulq sqoux Jouueuo 34 0 828 1 0 22 y iy 0 928 1uB 0 497 028 Jouueuo y iy 0 6188 Iy iH 0 497 91 y iy 0 9 21 Iy iy 0 914 14014 Hoddng jeueg 49 0 dol epis 14674 Jeued doy epis jaued dol 1684 80109 dol 1684 86009 jaued dol 88006 dol 82009 jaued dol 459 89009 dol 89009 dol 97009 40106 86009 88009 9 54 92006
63. preferably at the start of the heating season to remove soot and scale The inside of the combustion chamber should also be cleaned and inspected at the same time Have Burner and Controls checked at least once a year or as may be necessitated Do not operate unit with jumpered or absent controls or safety devices Do not operate unit if any control switch component or device has been subject to water NWARNING Appliance materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this 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 This appliance
64. to lubricate MAIN BURNER FLAMES Main Burner Flames should be checked at initial start up annually thereafter or after flueway cleaning or after an extended shutdown period Main Burner Flame should have a clearly defined inner cone see Fig 55 with no yellow tipping Orange yellow streaks caused by dust should not be confused with true yellow tipping Yellow tipping indicates a lack of primary air and normally can be corrected by opening the air shutter Improper alignment of burner on orifice will also affect primary air injection INCANDESCENT OUTER MANTLE BLUE WITH OCCASIONAL ORANGE FLASHING OUTER CONE DARKER TRANSPARENT BLUE INNER CONE SHARPLY OUTLINED WITH BRIGHT LIGHT BLUE FLAME RETENTION INNER CONE PARTIALLY LIFTED FROM BURNER FIG 55 MAIN BURNER FLAME ADJUSTMENT 6 PILOT FLAME Pilot Flame should be checked at initial start up annually thereafter or after flueway cleaning or after an extended shutdown period The EI Control System utilizes a Honeywell Q3481B pilot Flame should be adjusted by means of the pilot line regulator 5 5 WC pilot line press so that a medium hard center flame envelopes approximately 3 8 of the end of the sensing probe see Fig 56 If flame is yellow primary air slot may be covered with dirt or lint This can be removed with a soft brush or by vacuuming a To adjust or check spark gap between electrode and hood on Honeywell Q3481B intermittent pilot See
65. 012B 5020B 50218 50268 PART NO 1 1 1 N 1 1 1 0 N 1 1 1 N 1 1 1 0 N 80160942 8056022 8056019 806600006 806601506 806601507 806601508 806601547 81660500 81660501 81660505 81660503 806602503 806604501 8066030006 806601509 806600040 806603504 806603506 806603510 806603517 8141307 89 SECTION VI REPAIR PARTS continued 7000DERHC GAS TRAIN El 5006B THRU 5009B USA PART NO ITEM 81660151 Robertshaw 7000DERHC S7C 1 x 1 Gas Valve Nat 1 OR 81660158 Robertshaw 7000DERHC LP S7C 1 1 Gas Valve LP 1 806604002 1 Ground Joint Union 2 806600027 1 x3 Lg Nipple 3 90 1 1 2 3 BOILER SIZE 50068 5007 50088 1 1 3 5009 1 1 3 To 89209 82109 ge 89 09 89105 9 9 m 9 s m i ae ve z 2 9 106 86006 88009 89005 5 58 108 X AL 10 989 049 28 8 0 ab 589 06 928 8 03 gyojnugs 18 18 ve VZ Lit JO gIXe N Jeyur xee1 19 18 vOv Z Lit IOnIXEN Jer xee1 JA X AL 18 IXEN ab X ab 1974 OM 021 63 8 9 enig LOH seo X AL 18 IXEN abX ab 1974 OM 0 9 x 0 53514 ped pis
66. 1 66 L QL EL VL X 8 QL EL VL X 8 8 1 9 X vc QL EL GG X v 8 0S X v 9L S l t X Z L GE X v QL L VE X v 8 9 82 X v 9L SS X GZ v V 0S X GZ 9L l t X GZ 8 6 66 X GZ QL SL X GZ 860 X GZ 91 4 1 96 c L OL X 9 x 985 C L EG X C L 6 X C L 6 8 9 X C L 6 QL E LE X C L 6 VIE LE X C L 6 91 9 92 X Z L 6 3ZIS 48 6 67 9 X ZE OL MOIS 9LS COW sqouy 346 81 8 1 6 4 0 9 118 146 0 9 918 Jeuueu 146 018 146 68 146 88 Jeuueu 146 2 Jeuueu 146 01381 9 pued dol epis 19814 8 dol epis Jeued lnqns A eyeipeuuegul eueg dol 80109 joued dol 4999 86009 eued dol 88005 joued dol 1684 8 009 eued dol 89005 Jeued dol 99009 5 59 80105 86009 445 88005 92009 e nqaseA 89005 I8ued 4 5 99009 I ueq Pig uoddng jeueg pu3 Jeued 14 Jeued doy 90109 Jeueg dol 1901 86008 5 84 dol 88008 Jeueg dol 87009 Jeueg dol 89009 Jeued dol
67. 1 81660302 Relief Valve ConBraCo 10 614 10 3 4 x 1 50 psi 1 81660359 Relief Valve ConBraCo 10 615 10 1 x 1 1 4 50 psi 1 81660362 Plug extra tappings Plug Pipe 3 4 Countersunk 3 3 3 806603504 Plug Pipe 1 1 2 Countersunk 2 2 2 806603506 Plug Pipe 1 2 Countersunk 5 5 5 806603510 Plug Pipe 1 Countersunk 2 2 2 806603517 SECTION VI REPAIR PARTS continued Steam Trim Carton Number Description Pressuretrol Honeywell L404F 1060 Steam Gauge 4 Dia 30 0 30 PSI 1 4 Gauge Glass Set Conbraco 20 104 10 624 Safety Valve Piping Nipple 172 x 3 Black Elbow Reducing 172 x 54 x 90 Elbow Reducing 172 x 1 x 90 Elbow Reducing 172 x 174 x 90 Elbow 172 x 90 Safety Valve ConBraCo 13 211 08 32 15 psi Safety Valve ConBraCo 13 202 08 1 x 1 15 psi Safety Valve ConBraCo 13 213 08 174 x 1 15 psi Safety Valve Conbraco 13 214 08 155 x 2 15 psi Miscellaneous Fittings Coupling Reducing 72 x Mount Syphon Extension Adapter FPT x gt MPT Mount Gauge Glass Syphon 74 x 90 Mount Pressuretrol Elbow street 77 x 90 Mount Syphon Nipple 72 x Close Mount Syphon Plug Extra Tappings Plug Pipe 34 Countersunk Plug Pipe 172 Countersunk Plug Pipe Countersunk Plug Pipe 1 Countersunk Lowest Permissible Water Level Plate TABLE 4G Steam Trim 751 752 753 754 5006B 5008B 5009B 5011B 5
68. 113063 61113073 61113083 61113093 61113103 61113063 61113073 61113083 61113093 61113103 61113063 61113073 61113083 61113093 61113103 61113063 61113073 61113083 61113093 61113103 TABLE 3A Canopy Draft Hood No 5006B 1 5007B 2 5008B 3 5009B 4 5010B 5 5006B 1 5007B 2 5008B 3 5009B 4 5010B 5 5006B 1 5007B 2 5008B 3 5009B 4 5010B 5 5006B 1 5007B 2 5008B 3 5009B 4 5010B 5 SERIES 5B INTEGRAL CANOPY DRAFT HOODS BOILER SIZES BOILER SIZE QUANTITY 5006B 5007B 1 5011B 5012B 2 1 1 5016B 5017B 5021B 5022B 1 1 2 5009B 5014B 5019B 2 5026B 5010B 1 5015B 5020B 3 6 6 2 9 1 9 61 81 9 9 9 gozos arcos 42208 2 9 9 9 9 9 91 91 9 9 9 gozos 86105 88105 9 9 9 9 9 9 9 9 9 9 9 9 v1 LL OL 6 8 8 2 9 g 7 9 9 9 9 9 9 9 9 9 9 9 9 82 09 89 04 985 09 advlOS gelos 42109 glos 90109 46006 98009 82009 89009 4215 Y37108 L9 0 IHVHO IN3A39V Id33 NOILO3S 85 531445 ge 318V1 S L3 Vd Vd33 NOILOAS 052 2668 3 jueouqn 09 269 6941907 3ueouqn ejddiN 4 6 addin pedde 49 9 pebBnig 10N pedde uo
69. 209 NYHL 89109 SNOILLO3NNOO AlddNs NYNLAY ALIAVHO9 3 08 INV3LS Q33N3AINOO3H L Old 3ZIS WNWININ TVWHON 82 NVHL 5531 LON OL S NIVN AlddNS 30 LNIOd 13 S ON3 3 08 1NIOd H9IH NMOG 34015 S NIVN AlddNS uzos 10 1NOMJ W3LSAS 08 ONIHSM4 9Md LNO NVI1D 803 JANIWA 30 084 HUM 331 43108 OL NMOG HOlld N30133 13 W31SAS iu d 3 ONidid 034N34334d E ONidld 1 NOILOSNNOO NYALIN AG 3AWA 31 9 3 m p 277 3AWA 2 1 44 38019 alvo hs 31ddlN 80 3 0 5 3 30 9 NIHLIM NO 35010 OL 3ONVHOSIO 3414 INN OL 831114 3 08 4337 319NV Sb V MO ATIVOLLNSA 10 401 440 3381 OL S NIVW AIddNS H31VA TVWHON 3AO08V 76 WOWININ 330Vv3H W3LSAS MCN SNOILONYLSNI NOLLV TIVAISNI III NOILO3S 18 89208 NYHL 81209 SNOLLO3NNOO AlddNS S HO ALIAVYD ONIdld INV31S Q330N3AINOO3H vl Sls i zi Liz 9 26 12 3 e gagne SH3SlH AlddNS 3Ad 325 3dld WNWININ N31VM TVWHON 3AO8V 82 NVHL SS31 LON OL S NIVN AlddNS JO 1 04
70. 3 VSN ees 89206 85109 Spjoyluew fend x 9687 ZL 4 Ob 2 2 056 0 8 8 zv 8 awo zv sor _ 2 0 0 6 a 0186 eri 2 c 2 89209 garzos 92209 SHHONI NI SNOISNAWIC 9 164 SI TANSSIA ONDRIOM WANIXYN 831IOS WVALS 8205 164 OS 41168444 ONDPIOA 80209 NDISHG WAWIXVW WHIVA 96109 88109 CINDINIXVIA 82109 SVO dT 4610 NAHL 85105 90105 98005 NAHL 89009 OMS 897109 89206 NAHL 90205 86 08 89109 NAHL 91105 96005 92109 S S 8109 CIAQINTXVIN SOLOS SV5 TVUNLVN E 98005 SUATION 89706 NAHL 95105 7 2 onze veo sese azos SUATION 48105 82105 1 vt 89009 39 38 HH IOS JO LHOT3 OL sss ESES oja V 5 JO AN4 LAAT wem senno eni MD ds 40 NO NOLIV2O NIVUL SVO ATONIS jo 23 e10 8 SUATION 106 NAHL 89006 T 529 Jees pue pue ezis 44 eq yeyoer TILON A ddng 901 OT N IM Eu 3 e
71. 3101 5010B Base Front and Rear Frame Assembly 12 1 2 x 48 15 16 5 80861601 Burner Access Panel Attaching Screw 7 7 7 7 7 7 7 7 7 6181301 Base Spacer Assembly 11 22 3 4 8 8 8 8 71813062 500685 Base Rear Panel 9 5 8 x 26 15 16 9 71813072 5007 Base Rear Panel 9 5 8 x 32 3 8 9 71813082 5008 Base Rear Panel 9 5 8 x 37 13 16 9 71813092 5009B Base Rear Panel 9 5 8 x 43 1 4 9 71813102 5010 Base Rear Panel 9 5 8 x 48 11 16 9 71813112 5011B Base Rear Panel 9 5 8 x 54 1 8 9 71813122 5012 Base Rear Panel 9 5 8 x 59 9 16 9 71813132 5013B Base Rear Panel 9 5 8 x 65 9 71813142 5014 Base Rear Panel 9 5 8 x 70 7 16 9 72013065 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 26 15 16 11 1 pc 72013075 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 32 3 8 11 1 pc 72013085 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 18 7 8 11 2 pes 72013095 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 21 5 8 11 2 pcs 72013105 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 24 5 16 11 2 pcs 72013115 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 29 3 4 11 2 pcs 72013125 Base Rear Panel Insulation 1 Supertemp 8 3 4 x 35 3 16 7181312 Front Int Panel Support Bracket 13 13 13 13 7181313 Lower Rear Int Panel Support Bracket 14 14 14 14 7181302 Low Base End Panel 11 7 8 x 25 3 4 15 15 15 15 15 15 15 15 V 7201320 Low Base End Panel Insul 1 Supertemp 11 3 8 x 21 1 2
72. 311 04 8 4 938 33055339 599 JA WA 449 4 5 X NUILVOD Nival 599 1 824 Vx N393 I 05 0106 CIOsINVW 106 ID3INVN 0105 CIDJINYW 6106 12 0106 1 2106 0105 2008 4006 0106 2006 5005 Fj 2206 X 1205 0208 G ID JINVA 0105 0106 CO 1 0106 G ID JINVA 6006 0105 0106 3415 NO 1311 1 lt 0106 6005 65841108 NIval 599 31 NOILVOO1 12114 GIO3INVN 330 LAKHS 4001 10 Id 13495 NDILINDI LN3LLIWSSLNI OIND3I2313 31dnnonWa3Hi O SHWIIOH 40 SHWIIOH 40 4015 LAHT Adis 183518 03 IOHWAS 40114 11041 6008 C7O4INVW 6006 01 6005 41 8006 jC IOAINVW 8005 G IDJINVW 8006 6006 6005 6005 800 8006 800 3 1105 9105 5106 SHWIIOH 40 AVAAN 8389801803 FOIANAS NOLLO IS 69 10 SECTION V SERVICE continued If Burners must be removed use the following procedure a Mark location on manifold of all burners with pilots b Using a pair of pliers remove hitch pin clips shaped like a hairpin from groove in main burner orifices SAVE ALL CLIPS c Remove all burners without pilots by lift
73. 3IVAInO3 SLI HO NMOHS SV 3 38 LSAW 32 133 38 ISAW 5 SV 3 IWNIDINO JHL JO ANY 3l L ANADAI WV4SVI WOL98S Ave 2 Muvds SNIMIM S9NIMIM APZ SSLLON 9 e 1014 OL XILINI 1014 01 00001 1 380 8 O ML FINGON WOL98S Ad AN MOTIJA ang 31IHM x 80 Ave 49 anig 18 a 000 e vas HM Alddns Svo 401 m ag 9 1014 12 x ABVONOO3S ro zx HOLMS 5 193NNOOSIQ 03504 1 09 01 Alddns W3MOd 21 035 4 390091 31 864077 3 5 13538 V NVN O
74. 4 JO eq j snu 555 sos AINO 5531108 3 5 31 18 13A31 N31VM 31815514134 153 01 5 08840994 Jeued einqnsaA jo uonejnuaA 10 19 IOq JO 3UOJJ 49 0 9 54 43 2 8 1 04405 13NYd 30603 834 LNOYS 73NYd 138 31VI03NH31NI 1 083 gt KINO 583 08 13 15 13881 3 1N3n0333 13 13 2wf BON QN3 1331 33ddn 4282 8 15099015 T3NVd 2 4 14383 513 4 1NOMJ 40 NOILYTIVLSNI T3NVd 132 3010388318 AVIY XIMON 1NONJ Y3ddn V 140 3 4 1383 7 33M01 M3MOT 3 3ovid 8 335 NY3N 83 0 FINBUS3A 3 D 4 83 8380 3 83 4 m d ON3 438 3 01 sona H108 1349749 LYOddNS T3NVd ONJ 1383 301 gt 455 qox 3 39d 13 28 TANVd 3 83440 N NGNOS 3NIHO VW 1N0H3 asa x ze oid 8 53 31VIG3WS31NI JSNNVHO if 9315 N3401 1 GNvd 132 319103 H31NI 1 838 8344 13 1383 083 IHIH 8344 3 4 413828 3 4 432 T3NYd 43 3 401 INONJ 401 305 401 8938 43 2
75. 5 psig INSTRUCTIONS continued FIG 9 TESTING BOILER ASSEMBLY FOR LEAKS 2 HOT WATER BOILERS The assembled boiler must be subjected to a hydrostatic test of 75 psig to 85 psig Z WARNING Failure to properly hydrotest all boilers at the correct pressure may result in section assembly failure in operation 11 12 EXAMINE BOILER CAREFULLY INSIDE AND OUTSIDE to insure against leaks from cocked nipples or through concealed breakage caused in shipping and handling This precaution is for your protection and will simplify handling of necessary replacements and adjustment claims After making certain that there are no leaks drain boiler and remove plugs for boiler trim and other connections Open Boiler Sealing Carton SEAL BETWEEN BOILER SECTIONS AND BASE see Fig 10 a Push 32 braided ceramic fibre Rope furnished into gap between bottom of End Section and Low Base End Panel until rope touches Front and Rear Base Frames Place the 1 1 2 x 2 x 5 8 steel spacers between low base panel and section and in front of rope align holes Secure section to low base end panel with 3 8 16 x 2 Cap Screws washers and nuts b Secure opposite end section to high base end panel with 3 8 16 x 2 Cap Screws washers and nuts c Apply Furnace Cement to gaps between section assembly and base to make gas tight seal d Check all joints between Boiler sections and use remaining Furnace Cement or Sealer Co
76. 6009 Jeay J9 07 88009 581 Jeay 190 008 J9 07 89009 Jeueg ees 1 99009 Jeueg 89005 Jeueg seay 86009 I8ueq 1894 88009 I8ueq 1894 Jedd 82009 seay 89009 I8ueq 89005 joued 97009 dol 4998 14 dol Jeuegd dol 10014 5 84 dol 14014 80108 jaued dol 11014 96009 jaued dol 88009 jaued dol 11014 92009 8 8 dol 89009 Jeueg dol 146014 89009 Jeueg dol 146014 gr00S Wall 0 4 1202 0 1702 TVOEVVOZ VZ0 Lv09 6c Lv09 V O Lv09 0 09 09 60 Lv09 68061709 81061909 2902 709 2902 709 9 260 709 2802 709 21061909 2902 709 24061909 cvO LvO9 8061 09 14261909 91610902 60LELVO9 6602 Lv09 680 1709 61061909 690 1709 68061909 6702 709 8 lHVd 86 49 99 rp sv 8 cv 21 52 12 8 61 81 02 91 SL 86 46 09 89509 87061709 80061709 861709 ON Lad vv 8 sv 29 Lv 21 22 2 8 9 9 oz 8 61 91 91 89 09 89509 09 80061709 92209 8611709 91209 88161709 3218 8 ON Tove 49 49 9
77. 8 30 ONINCOTS 8 3 8 5 8 03 3214935 GNYd 1383 AINO 2 401 3 RINO YOYNV2 38 15 NYIQVNVO 138 1 39 1 0 3 13307 401 306 19 8 6 16 NOILVTIVLSNI Ill NOLLO3S 30 SECTION INSTALLATION INSTRUCTIONS continued 32 TIGHTEN ALL SHEET METAL SCREWS types of Low Water Cut Offs and Low Water Cut a Install the following plates or labels which are found Off amp Feeder combinations Fig 28 illustrates the in the Instruction Envelope See Fig 25 or 26 for required mounting elevations for a M amp M 150 and a location 67M float LWCO Fig 15 illustrates a typical steam i Rating Label piping arrangement for pumped return systems ating Labe 2 Operating Instruction Plate 8 SMS required to fasten c Install Gauge Glass Fittings into ends of tees used to connect the 67BC 2 or 47 2 Control If other control is furnished install Gauge Glass Fitting 3 Combustible Clearance Flooring amp Adequate directly into 14 pipe extensions Combustion Plate d Install Pressure Limit Controls as follows 1 Boiler equipped with 67BC 2 Low Water Cut Off Connect Pressure Limit furnished to 1 4 street ell and 4 pigtail siphon For installation of second pressure limit not furnished
78. 81 gi sod y 11 21 62 8 21 91 91 91 SL v1 1 sod 11 sod 2 LL 8 6 Ze 8 4 6 26 8 6 8 8 2 9 8 s 9 9 9 8 s y y 9 6 6 9 9 9 82108 89108 88108 9 sod y 11 X VIL EV QL EL LE X 1 2 8 6 66 X 91 91 92 X 2 9L EL 44 X edid 2 1 1 8 X edid 2 1 1 94 91 99 X edid 2 1 1 Z L L9 x edid 2 1 1 9 96 edid 2 1 1 8 9 08 X edid 2 1 1 9L G X edid X B E LL VIE GC 8 1 11 91 6 86 X 8 v 6c X 8 9 9 X 8 8 9 12 X 8 8 X 8 8 E CE X 8 QL SL 9 X 6 8 91 2 02 X 8 9 6 99 8 9 6 91 6 69 X 8 9 6 8 L vS X 8 9 6 X 8 6 6 X 8 9 6 QL EL LE X 8 9 6 6 22 LL 2 1 01 21 6 X clic 91 1 86 2 1 21 8 9 2 1 21 9 6 14 X ele 21125441 v e Sc X 2 1 21 3ZIS LuWd INN Bum OZ 19 02 698 uoneajesqo A quiassy jeued sseooy 49 8 80109 A quiassy 54 19 86009 A quiassy jeued 49 8 88009 quiessy sseooy 1euing 82005 A quiassy jeued sseooy 49 8 89009 898 41 seoguo seo 10 0 585 555 581 0 4 349 20 4 Z O
79. 890A may be the cause but items 1 thru 5 should be followed first Refer also to RM7890A relay literature furnished with the control d By referring to the Sequence of Operations step by step operation of the system can be controlled and the cause of pilot failure can be readily found After the cause of pilot failure has been corrected resume normal operation by following the Lighting Instructions 3 SHUTDOWN INSTRUCTIONS a Close manual shut off valves and pilot valves b Turn off main electric switch SECTION IV OPERATION continued THERMOCOUPLE CONTROL SYSTEM Canada Only The 5006B thru 5014B boilers are equipped with a Thermocouple Control System that utilizes a constant burning Q327A pilot a Q309 thermocouple and a L62GB 3C Pilot Safety Switch The Q309 thermocouple proves pilot flame and in the absence of such will cool and within 45 to 90 seconds will cause the L62GB 3C Pilot Safety Switch to which it is connected to break the electrical circuit to the main gas valves as well as shut off the flow of gas to the pilot Thus 100 shut off is achieved The 5015B thru 5024B boilers utilize two Thermocouple Control Systems that are interconnected electrically thru all operating and safety controls Should any of the aforementioned controls break the power supply circuit both Thermocouple Control Systems would be de energized The proceeding paragraph describes the function and operation of each The
80. 9 99 v v 29 019 Ly 21 21 21 zz zz 2 2 9 9 9 8 9 02 02 81 6 61 81 91 91 91 St 66 66 46 86 8 26 82208 91209 80509 80405 86105 88105 3218 S13M2Vf 313 ldWOO Av ATEVL 29 Ly 20 2 22 2 02 81 61 91 SL 66 ze 86 4215 Ou JequinN 9 81 ui jequinN S13MOVFf 8S 539435 qr 318 1 SLYWd NOILOAS 27 99 8 19 9 9 6 8 91 SL 2 81161919 8918 709 8918 709 Lad 2 99 zv v zv Ly 21 2 52 9 9 9 8 61 81 91 81 19 82 46 86109 88109 82109 89109 898109 3215 giog 87161709 86161 709 8612 709 Lad 49 27 97 99 8 27 29 Ly 21 zy 52 52 9 8 s 9 0 61 8 81 61 8 5 091 94 91 SL 8 26 86 92109 89108 89109 8111709 86109 801 61 709 82108 8602 Lv09 3215 a108 814409 80109 86009 3218 88061909 88009 81402 709 87005 8902 709 89009 3zis
81. 92628 21092428 9009228 98009918 88009918 1009918 81009918 21009918 11009918 01009918 93 89109 2 2 2 9 EA X VL0 98S 0S 02848402 9 9 hb X 710 695 069 03848 03 12987 u9S LLI AL L9vv8x 99 111 Sec um L 1 019 68 L L SED o1 IH 01 89109 86009 89005 IN3 LI 4215 X41109 SVO VSN NIVH L SVO OT IH O 1 JAVA INDVHHdVIG SLYWd MIVd33 NOILOAS Sv9cc8 9 9228 819228 16009918 18009918 08109918 6v 109918 LNVd 94 89209 82109 89109 89109 1 WOOZ ub INOOZ 9 9 eqni qO X LdNA 8 6 X AL 10 989 04 8 8 02 S ub X ub VL0 S8S 0S 92 848 00 v ve vz L r 9 Li 7 XA IXEN ab LO AY IO 0IXEIA 071 99 Buds enig 401e nBes sec 47 DAE XA IXEN ab LO AY lonixe lN OM 0 9 X 0 Buuds
82. 9926 xli 020 0 80 0790 0970 0855 9805 9681 0211 959 2 expo ala 89109 88109 alslale 21 99 8 1 19 6 44 s pes 2 Eus EZ e x 886 seze e lt e lt 09 SECTION GENERAL INFORMATION BOILER INSTALLATION must conform to the WARNING requirements of the authority having jurisdiction or in the absence of such requirements to USA National Fuel Gas Code ANSI Z223 1 When required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers No CSD 1 a Determine volume of space boiler room Rooms communicating directly with the space in which the appliances are installed through openings not furnished with doors are considered a part of the space CANADA Installation Codes for Natural and E Propane Gas Burning Appliances and Equipment Volume ft Length ft x Width ft x Height ft CAN CSA B149 1 or 2 b Determine total input of all appliances in the space DO NOT INSTALL THIS BOILER ON CARPETING Add inputs of all appliances in the space and round the result to the nearest 1000 Btu per hour 2 BOILER LOCATION locate on a level NON COMBUSTIBLE FLOOR as close
83. A Elec Ign Q179C 1 H91WA 4 2 V88A CONTROL TYPE OF GAS VALVES OPTIONAL MAIN REFERENCE SYSTEM PILOT PILOT MAIN VALVES PAGE 5006B 5009B USA EI Elec Ign 1 7000DERHC S7C 47 MODEL A 1 Honeywell V5055B Motorized Gas Valve with V4055A V4062A V9055A Actuator and 1 ITT K3A Solenoid Valve 120V B 1 Honeywell V8944B Combination Gas Valve and 1 ITT K3A Solenoid Valve 24V To be used with 1 H91WA 4 Pilot Valve 120V To be used with 1 H91WG 6 Pilot Valve 24V NOTE 1 For Steam or Water 2 For 24V Thermostat Application Wire S861OM Relay in Place of Operating Control Set Thermostat Heat Anticipator at 0 4 Amp See Pages 47 48 and 49 3 All Battery Operated Thermostats must be Electrically Isolated From the Primary Circuit by an Isolating Relay 45 SECTION IV OPERATION continued 4 EI CONTROL SYSTEM The EI control system utilizes a solid state 1gnition control which lights the pilot burner by spark Pilot gas is ignited and burns during each running cycle intermittent electric pilot Main burner and pilot gas are extinguished during the cycle This system permits the main gas valves Robertshaw7000 for 5006B thru 5009B 2 V88A s for 5010B thru 5014B to open and the pilot line gas valve to remain open only when the Pilot Burner is proven to be lit Should a loss of flame occur the main valve closes and the spark reoccurs within 0 8 second The i
84. AL INFORMATION continued equipment in space Duct cross sectional area shall be same as opening free area 3 Horizontal ducts Minimum free area of 1 square inch per 2 000 Btu per hour input of all equipment in space Duct cross sectional area shall be same as opening free area Alternate method for boiler located within confined space Use indoor air if two permanent openings communicate directly with additional space s of sufficient volume such that combined volume of all spaces meet criteria for unconfined space Size each opening for minimum free area of 1 square inch per 1 000 Btu per hour input of all equipment in spaces but not less than 100 square inches 4 LOUVERS AND GRILLES of Ventilation Ducts All outside openings should be screened and louvered Screens used should not be smaller than 1 4 inch mesh Louvers will prevent the entrance of rain and snow a Free area requirements need to consider the blocking effect of louvers grilles or screens protecting the openings If the free area of the louver or grille 18 not known assume wood louvers have 20 25 percent free area and metal louvers and grilles have 60 75 percent free area b Louvers and grilles must be fixed in the open position or interlocked with the equipment to open automatically during equipment operation SECTION INSTALLATION INSTRUCTIONS SUPPORT BRACKET FIG 2 SINGLE MANIFOLD BASE 5006B THRU 5014B SECTION BOILERS BASE BURNER
85. ALL WATER TRIM AND CONTROLS see Fig 7 and 29 a Temperature Gauge is to be installed with gt nipple and x reducing coupling in tapping provided in upper corner of End Section On boilers with Built in Tankless Heater install operating control in 54 tapping in Heater Plate plug tapping in Second Heater when supplied On boilers equipped for forced circulation hot water heating without domestic hot water a reverse acting circulator control may be needed to prevent condensation of flue gases during periods of low boiler water temperature This control can be installed in the Tapped Heater Opening Cover Plate TANKLESS HEATER PERFORMANCE Tankless heater ratings in Series 5B boilers are based on continuous draw temperature rise of 100 F 40 140 F and boiler water temperature of 200 F Some of the items affecting the coil performance are as follows 1 FLOW REGULATION If flow through the heater is greater than its rating the supply of adequate hot water may not be able to keep up with the demand For this reason a FLOW REGULATOR matching the heater rating should be installed in the cold water line to the heater FLUSHING OF HEATER All water contains some sediment which settles on the inside of the coil Consequently the heater should be periodically back washed This is accomplished by installing hose bibs as illustrated in Fig 30 and allowing water at city pressure to run into
86. ANEL TO UPPER END PANELS using 8 SMS Refer to Fig 21 INSTALLATION OF CANOPY DRAFT HOOD 5006B thru 5010B Section Boilers see Fig 22 Place Cerafelt strips on top of section assembly next to ledges formed by center sections and next to ledge on end sections Overlap at corners SECURE CANOPY DRAFT HOOD with 5 16 18 x 5 8 MS driven into the tapped lugs provided for this purpose on top of the sections Two screws are required at each end Refer to Fig 23 WASHER amp JAMNUT TO SECURE BOLT TO SECTION CARRIAGE BOLT FRONT OF BOILER SECTION FLUE COVER PLATE INSULATION FIG 19 INSTALLATION OF JACKET END PANELS FIG 20 VESTIBULE ATTACHMENT DIAGRAM FLUE COVER PLATE FIBERGLASS INSULATION VESTIBULE PANEL WASHER amp NUT TC SECURE COVER TO BOILER HEX COUPLING ATTACHED TO END OF CARRIAGE BOLT MACHINE SCREW TO SECURE VESTIBULE PANEL TO BOILER 23 5 NOILO3S 801098 NYHL 89005 4 AO Le 313 S 3Nvd ONY 1NOM4 NOUYTIVISNI SNOLNBO dE 3H LiWOVT 839621 ko 3 iia SNM HOT f 8351 77 T Nya ON 1437 es E Avii 1 d SN 83440 2 i Mapa 1 9 4365 1 T3NNTHO WMO Nd
87. D MOUNTING BRACKET EP CONTROL SYSTEMS 1 4 O D ALUM TUBING SECTION VI REPAIR PARTS continued 103704 01 100332 01 6136054 6137375 8236015 8236016 8236048 EI CONTROL SYSTEM HONEYWELL Q3481 PILOT ASSEMBLY EI CONTROL SYSTEM PILOT ASSEMBLY 6236072 1 50068 5009B Sections 6236075 EI 1 LP 50068 50098 Sections 6236076 El 2 NAT 50108 5026B Sections Not Available LP 5010B 5026B Sections ITEM Pilot Burner Igniter Sensor Honeywell Q3481B1206 Nat Gas with NE24 orifice Pilot Burner Igniter Sensor Honeywell Q3481B1180 LP Gas with KR14 orifice Pilot Ground Wire Assembly 36 5006B 5009B Pilot Ground Wire Assembly 72 5010B 5026B 3 Vent Tube Tip USA Only 5010B 5026B Sections Only 4 Vent Tube Clip Tinnerman C4886A4 27 USA Only 5010B 5026B Sections Only 5 Vent Tube x 18 Long Aluminum Tubing For Canada Omit Vent Tube Vent Tube Tip and Vent Tube Clips These items are not used on 5006B 5009B Sections Robertshaw Gas Valves USA 2 103 SECTION VI REPAIR PARTS continued FLAME ROD IGNITION 1 4 O D ALUM ELECTRODE TUBING EP CONTROL SYSTEM PILOT ASSEMBLY 6236003 NAT GAS Not Available for LP PART NO ITEM 8236017 1 Flame Rectification Pilot Ass y Natural Gas Honeywell Q179C1009 w 388146 AG Orifice 7136255 2 Ignit
88. E POWER TO MODULE 24 V NOMINAL DAMPER SWITCH CHECK DAMPER IS OPEN CONTROL WAITS 60 SECONDS FOR DAMPER TO CLOSE ONCE CLOSED CONTROL WAITS 60 SECONDS FOR DAMPER TO REOPEN IF DAMPER IS CLOSED CONTROL WAITS 60 SECONDS FOR DAMPER TO OPEN IF CONFIGURED CHECK DAMPER CONNECTION DAMPER WIRING AND 24 V CONNECTION ON CONTROL REPLACE DAMPER AND DAMPER HARNESS IF NECESSARY YES IF CONFIGURED BEGIN PREPURGE FOR 30 SECONDS REPLACE MODULE PULL IGNITION LEAD AND CHECK SPARK AT 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 VALVES ARE OPEN SUPPLY TUBING AND GAS PRESSURES ARE TO SPECIFICATION AND PILOT BURNER ORIFICE IS NOT BLOCKED CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL CHECK FOR 24 VAC ACROSS PV MVIPV TERMINALS ON MODULE IF VOLTAGE IS OKAY REPLACE GAS CONTROL IF NOT REPLACE MODULE NOTE IT MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT TO CLEAR THE PILOT SUPPLY TUBING OF AIR NOTE IF MODULE GOES INTO RETRY DELAY RESET THE CALL FOR HEAT 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
89. E EVENT OF EXCESSIVE STEAM PRESSURE STEAM BOILER OR EXCESSIVE BOILER WATER TEMPERATURE WATER BOILER THE HIGH LIMIT CONTROL WILL DE ENERGIZE THE PILOT GAS VALVE AND THE MAIN GAS VALVES STOPPING BURNER OPERATION THE LOW WATER CUT OFF WILL ALSO STOP BURNER OPERATION IF THE WATER LEVEL IN THE BOILER SHOULD DROP BELOW THE LOWEST SAFE LEVEL 1 2 GND POWER SUPPLY HONEYWELL RAB9A 120 60 1 FUSED 63 oo 56 286 SWITCH 24 VOLT THERMOSTAT BY OTHERS 2 5 364 SERMCE SWITCH OPTIONAL 24V THERMOSTAT CONTROL SEE NOTES 5 6 AND 7 x2 POWER 4 Qoi SUPPLY PRIMARY d 120 60 1 5 T OPERATING CONTROL 2 STEAM L404F qp pcnc 21 0 Se eS eS See exe 2 LOW WATER CUT OFF pon i 2 5 AMP IN LINE FUSE SECONDARY 1 a STEAM M amp M 67 BC 2 NOT FURNISHED AS OPTIONAL CANADA ONLY WATER M amp M 64 FUSED STANDARD EQUIPMENT 2 DISCONNECT 2 SWITCH oce Phor a WH Gi IGNITER NI 5 I SERVICE v v spark BNR GND SWITCH Lwco LIMIT OPERATOR LIMIT CONTROL L o x3 x 24 24v onc I Ty MANUA
90. E PLUG 1 8 N P T MALLEABLE TEE 1 4 O D TUBE X 1 8 M P REMOVE FOR CANADA 1 2 d BRASS COMPRESSION ADAPTER 1 4 O D ALUMINUM TUBING TO PILOT BURNER TRANSFORMER PENN H91WA 4 PILOT SOLENOID VALVE amp PILOT LINE REGULATOR EP CONTROL SYSTEM PART NO ITEM 7016003 1 EP Control Mounting Bracket 24V 40 VA Transformer 120V 60HZ Primary 80160039 2A USA Honeywell Plate Mounted AT140D1012 80160014 2B Canada Honeywell Foot Mounted AT72D1089 822662 3 Penn Pilot Solenoid Valve H91WA 4 120V 8226005 4 Nat Gas Maxitrol RV 12 LT w orange spring 4 to 8 WC 80160018 Webster 612 6A7 Ignition Transformer not shown 101 SECTION VI REPAIR PARTS continued OPTIONAL HEAT SHIELD P N 70116003 CONTROL CABINET COVER P N 70116002 CONTROL CABINET P N 70116001 102 DUST COVER CAPTIVE SECURING SCREWS FLAME AMPLIFIER P N 80160207 R7847A RECTIFICATION FLAME AMPLIFIER 2 HONEYWELL RM7890 CONTROL P N 80160253 RM7890A INT SPARK PILOT HONEYWELL 07800 508 P N 8136432 v CONTROL BOX WIRING HARNESS Can 81316005 8 x 3 10 SHEET METAL SCREWS TYPE B P N 80860019 PART NL 60116022 CONTROL CABINET ASSEMBLY EP SYSTEMS INCLUDES CONTROL CABINET 70116001 CONTROL BUX WIRING HARNESS 81316005 e CONTROL CABINET COVER 70116002 HONEYWELL 07800 SUB BASE 8136432 JACKET FRONT TOP PANEL CONTROL ASSEMBLY AN
91. G AFTER 5 MINUTES OF MAIN BURNER OPERATION USE THE FLAME OF A MATCH OR CANDLE OR SMOKE FROM A CIGARETTE CIGAR OR PIPE AFTERIT HAS BEEN DETERMINED THAT EACH APPLIANCE REMAINING CONNECTED TO THE COMMON VENTING SYSTEM PROPERLY VENTS WHEN TESTEDAS OUTLINED ABOVE RETURN DOORS WINDOWS EXHAUST FANS FIREPLACE DAMPERS AND OTHER GAS BURNING APPLIANCE TO THEIR PREVIOUS CONDITIONS OF USE ANY IMPROPER OPERATION OF THE COMMON VENTING SYSTEM SHOULD BE CORRECTED SO THE INSTALLATION CONFORMS WITH THE NATIONAL FUEL GAS CODE ANSI 2223 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 CHAPTER 10 IN THE NATIONAL FUEL GAS CODE ANSI Z223 1 42 SECTION IV OPERATION Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21 13 GENERAL a INITIAL FILL Before putting water into a new wasted operate boiler only for the length of time it takes for condensate to run clear If the latter cannot boiler make certain that the firing equipment is in operating condition to the extent that this is possible without actually firing into an empty boiler This 18 necessary because raw water must be boiled or heated to at least 180 F promptly after it is introduced into the boiler in orde
92. GE SIZE 14 AWG TYPE TW OR TEW AWM IGNITER SENSOR CONTINENTAL SRGX600 SIZE 18 AWG WIRE 200 C MODULE TERMINAL HONEYWELL 58610 lt lt 26 26 HONEYWELL V88A MAIN GAS VALVES FIG 41 SCHEMATIC WIRING DIAGRAM CONTROL SYSTEM V88 GAS TRAIN U S A 5010B THRU 5014B CANADA 5006B THRU 5014B 48 WALSAS 1OH LNOO SH3 108 NOILOAS 89009 NYHL 89109 INVHOVIO OILVINN3HOS cv 213 50 31 N3WHOJSNvHL 1092 MOTI3A 8052 O3snNn dvo 6 80290 TIM ONISWHd SSONO SHO100 3 33953 O3193NNOO 38 ISMW 50 31 N3AHOJSNVHL V 38 03 SLVLSOWYSHL Q3lvH3dO TV 4 A dv ONILLES YOLWIOILNY 1V3H IVISOWN3HL 79 m 22 NMOHS SV Q3103NNOO 3MIM 83114405 01314 S d3ONvMIS WMW MAL 2 501 81 3ZIS 39VLIOA M
93. H BASE SUBASSEMBLIES BOLT SUBASSEMBLIES TOGETHER ion ATTACH FRONT INTERMEDIATE JACKET PANEL SUPPORT BRACKET TO FRONT BASE FRAMES 4 ATTACH LOWER REAR INTERMEDIATE JACKET PANEL SUPPORT BRACKET TO REAR BASE FRAMES FIG 3 DUAL MANIFOLD BASES 50158 THRU 5026B SECTION BOILERS Center Sections on 11 section and larger boilers THIS IS IMPORTANT a Carefully join a Center Section with nipples in adjoining section and bump lightly to secure b Run nut approximately 8 on two 2 34 draw up rods of equal length Note more than one set of draw up rods are furnished on 8 section and larger boilers Place draw up channel and one flat washer against nut 3 4 MEX NUT 3 4 WASHER 3 4 DRAW UP ROD i J 0 2 DRAW UF 4 FRONT OF BOILER 8 1 2 DRAW UP FIG 4 CHANNEL LEH SECTION ON BASE 12 ASSEMBLY CENTER SECTIONS S AdONVO SNOILO3S dO LN3I AI3ONVHHV 9 9 13599714 0 335 H3IN39 NO 3 1 3 5 LON 0 335 NO 2 5 O LON SNOLLO3S 1421 1 49 NO 7325 AdONV2 31NOIONI S3IdONVO JHL NO 5 38 JHL 034491 LON JON 034 0 5 3 33 2 5 N 12 0 6 16 N
94. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 5B GAS FIRED BOILER 619 LigTEO Intertek 3050579 AR 4 CERTIFIED G www ahridirectory org ZNWARNING This manual must only be used by a qualified heating installer service technician BEFORE installing read all instructions in this manual and all other information shipped with the boiler Post all instructions and manuals near the boiler for reference by service personnel Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage www burnhamcommercial com 8141302R18 1 15 PRICE 5 00 IMPORTANT INFORMATION READ and save these instructions for reference HAZARD DEFINITIONS The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product CAUTION Indicates an imminently hazardous situation Indicates a potentially hazardous situation which which if not avoided will result in death serious injury or substantial property damage if not avoided may result in moderate or minor injury or property damage Z WARNING NOTICE Indicates a potentially hazardous situation which Indicates special instructions on installation if not avoided could result in death serious injury operation or maintenance which are important or substa
95. ION continued El SEQUENCE OF OPERATION 5010B THRU 5014B WHEN OPERATING CONTROL CLOSES THE ELECTRIC SPARK AND PILOT VALVE ON EACH SIDE ARE AUTOMATICALLY ENERGIZED THE SENSING PROBE ON EACH OF THE PILOTS PROVES THE PRESENCE OF THE PILOT FLAME INTERNAL SWITCH ACTION IN EACH IGNITION MODULE DE ENERGIZES THE SPARK AND ENERGIZES THE MAIN GAS VALVES FOR ITS RESPECTIVE GAS TRAIN STARTING MAIN BURNER OPERATION WHEN THE OPERATING CONTROL IS SATISFIED THE PILOT GAS VALVE AND MAIN GAS VALVES FOR EACH GAS TRAIN ARE DE ENERGIZED STOPPING BURNER OPERATION IN THE EVENT OF EXCESSIVE STEAM PRESSURE STEAM BOILER OR EXCESSIVE WATER TEMPERATURE WATER BOILER THE HIGH LIMIT CONTROL WILL DE ENERGIZE THE PILOT VALVES AND MAIN GAS VALVES ON BOTH SIDES STOPPING BURNER OPERATION THE LOW WATER CUT OFF WILL ALSO STOP BURNER OPERATION IF THE WATER LEVEL IN THE BOILER SHOULD DROP BELOW THE LOWEST SAFE LEVEL SHOULD ONE OF THE PILOT FLAMES FAIL TO IGNITE OR BECOME EXTINGUISHED THE MAIN GAS VALVES CONTROLLED BY THAT PARTICULAR PILOT WOULD CLOSE STOPPING BURNER OPERATION ON THE BURNERS SUPPLIED BY THAT GAS TRAIN OPERATION OF THE BURNERS SUPPLIED BY THE SECOND GAS TRAIN WOULD BE UNAFFECTED 120 60 1 power 8065 FUSED SHC PRIM T TRANSFORMER TRANSFORMER TTT PM CANADA SEC CANADA ONLY ONLY 4 2 5 OPTIONAL
96. ISNI 3NIHOVW 91 9 X 81 91 6 4 038 1 JNN 39NVli 5 81 91 6 6 16 NOILVTIVLSNI Ill NOLLO3S 26 85841108 NOILO3S 861098 NYHL 81405 I339Vf dO ve Sls SNOLWHOIYSd 0901 WVHNYNE T3NNVHD T3NNVHO NOY 83 4 083 8344 7T3Nvd 13 3 1 083 8301 138288 1HOddnS T3Nvd INO BON CBNvd 1383 ST3NVd 14084 40 NOILVTIVLSNI T3NVd 135O9VP 31VIQ3 3 31NI 1NON3 1NOBJ N3ddn V HYLJA STANNVHD 33MO1 13 4 ANO83 N3M01 513 8344 Ni 30vid 8 1 33S 3 N3MO1 31n8UuS3 2 2 GNvd 13 3 QN3 1H9hJ 3401 50 3 H108 1342v48 LNOddNs T3NVd ONJ 1382 N3MO1 3315 28 dais 33 38 3 TANVd 8 38 834 4 0 3 3 df 3NNVHO M dais T3NNVHO L 3 TANYA 4383 ON3 Mi3ddn 3NVd 1383 ANY 13 0Vh 13 13 0vn 401 INONJ 401 305 401 3 4 Love W3ddn 38 331108 2 201 138 1 UVLAG T3NVd 133097 301 3Nvd 3 31VIQ3W331NI 1 084
97. L JACKET PANEL STEP 1 UPPER FRONT UPPER REAR PANEL JACKET PANEL IN PLACE STEP 3 DOWN Ix UPPER CHANNELS LOWER FRONI PANEL LOWER REAR PANEL LOWER CHANNELS FIG 51 REMOVAL OF JACKET FRONT PANEL Important Product Safety Information Refractory Ceramic Fiber Product Z WARNING The Repair Parts list designates parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures above 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 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 airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the Unit
98. L RESET 5 5 25 STEAM 140798 CE p Keen N LINE WATER L4006E FUSE IF USED HONEYWELL 2112 47 OPTIONAL S8610M PILOT GAS HONEYWELL VALVE ON PILOT BURNER PILOT VALVE BK YE LADDER DIAGRAM LEGEND 1 ep 24 WIRING V88A of leas LL 120V WIRING GAS VALVES NOTES WIRE CODE WH gt 1 IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THE APPLIANCE MUST BE BK BLACK REPLACED IT MUST BE REPLACED WITH WIRE AS SHOWN OR ITS EQUIVALENT BL BLUE 88 2 ALL WIRING INCLUDING GROUNDING CONNECTIONS MUST COMPLY WITH BR BROWN 5 JUNCTION NATIONAL ELECTRIC CODE AND APPLICABLE LOCAL CODES CR GREEN waled BOX 3 ALL GROUNDS IN MODULE ARE CONNECTED INTERNALLY ORANGE pese eal 4 GROUND CANADA ONLY Wh WHITE 5 FIELD SUPPLIED WIRE CONNECTED AS SHOWN YE YELLOW n 6 THERMOSTAT HEAT ANTICIPATOR SETTING 0 4 AMP N 7 ALL BATTERY OPERATED THERMOSTATS REQUIRE A RELAY 8 CAP UNUSED RED 208V amp YELLOW 240V TRANSFORMER LEADS RD aw ER TRANSFORMER Spo 92 ul de E Ra SCHEMATIC DIAGRAM LEGEND LOW VOLTAGE SIZE 18 AWG TYPE TEW AWM STRANDED WIRE gt 105 C EH v LOW VOLTAGE SIZE 18 2 ANG POWER LIMITED CIRCUIT CABLE 105 C w C LINE VOLTA
99. LINS WALSAS 584109 NOI LO3S 890096 NYHL 89109 INVHOVIO ONIHIM Sr Sls 5 JAVA 5 9 ZS HOLIMS H3MOd 15 LNANOdNOD TANVd INIT LINGNOD NNY LON 00 5 2 35 2 425 81 3215 QNnONO WAV M3L MO ML 81 3215 JOVLIOA WAV M3L YO ML OMY vi 3215 2 501 G3ONVYIS 2 81 3215 39 1 25201 5 WMV MAL 9 81 3215 FOVLIOA 02086218 TISMA3NOH Qv31 QOY 3AY1J HO 2 002 009 9 5 VIN3NIINOO 0 9 OLLVWSHOS AINO QNnOND 53003 7 201 318 3 4 3003 7 21412313 ATdWOO ISNW SNOLLO3NNOO 9 TY MATIVISNI A8 5 213 440 112 s31VM 38 34831 SLIN TWNOLLIGGY Z 4N3IVAInO3 YO NMOHS SV 3MIM HIM Q3ovid3N 38 LSAW L 039 1438 38 LSNW 3oNvrlddv 03119905 SV TWNIDINO JHL 30 3l 254108 AWA 5 9 1014 35 XO8 S
100. MAXITROL REGULATOR uM MODULE SUPPORT BRACKET MANIFOLD HONEYWELL GAS VALVES COMPRESSION UNION COMPRESSION NUT W ATTACHED SLEEVE PILOT FIRING VALUE MAL IRON TEE MALE COMP ADAPTER FIG 36 PILOT PIPING THERMOCOUPLE CONTROL SYSTEM CANADA ONLY MANIFOLD MODULE SUPPORT BRACKET PILOT SAFETY SWITCH 2 8 X 1 2 SHEET METAL SCREWS 2 10 32 X 2 R H MACH SCREW WITH NUTS MANIFOLD FIG 37 NOTE TWO PILOT SAFETY SWITCHES REQUIRED ON 15 SECT AND LARGER BOILERS INSTALLATION OF PILOT SAFETY SWITCH 40 THERMOCOUPLE CONTROL SYSTEM SECTION INSTALLATION INSTRUCTIONS continued Venting INSTALL VENT CONNECTOR from canopy Draft Hood or damper to chimney maintaining 6 clearances from combustible materials INSTALL VENT SYSTEM Typical vent systems are shown in Fig 38 and 39 Some of the factors affecting vent sizing and construction accompany these figures Vent installation shall be in accordance with local building codes or the local authority having jurisdiction or the National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances ANSI NFPA 211 Both of the aforementioned standards ANSI Z223 1 and ANSI NFPA 211 specify Type B and Type L double wall metal vents and fire clay tile lined masonry chimneys as suitable chimney constructions for Category I draft hood equipped appliances such as this Series 5B boiler Both stan
101. MINOO A A 255 x 2 1N3WdInO3 15 Sv 3 8 4 LON 9001 47071 Wv3ls 7OMINOO 9NlVN3dO v9 WRN M3lvM 2 28 9 WRN 5 330 112 YALVM 9 S v 5310 33S LVISONYSHL yi 59310 A8 1VISONS3HL 1 V68VM TI3MA3NOH NOILWYAdO Al NOILO3S Ov YINYOJSNVYL xog y a Ly Ik 2 HOLIMS 30435 HOLIMS B 193NNOOSIG 035014 b 9 2 e 1709 021 13 21 x 5 m 3 0 47 SECTION IV OPERATION continued El SEQUENCE OF OPERATION 5006B THRU 5009B WHEN OPERATING CONTROL CLOSES THE ELECTRIC SPARK AND PILOT VALVE ARE AUTOMATICALLY ENERGIZED THE SENSING PROBE PROVES THE PRESENCE OF THE PILOT FLAME INTERNAL SWITCH ACTION DE ENERGIZES THE SPARK AND ENERGIZES THE MAIN GAS VALVES STARTING MAIN BURNER OPERATION WHEN THE OPERATING CONTROL IS SATISFIED THE PILOT GAS VALVE AND THE MAIN GAS VALVES ARE DE ENERGIZED STOPPING THE BURNER OPERATION IN TH
102. NS continued 4 E BH FIG 22 SECURING OF CANOPY DRAFT HOOD 25 INVHOVIG ONILNNOW GOOH LaVed AdONVO c 213 51108 3NIHOYW 91 8 X 81 91 6 05 05 81108 3NIHOVW OH 91 8 X 81 91 9 zzos az0s 51108 91 8 X 8 8 6102 1105 51108 3NIHOVW 91 9 X 81 91 S 9208 9208 51108 3NIHOVM 91 9 81 91 6 52 69 LON OOOHLAVHO AdONYO ONY N33AL38 LOU V 81108 3NIHOVM OH 9 9 X 81 91 6 LE DE ge 5895 6265 865 XTALWWIXOUddY 5 08 3NIHOVM 30 SOV3HHL JHL 30 401 JHL OL SINN TAON ONV SINN NAY 8 08 8 355 NOLLO3S Ya 1NOMJ TIVISNI 2713 91 5 SM3MOS 791 8 6 X 81 91 8 Ha c GOOHLIVEG AdONVO EL NO 0 038 1 INN 81 91 13290888 NI TIVISNI 1108 3NIHOVME 791 8 X 81 91 6 412 48 w3NOS 3NIHOWN 0 038 1 MW3HSVM 1813 91 6 1 NI do al SMGYOS 3NIHOVM 91 9 6 X 8 91 6 QoOHLSVHO AdONYO 48084 NO 0 538 1 INN 81 91 6 130988 ONUNDOM NI TIV
103. O1 39 80 ix VOVNvO ONnONO 2 601 318 2 O3LIAI N3MOd 2 8 32 5 39 3385 X9 sis x ATIVNS3INI O3103NNOO 38 31000 NI TV 9 002 81 3715 009585 AINI NMONB 88 1 09 01 1 a 52003 WOOT dlBvOllddv 3009 21410313 2 500 WMY MIL OMY 91 325 SONTIQN INE 59 78 5 A HLM AIdWOO LSNW SNOILOJNNOO ONIGNNOYD ONIBIM TIY Z 0 501 15 34 81 9215 39 MOT gt 1 1 3 SLI YO NMOHS SV 032 1 3 38 15 0323 1438 03 x 38 1SnW 03114405 SV JAIM WNIORO IHL jO ANY dl L GOGNSOWI WVA VIA OLLVWAHOS ds SELON M3TVVISNI A8 03114405 SWall xog FH xog 44 4 JANA NOILONAP JAVA 5 1014 Sv9 10719 AT AIN 5525 pm SAN SV9 NIV ol La WNOILdO S3AIVA 5 9 NIVA wNolLdO TI3MA3NOH 3504 TI3MA3NOH asn4 ACTED 3NHI NI E _ 3NI1 NI 9 9 9 9 B dW SZ 9 9 9 9 SZ gt p gt gt gt wo A HM gt gt
104. OILVTIVLSNI Ill NOLLO3S 13 SECTION 11 INSTALLATION INSTRUCTIONS continued Tapping Per End Section sS Insert short end of draw up rod through front amp rear nipple ports on both sections see Fig 5 Place two 2 flat washers draw up channel and a nut on each end of draw up rods and finger tighten DRAW UP CENTER SECTION SLOWLY AND EVENLY tightening each DRAW UP ROD a little at a time so that sections are equally spaced KEEP NIPPLES ALIGNED WITH NIPPLE PORTS If necessary tap Nipples lightly with a blunt tool or rod to keep Nipples from cocking while Sections are being drawn up DO NOT DRAW UP SECTION S WHEN NIPPLES ARE COCKED Continue tightening Draw Up Rods equally until Sections meet iron to iron on the ground surface BUMPING OUTER EDGES OF SECTION WITH WOODEN BLOCK WILL EASE DRAW UP OPERATION KEEP DRAW UP ROD THREADS NUTS AND WASHERS LUBRICATED with grease or heavy oil to prevent damage to rods and threads and to make assembling easier g USING A PINCH BAR insert WOOD WEDGES under last Center Section assembled so as to raise it just above Boiler Base This will keep the next section to be assembled above the base thus making it easier to join and draw up MOVE WOOD WEDGES FORWARD EACH time a Section has been drawn up 7 ASSEMBLE REMAINING END SECTION WITH DRAW UP RODS in a manner similar to that for assembling Center Sections Remove wedges from under Boiler Be sure Boiler is aligned
105. QUO 28 uo FINGOW 22 31000W 22 WOL98S TISMA3NOH WOL98S TI3MA3NOH HM L uo 26 rea 26 1 8605 9 m 2 uo J 85 1 GND y OND Ave 1124 ONIMIM tJ Nivel 9 4491 SvO 1431 e t T 5 e uvas 8 Adds 599 Svo 1014 AO ld E a u9 89 s 10114 1014 TISMA3NOH TI3MA3NOH xg 9 S 3ION 335 7OMINOO IVISONNIHL TWNOILdO SV LON X IX 990091 21 0 AV31S L E up 22 e TOYLNOD 6 O 9 4 2 1 4 5 2 AVIAN 68 8 2900 2 08 9 WRN WLS 49 58340 A8 1VISOWMH3HL 72 86 0 1 215 4353 JOMINOO 140 102 N3lVM NOILWYAdO NOILO3S SECTION IV OPERAT
106. SHUT OFF 5 BOILER SHUT OFF J oxygen absorption VALVES _ 5 4 Use of non permeable materials in the distribution BE 54 p system AIR AN 5 Isolating the boiler from the system water by CH i installing a heat exchanger CIRCULATDR b Open Jacket Parts Carton SUPPLY MAIN TD RETURN MAIN FROM 15 INSTALLATION OF JACKET PARTS COMMON TO CDMBINED HEATING COMBINED HEATING ALL BOILER SIZES amp COOLING SYSTEM amp COOLING SYSTEM 1 Attach Lower Jacket End Panel Support Bracket to Base End Panel Both ends using 4 20 x self tapping screws see Fig 2 and 18 2 Attach Lower Left and Lower Right Jacket End Panels to their respective brackets using 10 32 x 1 2 self tapping screws see Fig 19 FIG 17 RECOMMENDED BOILER PIPING FOR COMBINATION HEATING amp COOLING SYSTEMS There are many possible causes of oxygen contamination such as 1 3 See Fig 7 Purpose of Tappings and Their 1 Addition of excessive make up water as a result of Location and remove necessary knockouts from system leaks Upper Left and from Upper Right Jacket End 2 Absorption through open tanks and fittings Panels 3 Oxygen permeable materials in the distribution 4 Place Upper Right End Panel on top of Lower system Right End Panel with lip on bottom of Upper Panel positioned behind Lower Panel Secure to section using 10 32 x gt self tapping screws Attach Up
107. SYSTEM FIG 39 MANIFOLD VENT SYSTEM 10 Provide cleanout in chimney 11 Slipjointordraw band facilitates installation and future servicing when necessary 12 Venting of other appliances into same chimney or into a common vent will affect sizing of the chimney or common vent 13 Correction for altitude design vent system for sea level input 14 Provide adequate ventilation of Boiler Room see page 10 this cannot be overemphasized 15 Never pass any portion of a vent system thru a circulating air duct or plenum 16 Support of lateral runs so that vent pipe does not sag 17 Support of common vent where it passes thru a ceiling or roof 41 SECTION INSTALLATION INSTRUCTIONS continued 18 Clearances to combustible material use of 1 Warm up is faster with type B vents than vents thimbles having greater mass 19 Firestops 2 Type B vents permit closer clearance to 20 Flashing and storm collars combustible material than single wall metal 21 Guying or bracing of common vent pipe above vents unless special precautions are taken with roof the latter 22 Securing and gas tightness of joints 3 Type B vents are less prone to condensation and 23 Lightning arrester if top of metal vent is one of corrosion than single wall metal vents highest points on the roof 4 Type B vents are lightweight easy to handle and Where choice is possible many advantag
108. Since input is a function of heating value specific gravity and volume of gas flow contact your utility for the first two items in order to utilize the formula below The gas meter should then be clocked for three 3 minutes with stop watch and substituting the appropriate values in the formula below determine what the gas flow should be in this 3 minute period to give the input shown on the Rating Plate Btuh Input cu ft per 3 min Heating x 20 x multiplier Value from of gas table Btu cu ft below spec gravity multiplier 50 1 10 55 1 04 60 1 00 65 0 96 TO 0 93 c ADJUST AIR SHUTTERS See Section V 5 Burners are normally shipped with the air shutters in the wide open position Loosen air shutter securing screws and close air shutters until yellow tips appear on flames then open shutters slowly until defined inner cones may be seen Lock shutters in this position d ADJUST BLEED LINE REGULATOR V88A s All gas boilers for the USA and Canada are normally equipped with two diaphragm gas valves per manifold The gas valve s nearest the manifold on all boilers is equipped with an adjustable bleed This bleed regulator should be adjusted so that the burners reach full fire in approximately 10 12 seconds after the main gas valves have been energized e ADJUST PILOT LINE PRESSURE See Section V Service 6 Pilot Flame Shut down boiler and remove gas valve and manometer fr
109. Wall Jeueg eseg yH 00609808 1009812 0181819 26061819 28061819 061819 9061819 709008 629228 829228 7061608 6061608 206 628 LOELEZS YLELZZ8 LELZ88 21612628 11612028 0 6 228 60612828 806158 026102 20618112 80161021 81161021 80 61022 86061022 88061022 81061022 89061022 20161811 26161811 20161811 21161811 20 61811 26061812 28061811 101819 1091 9808 1011819 6061819 8061819 11061819 19061819 60519808 19919808 61 8102 10681812 8 18 73225 31VOlONI 5340 JHL NO 5 388 L SNOILOAS 9 54 14 AdONVO 1 idus 5 HAIN NO 144059 6 LON 5 N3IN3O NO 3 O SNOLLOSS 1431 NO 3 278415 9 SWWIIOH 40 61 HI Vd33 NOILOAS 79 80 PART SIZE 36 1 2 X 25 3 4 36 1 2 X 31 3 16 36 1 2 X 36 5 8 36 1 2 X 41 1 16 36 1 2 X 47 1 2 36 1 2 X 25 3 4 36 1 2 X 31 3 16 36 1 2 X 36 5 8 36 1 2 X 41 1 16 36 1 2 X 47 1 2 36 1 2 X 25 3 4 36 1 2 X 31 3 16 36 1 2 X 36 5 8 36 1 2 X 41 1 16 36 1 2 X 47 1 2 36 1 2 X 25 3 4 36 1 2 X 31 3 16 36 1 2 X 36 5 8 36 1 2 X 41 1 16 36 1 2 X 47 1 2 SECTION VI REPAIR PARTS continued PART NO 61
110. ablish pilot flame If not pilot flame can be sensed by the flame rod circuit terminal 8 and 10 are de energized and the relay will lock out on safety c Pilot failure is caused by the following 1 Complete loss of gas supply 2 Poor ignition spark caused by low voltage poor ground connection faulty wiring and possibly a defective ignition transformer 3 Low gas pressure will prevent flame rod circuit from sensing pilot flame properly 4 Unusually strong secondary air drafts can blow the pilot flame away from the flame rod momentarily causing nuisance shutdown 5 A pilot line solenoid valve will not open because offaulty wiring low voltage or possibly the valve is defective 6 defective RM7890A may be the cause but items 1 thru 5 should be followed first Refer also to RM7890A relay literature furnished with the control d By referring to the Sequence of Operations step by step operation of the system can be controlled and the cause of pilot failure SECTION IV OPERATION continued can be readily found After the cause of the pilot failure has been corrected resume normal operation by following the Lighting Instructions 3 SHUTDOWN INSTRUCTIONS a Close manual shut off valves and pilot valves b Turn off main electric switch EP CONTROL SYSTEM 5015B thru 5026B see Fig 45 The 5015B thru 5026B boilers utilize two EP control systems that are interconnected electrically thru all
111. ain piping pilot piping bleed piping and orifices for leaks THE INSTALLATION OF THE REMAINDER OF THE GAS CONTROLS IS DEPENDENT ON THE CONTROL SYSTEM FURNISHED REFER TO THE TABLE BELOW FOR THE FIGURES IN THIS MANUAL APPLICABLE TO THE VARIOUS CONTROL SYSTEMS OFFERED AS STANDARD OR AS OPTIONAL EQUIPMENT IF THE CONTROL SYSTEM ORDERED IS NOT LISTED SPECIAL INSTRUCTIONS HAVE BEEN PREPARED BY THE APPLICATION ENGINEERING DEPARTMENT AND CAN BE FOUND IN THE INSTRUCTION ENVELOPE FURNISHED WITH THE BOILER CONTROL BOILER SIZE SYSTEM 6 thru 9 sect 10 thru 26 sect REFERENCE FIGURES 35 SECTION 11 INSTALLATION INSTRUCTIONS continued 36 EI Control System INSTALLATION OF GAS VALVE TRANSFORMER AND PILOT PIPING for Robertshaw Pilot Piping see Fig 32 Attach the bracket for mounting of the junction box to the lower front corner of the Jacket Upper End Panel using two 10 32 x MS and nuts Mount junction box to bracket using 8 SMS see Fig 27 or 29 Connect pilot solenoid valve to bottom center knockout of J box using conduit fittings furnished V88 Gas Train only see Fig 33 Mount transformer on J box If Foot Mounted Transformer connect to J box with Straight Connector BX Straight Connector and 7 pipe coupling Drill holes in Jacket and fasten Transformer using SMS Install RV 12LT pilot line regulator packed in Gas Train Carton and other 1 8 pipe fittings as shown in Section VI Repair Parts
112. ater Cut Off in 1 pipe tapping H Fig 7 and System Return Piping Control 33 SECTION INSTALLATION INSTRUCTIONS continued TABLE NATURAL GAS rers Maximum Capacity of Piping in Cubic Feet of Gas Per Hour Based on a Pressure Drop of 0 3 Water and 0 6 Specific Gravity Pipe NOMINAL IRON PIPE SIZE IPS INCHES Length 1 seo 1 0 6 0 aoo TABLE Multipliers to be used with Table when Pressure Drop is not 0 3 x 3 7 TABLE III Multipliers to be used with Tables and II for Specific Gravity Other than 0 60 FIG 30 1 RECOMMENDED PIPING TO e BUILT IN TANKLESS HEATERS 00 must be mounted so that cut off point is above marking on Lowest Permissible Water Line Plate f Install Pressure Safety Relief Valve using fittings 36 OPEN GAS TRAIN CARTON S furnished into 1 1 2 pipe tapping in upper corner CONNECT GAS TRAIN S ELBOW ON END OF OE ETE MANIFOLD S according to the Gas Trains on pages TATEN SAEC DER 90 thru 96 On those boilers with two manifolds 15 2 4 e lou ns bs sect and larger two identical sets of Gas Controls are IIS furnished Hence the procedure for installing one set 15 g In
113. bush 1 pipe tapping in upper corner of End Section Connect Pressure Limit to this bushing with 4 pigtail siphon 4 Minimum Service Clearance Label 5 Burnham Logo Apply to Top Panel 6 Boiler Ventilation For Your Safety Label b Proceed to Paragraph 33 Steam Boilers or Paragraph 34 Water Boilers NOTE IF WATER BOILER PROCEED DIRECTLY TO Paragraph 34 33 INSTALL STEAM TRIM AND CONTROLS See Boner equiped with Low OF oiher Fig 7 and 27 than 1 above or with Low Water Cut Off Feeder Combination Bush 1 2 pipe tapping a Pressure Gauge is to be installed with nipple and in upper corner of End Section and connect 2 x reducing coupling in gt tapping provided Pressure Limit furnished to this bushing with in upper corner of End Section using wrench applied pigtail siphon For installation of second to square shank on back of gauge DO NOT APPLY pressure limit bush any available tapping on FORCE ON GAUGE CASE opposite end section that is above normal water Install 67BC 2 Low Water Cut Off or 47 2 line Connect Pressure Limit to this bushing Combination Feeder and Low Water Cut Off in with 4 pigtail siphon accordance with the Instructions packed with the 3 Tighten limit controls by using wrench on hex control pipe extensions are provided and must fitting at bottom of control be installed in the 2 tappings adjacent to the 4 The L404 Pressuretrol must be accura
114. components which can lead to failure As such any system must be designed to prevent oxygen absorption in the first place or prevent it from reaching the boiler Problems caused by oxygen contamination of boiler water are not covered by Burnham s standard warranty 108 NYHL 99006 5 AlddNs HO NYNLAY ALIAVH9 SNIdld 3 08 WWALS Q33N3AINOO3H cV 914 MWNOlLdO YASIN AlddNS GNOOAS W3LSAS 831108 5014 100 NvV31O JAWA HLIM 334 337108 OL LIM W3lSAS non d 0398834383 31 831 NOLLO3NNOO 2 2 1 42 QNO3INVH JAVA 31 6 b P 27 3 38019 31v9 YILYM WNHON OL 031114 831108 3337 AINO 80 33G1n0HS 40074 30 9 NIHLIM MO 350710 OL 393VHOSIG M31VM TVWHON 82 NVHL 5531 LON OL S NIV AlddNS LNIOd NYNLIY OLNI S ON3 83108 1 04 34015 AlddNS W3lSAS 6 16 NOILVTIVLSNI Ill NOLLO3S TIONV 5 V ATIVOILYSA 3QV3H 40 401 440 38 OL S NIVN A1adns ANN 331VM VWSON 3JAO8V WOWININ 33Q0v3H 17 90
115. dards prohibit the use of unlined masonry construction as a chimney with the exception in ANSI Z223 1 NFPA 54 that 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 input rating and efficiency ANSI NFPA 211 prohibits the use of single wall metal vent as a chimney while ANSI Z223 1 allows it under very restrictive conditions In Canada refer to CAN CSA B149 1 or 2 M86 and local codes for venting SOME ITEMS RELATIVE TO CONSTRUCTION AND SIZING OF VENT SYSTEM 1 Total Vent Height 2 Vent Connector make Initial Rise as high as possible 3 Length of Lateral hold to a minimum 4 Number of Elbows hold to a minimum 5 UL Listed Vent Cap assures full vent capacity and freedom from adverse wind effects 6 Locate Boiler as close to Chimney as possible consistent with necessary clearances see page 10 lower table 7 Run Breaching Horizontal and slope upward to Chimney maximum of per ft 8 Use thimble where Breaching enters masonry chimney keep breaching flush with inside of flue liner do not connect into same leg of chimney serving an open fireplace 9 Install vent above bottom of Chimney to prevent blockage inspect chimney for obstructions or restrictions and remove clean chimney if necessary FIG 38 SINGLE VENT
116. e boiler creates a corrosive atmosphere which if the concentration becomes high enough can corrode the cast iron through from the inside Since neither of these failure types are the result of a casting defect the warranty does not apply Clearly it is in everyone s best interest to prevent this type of failure The maintenance of system integrity is the best method to achieve this 72 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 Boiler Serial Number Installation Date Heating Contractor Phone Number SERVICE RECORD SERVICE PERFORMED DATE 13 14 SECTION VI REPAIR PARTS REPAIR PARTS INDEX ITEM PAGE NOS Parts RE ER CERTI 75 thru 78 Integral Draft Hoods amp Sections oer ne tere T recte tpe ia uad 79 thru 80 DOCUONS Lp 81 Assemblies 3 82 Jackets E 83 thru 87 Water 7 Steam Trim uice erre 88 and 89 Gas 15 Sus uuu an 90 thru 96 Support Brackets Ignition 1 97 thru 101 Pilotstats Transformers Pilot Solenoid Valves amp Pilot Line
117. e not used 14 WASHER amp JAMNUT TO SECURE BOLT TO SECTION FRONT OF BOILER SECTION FIBERGLASS INSULATION VESTIBULE PANEL WASHER amp NUT TC SECURE COVER TO BOILER HEX COUPLING ATTACHED TO END OF CARRIAGE BOLT MACHINE SCREW TO SECURE VESTIBULE PANEL TO BOILER COVER PLATE FLUE INSULATION COVER PLATE FIG 11 ATTACHMENT OF FLUE COVERS a With Steam Heating System refer to Fig 12 13 14 or 15 With Forced Circulation HOT WATER HEATING SYSTEMS see Fig 16A and 16B For additional reference consult I B R Installation and Piping Guide No 250 NOTE When Hot Water Heating Boilers are connected to Heating Coils located in Air Handling Units where they may be exposed to refrigerated air circulation the Boiler Piping System must be equipped with Flow Control Valves or other automatic means to prevent gravity circulation of the Boiler Water during the cooling cycle With COMBINATION HEATING AND COOLING REFRIGERATION SYSTEMS having the same Distributing Units Piping and Circulator See Fig 17 For additional reference consult ASHRAE Systems Handbook 2008 Edition NOTE Valves must be installed in the supply and return branches to the Heating Boiler and Water Chiller so as to prevent circulation of Chilled Water through the Boiler or Heated Water through the Chiller OXYGEN CORROSION Oxygen contamination of the boiler water will cause corrosion of the iron and steel boiler
118. e screws and bolts as shown in Fig 23 Select the type of fastener indicated and drive them into the Tapped Lugs provided for this purpose on top of the sections Where two Canopy Draft Hoods join together the securing tabs will overlap iii Attach the Front Intermediate Panel to the Front Intermediate Panel Support Bracket s using 10 32 x 1 2 self tapping screws 29 INSTALLATION OF TOP FRONT JACKET PANELS a Remove knockout for supply piping Refer to recommended boiler piping diagrams in this manual b Attach Top Front Jacket Panels to left and right end Jacket Panels and also to top flange on the Vestibule Panel using 8 SMS Refer to Fig 25 or 26 30 PLACE TOP INTERMEDIATE PANEL S OF LEFT AND RIGHT PANELS making sure that Front Intermediate Panel s is under Top Intermediate Panel s Secure Top Intermediate Panel using 8 SMS 31 INSTALL KNOBS ON THE UPPER FRONT AND UPPER REAR PANELS using 10 32 x 3 16 MS Install Upper Front Lower Front Upper Rear and Lower Rear Panels using procedure we described in detail A of Fig 25 or 26 85844108 12335 82008 NYHL 80505 I339OVf dO Sc 213 3 LINOVI ON3 1331 YAMOT NOI 344 uonsnquio 990 EAM 38 ININYVM SNIMOO13 FIGUSNENOD pue 8 1 9 4910
119. ectively Thus pilot burner and main burner flames are extinguished Normal operation can be resumed when the cause of safety switch malfunction is corrected Any controls with Manual Reset must be reactivated Pilot Failure Pilot failure can occur during the start up or during the operating cycle of the boiler Any failure of a Q3481B pilot will close the main gas valves controlled by this pilot within 0 8 second For 90 seconds after pilot failure the Ignition Control will try to reestablish pilot flame If the pilot flame cannot be sensed by the sensing probe 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 On 15 section and larger boilers where two manifolds gas trains and pilot systems are employed failure of one pilot will not affect operation of the other system Thus it is possible to fire the boiler at a reduced rate thru one manifold while the other is inoperative Pilot failure is caused by one of the following a Pilot burns yellow resulting in weak signal from sensor to Ignition Control may be due to dirt or lint that has covered the lower portion of the pilot burner remove with a soft brush
120. ed States and Canada First Aid Procedures If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with 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 65 SECTION V SERVICE continued Remove the Front Cleanout Panels first by removing CARE SHOULD BE EXERCISED IN REMOVING the upper and lower nuts and washers securing these THE CLEANOUT PLATES FROM THE BOLTS SO panels to the boiler sections see Fig 52 THAT THE INSULATION IS NOT DAMAGED IF DAMAGED ALL EDGES OF THE CLEANOUT INSULATION PLATES SHOULD BE SEALED WITH BOILER vesneuLe PUTTY WHEN REINSTALLED UNTIL PANEL INSULATION CAN BE REPLACED Using a flashlight examine all flue passageways If UEM m passageways are free of soot and obstructions it is not TE necessary to remove the rear cleanout panels Remove HEX COUPLING the Burner Access Panels at front of base and place END OD TO paper or cardboard over burners With long handle wire flue brush and vacuum brush flueways thoroughly through front and rear cleanout openings see Fig 53 lt gt ox
121. ed in ALL of the component instruction manuals Assure that all safety and operating controls and components are operating properly before placing the boiler back in service 1 GENERAL Inspection should be conducted annually Service as frequently as specified in paragraphs below While service or maintenance 18 being done Electrical Power and all Gas Supply to the Boiler must be off CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 2 VENT SYSTEM Vent system should be checked annually for a obstructions b accumulations of soot c deterioration of vent pipe or vent accessories due to condensation or other reasons d proper support no sags particularly in horizontal runs e tightness of joints Remove all accumulations of soot with wire brush and vacuum Remove all obstructions Replace all deteriorated parts and support properly Seal all joints See Fig 53 64 3 CLEANING OF FLUES AND BURNERS Flue passageways in the boiler sections should be checked annually for any blockage or accumulation of soot To obtain access to the flue cleanout panels which are installed on both the front and rear of the boiler the upper front and upper rear Jacket panels must be removed see Fig 51 Also remove front vestibule panel See Fig 20 FRONT TOP REAR TOP JACKET PANE
122. ef E 6 Gf amp 6 Gf OK e Onn On 3sva ans 15 00840 zs 3 WvHN3ng8 4 Al NOILO3S v9 WW M3lVM 2 08 9 5 90091 a 19091 vals 0 003 015 sv LON TOYLNOD 5 8340 035 3 390071 N3lvM 86 0 5 p En TOYXLNOD YATIVLSNI 03 5 SWALI 55 ano 8 21 eu HOLMS H LIMS 1 09 021 193NNOOSIQ AlddNS q3sn3 3804 YSN 40 1 43 CNvd 4315 NI STVNINYSL 3 GION310S gt lt MOIVDLOV INYA SVO VSSOPA NOH S3A1VA Sv 9 5 LINO SECTION IV OPERATION continued a OPERATING INSTRUCTIONS 1 Make sure all Manual Main Shut off Valves and all Pilot Valves have been off for at least five minutes 2 Set Operating and Limit Controls to desired setting 3 Turn all Manual Main Shut off Valves and Pilot Valves to Open Position 4 Turn on Main Electric Switch and Service Switch Pilots will automatically light main burners
123. enoid valve supplying gas to pilot Terminal 10 energizes ignition transformer creating electric spark ignition at pilot 4 Flame rod circuit between Q179C pilot and RM7890A proves presence of pilot flame electronically 5 Terminal 10 to ignition transformer is de energized 6 Terminal 99 is energized and supplies power to the main gas valves 7 Main gas valves open and main burners are lighted by pilot 8 When operating control is satisfied terminals 6 and 9 are de energized Main Gas Valves and pilot line solenoid valve are all de energized and main burner and pilot burner flames are extinguished c SAFETY SHUTDOWN 1 SAFETY SWITCH CIRCUIT If limit control low water cut off or any other electrical safety switch opens power to terminal 6 in relay is interrupted thus de energized terminal 9 and 8 in relay which de energizes main gas valves and pilot valves Main gas burners and pilot burners are immediately extinguished Normal operation can be resumed when the cause of safety switch malfunction is corrected Make sure all manual resets are activated where involved 2 PILOT FAILURE a Pilot failure can occur during the start of operating cycle of the boiler Any pilot failure on the Q179C electronic pilot after ignition of pilot flame will close the main gas valves in 0 8 second b For 15 seconds after failure of the Q179C pilot the relay through terminals 8 and 10 will try to est
124. es can be assemble listed for the UL Listed double wall metal type B vent Z WARNING WHEN AN EXISTING BOILER IS REMOVED FROM A COMMON VENTING SYSTEM THE COMMON VENTING SYSTEM IS LIKELY TO BE TOO LARGE FOR PROPER VENTING OF THE APPLIANCES REMAINING CONNECTED TOIT 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 PLACED IN OPERATION WHILE THE OTHER APPLIANCES REMAINING CONNECTED TO THE COMMON VENTING SYSTEM ARE NOT IN OPERATION A SEAL ANY UNUSED OPENINGS IN THE COMMON VENTING SYSTEM B VISUALLY INSPECT THE VENTING SYSTEM FOR PROPER SIZE AND HORIZONTAL PITCHAND DETERMINE THERE IS NO BLOCKAGE OR RESTRICTION LEAKAGE CORROSION AND OTHER DEFICIENCIES WHICH COULD CAUSE AN UNSAFE CONDITION INSOFARAS IS PRACTICAL CLOSE ALL BUILDING DOORS AND WINDOWS AND ALL DOORS BETWEEN THE SPACE IN WHICH THE APPLIANCES REMAINING CONNECTED TO THE COMMON VENTING SYSTEM ARE LOCATED AND OTHER SPACES OF THE BUILDING TURN ON CLOTHES DRYERAND 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 INSTRUCTIONS ADJUST THERMOSTAT SO APPLIANCE WILL OPERATE CONTINUOUSLY TEST FOR SPILLAGE AT THE DRAFT HOOD RELIEF OPENIN
125. es dirty again at a later date due to additional sediment loosened up in 515 008 45 open drain valve in return main turn on burner and allow condensate to flow to drain until it has run clear for at least 30 minutes while feeding water to boiler so as to maintain normal water level Turn off burner drain boiler open gate valve in Hartford Loop then repeat step 1 above 3 Make pH or Alkalinity Test Total harness ppm 3 the piping close gate valve in Hartford Loop 50 After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with Hydrion paper which is used in the SECTION IV OPERATION continued 3 CONDENSATION appears that the boiler is leaking This condensation 2 ted to st fter th iler is hot Following a cold start condensation sweating may gan De expevted 1o stop atter the poteras ho occur in a gas fired boiler to such an extent that it CONTROL VARIATIONS NATURAL GAS CONTROL TYPE OF GAS VALVES OPTIONAL MAIN REFERENCE SYSTEM PILOT PILOT MAIN VALVES PAGE 5006B 5009B USA EI Elec Ign 1 7000DERHC S7C B 5010B 5026B USA 5006B 5026B CANADA 5008B 5026B USA amp CANADA 5006B 5013B CANADA Standing 1 L62GB 3C 2 V88A 5015B 5024B CANADA Standing 1 L62GB 3C 2 V88A LP GAS MODEL NO EI Elec Ign 1 H91WG 6 2 V88
126. f devices require annual inspection and maintenance Refer to instructions in Section V Paragraph 7 for inspection and cleaning instructions NOTICE Series 5B cast iron boilers are designed built marked and tested in accordance with the ASME Boiler and Pressure Vessel Code Section IV Heating Boilers An ASME Data Label is factory applied to each Series 5B jacket which indicates the boiler Maximum Allowable Working Pressure MAWP Each cast iron section is permanently marked with the MAWP listed on the boiler s ASME Data Label Those values for the Series 5B are as follows MAWP Water 50 PSI MAWP Steam 15 PSI SECTION 1 EQUIPMENT CHECK LIST U S A EQUIPMENT CHECK LIST For Canadian Equipment Check List Turn to Pages 7 and 8 This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered It covers standard equipment for both steam and water boilers without Tankless Heaters Heaters or optional equipment ordered will be in addition to or in lieu of equipment shown below By opening cartons in numerical sequence boiler assembly is simplified If there is an exception it will be pointed out in the boiler assembly procedure When it does occur you will find that assembly of the boiler is further simplified BOILER SIZE 1 1 1 e 1 1 21 3 C Cast on Section When supply
127. functioning of the working parts Inspect connecting lines to boiler CENTER THERMOCOUPLE 58 PILOT FLAME HONEYWELL Q327A PILOT W THERMOCOUPLE for accumulation of mud scale etc and clean as required Examine all visible wiring for brittle or warn insulation and make sure electrical contacts are clean and that they function properly Give special attention to solder joints on bellows and float when this type of control is used Check float for evidence of collapse and check mercury bulb where applicable for mercury separation or discoloration Do not attempt to repair mechanisms in the field Complete replacement mechanisms including necessary gaskets and installation instructions are available from the manufacturer Set thermostat to the highest setting While boiler is operating open drain valve and slowly drain down boiler water 71 SECTION V SERVICE continued CAUTION interest to prevent this type of failure The maintenance of system integrity is the best method to achieve this Do not drain water below gauge glass Refer to Recommended Water Quality Requirements hart on Page 44 Main burners should turn off when water carton tage level drops below low water cut off At this 9 OXYGEN CORROSION point the water level in gauge glass will just be visible Z WARNING Be sure that it is the low water cut off Oxygen contamination of the boiler water wi
128. gnition module has an internal 100 lockout function to completely shutdown the system should the pilot gas fail to 1gnite within approximately 90 seconds 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 a OPERATING INSTRUCTIONS 1 Make sure all Manual Main Shut off Valves and all Pilot Valves have been off for at least five minutes 2 Set Operating and Limit Controls to desired settings 3 Turn all Manual Main Shut Off Valves and Pilot Valves to Open Position 4 Turn on Main Electric Switch and Service Switch Pilot s will automatically light main burners b NORMAL OPERATION SEQUENCE 5006B thru 5009B see Fig 40 5010B thru 5014B see Fig 41 5015B thru 5026B see Fig 42 c SHUT DOWN INSTRUCTIONS 1 Close manual shut off valves and pilot valves 2 Turn off main electric switch d SAFETY SHUTDOWN 1 Safety Switch Circuit If limit control low water cut off or any other electrical safety switch opens power to the 24V terminal of all S8610M Ignition Controls 18 interrupted thus de energizing terminals PV and MV Loss of power to these terminals means loss of power to all pilot gas valves and to main gas valves resp
129. hose bib A through the heater and out hose bib B until the discharge is clear The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop HARD WATER This is applicable to some city water and particularly to well water This should not be a deterrent but precautions are necessary A water analysis 1s necessary and an appropriate water softener installed This is not only beneficial to the heater but to piping and fixtures plus the many other benefits derived from soft water NOTE A hot water boiler installed above radiation level must be provided with a low water cut off device as part of the installation 2 3 NWARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to using wrench applied to square shank on back of gauge DO NOT APPLY PRESSURE ON GAUGE GLASS b Install Temperature Limit Controls as follows excessively hot water at fixtures Adjust and maintain the mixing valve in accordance with the manufacturers instructions Bush 1 1 2 tapping in upper corner of End Section to 3 2 and install Temperature Limit Control furnished following instructions supplied with control On boilers without Built in Tankless Heater Install second temperature limit control not furnished in Tapped Heater Opening Cover Plate e Following recommendations supplied with control install 64 Low W
130. iginal owner that its commercial grade water and steam boilers and parts accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation If any part of a commercial grade boiler or any part or accessory provided by Burnham Commercial is found to be defective in material or workmanship during this one year period Burnham Commercial will at its option repair or replace the defective part not including labor HEAT EXCHANGER WARRANTIES Burnham Commercial warrants to the original owner that the heat exchanger of its commercial grade boilers will remain free from defects in material and workmanship under normal usage for the time period specified in the chart below to the original owner at tho original place of installation claim is mado under this warranty during the No Charge period from the date of original installation Burnham Commercial will at its option repair or replace the heat exchanger not including labor a claim is made under this warranty after tho expiration of tho Charge poriod from the dato of original installation Burnham Commercial will at its option and upon payment of tho pro rated service charge set forth below repair or replace the heat exchanger The service charge applicable to a heat exchanger warranty
131. il for about 5 hours Open boiler feed pipe sufficiently to permit a steady trickle of water from the surface blowoff pipe Continue this slow boiling and trickle of overflow for several hours until the water coming from the overflow 18 clear d Stop burner and drain boiler in a manner and to a location that hot water can be discharged with safety e Refill boiler to normal water line If water in gauge glass does not appear to be clear repeat steps a through c and boil out the boiler for a longer time Low pressure steam boilers such as the 5B series should be maintained with appropriate water treatment compounds Add suitable water treatment compounds as recommended by your qualified water treatment company BOILER AND SYSTEM CLEANING 3 Remove temporary surface blowoff piping plug INSTRUCTIONS FOR TROUBLE FREE tapping and reinstall safety valve Boil or bring OPERATION water temperature to 180 F promptly in order to rx drive off the dissolved gases in the fresh water A qualified water treatment chemical specialist should be consulted for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations 4 If unsteady water line foaming or priming persist install gate valve in Hartford Loop and drain valves in return main and at boiler and proceed as follows a Connect hoses from drain valves to floor drain Close gate valve in Hartford Loop
132. ing front of burner slightly then pushing burner toward rear of boiler until front of burner clears orifice then lift rear of burner until head of weld pin on bottom rear of burner clears keyhole slot in base rear panel Burner is now free and can be lifted out thru opening in base front frame d Remove all burners with pilots by first tracing all electrical leads coming from pilot to their points of connection remove leads from terminals to which they are connected and then tag each lead with respective terminal designation Disconnect Pilot Tubing at nearest connection to pilot and remove burner as outlined in paragraph c above e When replacing burners reverse procedure used in removal of burners Make sure burners are secure in keyhole slots in base rear panel and hitch pin clips are installed in grooves in all main burner orifices Burners with pilots must be in same locations as original installation If markings placed on manifold when burners were removed are obliterated see Fig 54 Reconnect electrical leads and reconnect pilot tubing Reinstall Flue Cleanout Plates so that they are gas tight Reinstall Burner Access Panels and Jacket Panels LUBRICATION Manufacturers Instruction should be followed on all parts installed on the boiler that require lubrication Generally this involves only the circulator in a hot water system This includes a Type of lubricant to be used b Frequency of lubrication c Points
133. ing the cast iron When this addition of make up water happens the cast iron in that area gets extremely hot b Eliminating open tanks from the system and eventually cracks The presence of free oxygen in the boiler creates a corrosive atmosphere which if the concentration becomes high enough can corrode the cast iron through from the inside Since neither of these failure types are the result of a casting defect the warranty does not apply Clearly it is in everyone s best c Eliminating and or repairing fittings which allow oxygen absorption d Use of non permeable materials in the distribution system e Isolating the boiler from the system water by installing a heat exchanger If during normal operation it is necessary to add water to this boiler more frequently than once a month consult a qualified service technician to check your system for leaks A leaky system will increase the volume of make up water supplied to the boiler which can significantly shorten a life of the boiler Entrained in make up water are dissolved minerals and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas Both can result in reduced boiler life The accumulation of sediment can eventually isolate the water from contacting the cast iron When this happens the cast iron in that area gets extremely hot and eventually cracks The presence of free oxygen in th
134. ings install between tappings H and return B Use opposite return B for system return connection Water boilers using a probe LWCO must mount probe in suppl 14 y pipe above boiler without any stop valves 10 SECTION INSTALLATION FIG 8 INSTALLATION OF BUILT IN HEATER Open Steam or Water Trim Carton USE THE PLUGS IN THIS CARTON to plug tappings in End Sections that will not be utilized on final installation see Fig 7 Open Tankless Heater Carton s If Supplied Open Heater Opening Cover Plate Carton s INSTALL BUILT IN WATER HEATER S OR HEATER OPENING COVER PLATE S See Fig 8 Heater may be installed in either End Section or in some cases in both End Sections Heater Opening Cover Plates are used to cover any unused heater openings a Place rubber gasket against surface of plate and align holes b Place washer on each of 3 8 Cap Screws furnished and insert cap screws through plate and gasket Start all screws in taps before final tightening HYDROSTATIC TEST see Fig 9 After the boiler sections have been assembled it is essential that the boiler be hydrostatically tested before the canopy flue cover plates jacket or piping is installed a Plug all boiler tappings and fill boiler completely with cold water b Allcompletedboilers must satisfactorily pass the prescribed hydrostatic test 1 STEAM BOILERS The assembled boiler must be subjected to a hydrostatic test of 45 psig to 5
135. ion Lead Honeywell R1061012 6 Long 7136256 3 Flame Rod Lead Honeywell R1298020 6 Long 8236021 4 Female Rajah Connector Honeywell 37356 6236020 5 Ground Wire Continental SRGX 600 200 C Green 72 Long 8236015 6 Vent Tube Tip USA Only 8236016 7 Vent Tube Clip Tinnerman C4886A4 27 USA Only 104 Figure Number Page Number APPENDIX A FIGURES Description Section Equipment Check List USA KD Boilers Canada KD Boilers Fig 1 5 amp 6 7 amp 8 9 U S A Equipment Check List Canadian Equipment Check List Dimensional Data Section Il General Information Section III Installation Instructions Fig 2 11 Single Manifold Base 5006B Thru 5014B Section Boilers Fig 3 12 Dual Manifold Bases 5015B Thru 5026B Section Boilers Fig 4 12 LEH Section on Base Fig 5 12 Assembly of Center Sections Fig 6 13 Arrangement of Sections and Canopy s Fig 7 14 Purpose of Tappings and Their Locations Fig 8 15 Installation of Built in Heater Fig 9 15 Testing Boiler Assembly for Leaks Fig 10 16 Sealing of Base Installation of Flue Covers and Canopies Fig 11 16 Attachment of Flue Covers Fig 12 17 Recommended Steam Boiler Piping Gravity Return 1 or 2 Supply Connections 5006B Thru 5014B Section Boilers Fig 13 18 Recommended Steam Boiler Piping Gravity Return 3 Supply Connections 5015B Thru 5020B Section Boilers Fig 14 19 Recommended Steam Boiler Piping Gravity Return 4 or 5
136. ion of the burners supplied by the second gas train will be unaffected L1 L2 POWER e SUPPLY 120 60 1 OPERATING CONTROL 1 12 LON WAER CUTE OFE 5 NOT FURNISHED AS STD EQUIP 120 60 1 WATER M amp M 64 STEAM 1404 EQUAL POWER SUPPLY FUSED WATER 14006 DISCONNECT DISCONNECT SWITCH 1 2 m SERVICE sel LIMIT CONTROL SWITCH MANUAL RESET SERVICE STEAM 140798 _ WATER L4006E wa IF USED CONTROL CONTROL 9 JUNCTION JUNCTION 5 TRANSFORMER BOX BOX 8 Ee o rr p m m a PRIM WH 4 gt TRANS M 88 pem eem N gt wil wH SSS 444 Se PILOT SAFETY vANE Gs OS PAS 40VA FI HONEYWELL V88A TRANSFORMER TRANSFORMER ae HONEYWELL V88A AN RS MAIN GAS VALVES MAIN GAS VALVES PILOT SAFETY xi W VALVE COILS po 5 oS LEFT GAS TRAIN WIRING RIGHT GAS TRAIN WIRING Vy w BK R d BK R v v lt s
137. ition with Wire Ties furnished to provide strain relief Provide adequate support and strain relief for wiring outside jacket COMPLETION OF WIRING Connect power supply fused disconnect switch service switch primary and secondary side of gas valve transformer primary side of ignition transformer and remaining controls see Fig 44 for wire type and connections to be made All wiring must be adequately supported and strain relief provided All wiring including ground connections must comply with the requirements of the authority having jurisdiction and in the absence of such to the National Electrical Code ANSI NFPA No 70 2005 or the Canadian Electrical Code C22 1 whichever is applicable Thermocouple Control System INSTALLATION OF PILOT SAFETY SWITCH AND PILOT PIPING Using two 10 32 x 2 MS and nuts install the L62GB 3C pilot safety switch bracket on the manifold just to the right of the main burner with pilot Install L62GB 3C pilot safety switch on bracket using two 10 32 2 MS IN on pilot safety switch should be pointed in the direction of the Gas Train to which the pilot safety switch 1s to be connected see Fig 37 Using 4 OD aluminum tubing connect the pilot shutoff valve installed in the manual shutoff valve in the gas train to the inlet of the RV 12LT regulator packed in Gas Train Carton Regulator should be above Gas Train and near front of boiler see Fig 36 Install 3 8 tee into ou
138. ll cause control and not the room thermostat corrosion of iron and steel boiler components and pressure cut out or other control that has can lead to boiler failure Burnham Commercial s shut off the burners standard warranty does not cover problems caused Refill the boiler to the normal water level by oxygen contamination of boiler water or scale Main burners should reignite lime build up caused by frequent addition of water Clean out the boiler according to the instructions for steam boilers on page 43 There are many possible causes of oxygen Reset controls for normal operation contamination such as 8 FREQUENT WATER ADDITION a Addition of excessive make up water as a result of system leaks A leaky system will increase the volume of make up b water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up Absorption through open tanks and fittings c Oxygen permeable materials in the distribution water are dissolved minerals and oxygen When the system fresh cool make up water is heated in the boiler the In order to ensure long product life oxygen minerals fall out as sediment and the oxygen escapes sources should be eliminated This can be as a gas Both can result in reduced boiler life The accomplished by taking the following measures accumulation of sediment can eventually isolate a Repairing system leaks to eliminate the need for the water from contact
139. lves and the main gas burners and pilot burners are immediately Q extinguished Normal operation can be resumed when the cause of the safety switch malfunction Is corrected Make sure all manual resets are activated where applicable PILOT FAILURE a Pilot failure can occur during the start and operating cycle of the boiler Any pilot failure on either of the Q179C Electronic Pilots after ignition of pilot flame will close the pilot valve and the main gas valves controlled by that particular RM7890A relay in 0 8 second The burners controlled by the other RM7890A will continue to burn b For 15 seconds after failure of a Q179C pilot the relay through terminals 8 and 10 will attempt to re establish pilot flame If no pilot flame can be sensed by the flame rod circuit in 15 seconds terminals 8 and 10 are de energized and the relay will lock out on safety c Pilot failure is caused by the following 1 Complete loss of gas supply 2 Poor ignition spark caused by low voltage poor ground connection faulty wiring and possibly a defective ignition transformer 3 Low gas pressure will prevent flame rod circuit from sensing pilot flame properly 4 Unusually strong secondary air drafts can blow the pilot flame away from the flame rod momentarily causing nuisance shutdown 5 A pilot line solenoid valve will not open because of faulty wiring low voltage or possibly the valve is defective 6 A defective RM7
140. mpound to make joints gas tight 15 SECTION INSTALLATION INSTRUCTIONS continued CARRIAGE BOLT FLUE FIG 10 SEALING OF BASE INSTALLATION OF FLUE COVERS AND CANOPIES 13 INSTALL FLUE COVER PLATES over cleanout openings on Front and Rear of Boiler Use 4 Carriage Bolts installed at top and bottom of flue openings and secure with washer and jam nut to provide a fixed stud Install flue cover plates over studs with insulation against Boiler and secure with washers and nuts see Fig 11 CONNECT SUPPLY AND RETURN PIPING TO HEATING SYSTEM CLEARANCES Steam and Hot water pipes shall have clearances of at least from all combustible construction NOTICE Before using copper for steam piping consider the following characteristics of copper piping 1 high coefficient of thermal expansion can induce mechanical stresses and cause expansion contraction noises if not accounted for in the piping system design and installation 2 high heat transfer rate heat loss of uninsulated copper piping must be included in the normal piping and pickup factors used to size the boiler 3 soldering or brazing pastes and fluxes that end up in the system can cause poor heat transfer surging and unsteady water line and wet steam if not thoroughly removed during the boil out procedure and 4 galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water chemistries if dielectric unions ar
141. nd understand all instructions including all those contained in component manufacturers manuals which are provided with the appliance before installing starting up operating maintaining or servicing this appliance Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician This boiler requires regular maintenance and service to operate safely Follow the instructions contained in this manual Installation maintenance and service must be performed only by an experienced skilled and knowledgeable installer or service agency All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed Installation is not complete unless a pressure relief valve is installed into the specified tapping on the supply manifold located on top and at rear of appliance See Section Paragraph 33 of this manual for details This boiler is NOT suitable for installation on combustible flooring Do not tamper with or alter the boiler or controls Retain your contractor or a competent serviceman to assure that the unit is properly adjusted and maintained Clean boiler at least once a year
142. noeg 00595 HIY 08398 5 uonoes H31 WALI 5529508 5409908 620009908 061719 061712 20612121 8061111 10611171 81 119261819 116161819 19881819 69261819 2861 61819 16161819 12611819 89208 LOVLELBLO LLVLEL8LO 197161819 51819 97109 11 261819 116161819 47261819 67261819 286161819 126161819 116161819 246161819 garzos 196161819 116161819 LSELEL8LO CVELELBLO 86108 11061819 110161819 14681819 62681819 290 21819 1011819 12011819 280161819 82008 192161819 112161819 LGZLEL8LO CVCLELBLO 82108 11161819 12011819 11261819 61261819 120161819 120161819 2801 61819 9109 191161819 111161819 81161819 291161819 8 04 110261819 110161819 10681819 60261819 LVOZEL8LO LZOLEL8LO 110161819 280161819 80208 190 21819 110161819 190 21819 2 0161819 90109 116161819 110161819 16161819 66161819 1611819 120161819 120161819 286061819 86019 96061819 116061819 19601819 5876061819 86009 118161819 110161819 18161819 68161819 17811819 1011819 12011819 280161819 88019 98061819 8061819 19802 1819 5780651819 88009 51819 12601819 11161819 61161819 1 1161819 126081819 126081819 290 21819 92109 19201819 111061819 19102 819 2 1061819 81009
143. ntial property damage but not related to personal injury hazards NOTICE THIS BOILER HAS A LIMITED WARRANTY 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 The warranty for this boiler is valid only if the boiler has been installed maintained and operated in accordance with these instructions ADANGER 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 or fuel oil vapors do not try to operate the burner boiler system Do not touch any electrical switch or use any phone in the building Immediately call the gas or oil supplier from a remotely located phone Burner boiler systems produce steam or hot water in a pressurized vessel by mixing extremely flammable gaseous liquid or solid fuels with air to produce combustion and very hot products of combustion Explosions fires severe personal injury death and or property damage will result from improper careless or inadequate installation operation or maintenance of fuel burning and boiler equipment Z WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Failure to follow all instructions in the proper order can cause personal injury or death Read a
144. oiler slowly into supply main and back if necessary to bring the pH within the specified through return main flowing from drain hose range With this lower level of protection care must at about 180 F Continue until water runs clear be exercised to eliminate all of the free oxygen in from drain hose for at least 30 minutes the system d Stop feeding water to boiler but continue 4 Boiler is now ready to be put into service operating burner until excess water in boiler flows out through supply main and water lowers Recommended Water Quality Requirements by steaming until it reaches normal level in pH 8 3 10 5 boiler Turn off burner Drain boiler Open all radiator 559300 ppm valves Reinstall all supply main air valves Total alkalinity ppm as CaCO 1200 Open gate valve in Hartford Loop Total copper ppm lt 05 e When boiler has cooled down sufficiently Oily matter ppm 1 crown sheet of sections are not too hot to touch close the drain valves at boiler and in return main and feed water slowly up to normal Chlorides 50 ppm level in boiler Turn on burner and allow boiler to steam for 10 minutes then turn off burner Draw off one quart of water from bottom gauge TABLE IV WATER CONTENT glass fitting and discard Draw off another quart uum sample and if this sample is not clear repeat the cycle of draining the boiler and return main and refilling the boiler until sample is clear f Ifthe boiler water becom
145. om 1 8 pipe tapping in each manifold Plug tappings with square head pipe plugs Install gas valve in tee in each pilot line Connect manometer to each gas valve and with boiler in operation set pilot line pressure at 5 5 water natural gas boilers and 6 5 water propane gas boilers Shut boiler down remove gas valves and manometers and plug tees with square head pipe plugs Restart boiler SECTION IV OPERATION continued 11 MINIMUM INPUT ADJUSTMENTS This section covers Minimum Input Adjustments on Honeywell V8944B Diaphragm Type Lo Hi Lo Gas Valves Honeywell V5055B Fluid Power Gas Valves equipped with either a V4062A Lo Hi Lo Actuator or a 9055 Modulating Actuator a Minimum Input Adjustments Lo Hi Lo Combination Valve V8944B Natural Gas Only On boilers equipped with the V8944B combination diaphragm valve regulator Low Fire Adjustment should not be less than Minimum Input shown on Rating Plate 1 3 of full rated input Fig 48 shows the outlet pressure adjustment screws for low and high fire The V8944B low and high fire pressure settings are factory set at 0 8 and 3 5 W C respectively If further adjustments are necessary remove pressure regulator adjustment caps and insert a screwdriver to raise or lower the regulator pressure PRESSURE REGULATOR ADJUSTMENT f CAPS LO ATMOSPHERIC PRESSURE REFERENCE PORT WITH INTERNAL gt VENT LIMITER
146. on of lower framework a Install Vestibule Panel s refer to Fig 21 and 24 Attach Hex Couplings to end of Carriage Bolts which secure Flue Cover Plates NOTE Select Carriage Bolts which line up with holes in the Vestibule Panel s 28 b Attach Intermediate Vestibule Panel s to one of the Vestibule Panel s using 8 SMS c Secure Left and Right Vestibule Panels to Hex Couplings using 4 20 x 3 8 slotted pan head machine screws Attach the Lower Rear Intermediate Panels to the Lower Rear Intermediate Panel Support Bracket s using 10 32 x gt self tapping screws Attach the Upper Rear Intermediate Panel s to the Lower Rear Intermediate Panel s using 8 SMS f Attach Rear Top Intermediate Jacket Panel s to Rear Top Left and Right Jacket Panels using 8 SMS g Place Assembled Rear Top Jacket Panel in position and attach to Upper End Panels and Upper Rear Intermediate Panel using 8 SMS i INSTALLATION OF CANOPY DRAFT HOOD 50118 THRU 5026B SECTION BOILERS these boilers require two or more Canopy Draft Hoods refer to Fig 6 for proper arrangement Determine where ends of Canopy Draft Hood rest on intermediate sections Place 1 x 14 1 2 Cerafelt strips on top of intermediate section at these locations Place Cerafelt strips on top of section assembly next to ledges formed by center sections and next to ledges on end sections Overlap at corner SECURE CANOPY DRAFT HOODS with machin
147. ontinued U S A EQUIPMENT CHECK LIST BOILER SIZE Tsoose 5007 soos 50098 0108 50128 50138 50148 50158 50168 50178 50188 5019 50206 50218 56228 56228 156255 CARTONS PACKAGES OR BUNDLES Steam Trim Carton Steam Boilers Only Includes PA404 Pressure Limit Control 4 Sizes One Per Boiler Low Water Cut off Carton Steam Boilers Only One Per Boiler tw persa aes 28 1 1 ps Water Trim Carton Water Boilers Only Includes L4006A Temp Limit Control 3 Sizes One Per Boiler 6 Low Water Cut off Carton Water Boilers Only One Per Boiler 4 r popa 1 121 U 8 Complete Jacket Carton Assembly One Per Boiler Gas Train Cartons By Gas 2 Sizes One or Two Per Boiler 9 PO 9 51 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 EI Controls Carton s By Gas Intermittent Elec Ign 10096 Shutoff 24V 1 Size One or Two Per Boiler EI u Se SESI 2 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 U Plain Heater Cover Plate Not furnished on Water Boiler Ordered With Two Tankless Heaters One Per Boiler 1 rese s e spe ea
148. operating and safety controls Should any of the aforementioned controls break the power supply circuit both EP control systems would be de energized The succeeding paragraphs describe the function and operation of each EP Control System Should a pilot failure on one EP Control System occur the other EP Control System would not be affected Thus main burners on the unaffected side would ignite on a for heat and would continue to operate until the operating control was satisfied The EP Control System utilizes and RM7890A Relay Module and a Q179C Rectification Pilot which in addition to a pilot burner and rectifying flame rod flame detector to prove pilot includes an ignition electrode for spark ignition of the pilot A Webster 612 6A7 Transformer supplies the high voltage spark potential Once pilot flame is proven ignition stops but pilot flame continues as long as there is a for heat intermittent electrically ignited pilot The RM7890A Primary Control is a non programming amplifying relay which when used with the Q179C Pilot provides solid state electronic Flame Safeguard Protection that will not allow the main gas valve to open on call for heat or that will shut down main burners within 0 8 second if pilot flame is not proved Relay Module will lock out on safety shutdown within 15 seconds if there is a pilot flame failure on start or if during the run cycle pilot flame is not re established
149. osen the setscrew and rotate cam in the opposite direction to the desired set point 7 Shut down burner and then restart Repeat several times to be sure the low fire setting 18 that desired and suitable for correct burner lightoff Readjust if necessary 8 Disconnect power and reconnect controller lead removed in step 3 above 9 Replace the wiring compartment cover MINIMUM INPUT ADJUSTMENTS MOTORIZED MODULATING ACTUATOR 9055 On boilers equipped with Fluid Power Valves that have Modulating Actuators Low Fire Adjustment should not be less than Minimum Input shown on Rating Plate 1 3 of full rated input Fig 50 shows the Low Fire Adjusting Screw for increasing or decreasing low fire input on the Honeywell V9055A Modulating Actuator To adjust the low fire setting after the burners are the following procedure should be used 1 With power to actuator off remove the wiring compartment cover 2 Check to make sure the low fire adjustment is set at MAX full clockwise to insure a safe light off Low fire adjustment is preset at the factory in the MAX position 61 62 LOW FIRE ADJUSTMENT PROOF OF CLOSURE SECTION IV OPERATION continued LOW FIRE CAM SETSCREW DUAL LOW FIRE SETPOINT INDICATORS SHOWN AT MAX WITH VALVE OPEN FIG 49 LOW FIRE ADJUSTMENT V4062 ACTUATOR 3 Remove the lead to 9055
150. per Left End Panel in a similar manner see Fig 19 NOTE FOR INSTALLATION OF THE FRAMEWORK FOR THE LOWER UNCOMMON JACKET PARTS REFER TO THE FOLLOWING a 5006B thru 5010B section boilers Paragraph 16 Fig 21 b 5011B thru 5026B section boilers Paragraph 30 Fig 24 25 or 26 In order to insure long product life oxygen sources should be eliminated This can be accomplished by taking the following measures COMPLETION OF JACKET INSTALLATION 5006B THRU 5010B SECTION BOILERS NOTE Do not tighten any screws until Jacket installation is complete INSTALLATION OF LOWER FRAMEWORK 16 With U channel facing down slip upper front channel behind joints formed by End Panels and secure to End Panels using 8 SMS Position Lower Front Channel so that U of channel faces boiler Slip Lower Front Channel behind Lower End Panels and secure with 8 SMS Repeat similar procedure for installation of Upper Rear and Lower Rear Channels FIG 18 INSTALLATION OF JACKET SUPPORT 17 INSTALLATION OF VESTIBULE PANEL refer to BRACKETS TO BASE END PANELS Fig 20 22 SECTION INSTALLATION INSTRUCTIONS continued 18 19 20 21 Attach Hex Couplings to end of Carriage Bolts which secure flue cover plates NOTE Select Carriage Bolts which line up with holes in the Vestibule Panel SECURE VESTIBULE PANEL TO HEX COUPLINGS using 47 20 3 8 slotted pan head machine screws ATTACH REAR TOP JACKET P
151. r optional equipment ordered will be in addition to or in lieu of equipment shown below By opening cartons in numerical sequence boiler assembly 1s simplified If there is an exception it will be pointed out in the boiler assembly procedure When it does occur you will find that assembly of the boiler is further simplified BOILER SIZE S E ER Ed 1 CERT SR SER ER RR ES ER E SEN ER ERES RAT Pepes SE ie D e eol ese es 235418 C Cast on Section When supply and return connections are tapped and plugged section is paint stencilled CXP CARTONS PACKAGES OR BUNDLES Base Burner Manifold Assembly By Gas and By Pilot System One Left amp One Right Req d on 5015B and Larger Boilers 1 1 1 1 1 1 10 11 1 1 1 z N 2 COMPLETE 1 B B 1 1 B 4 L SUB BASE EN 4 EN 2 2 2 SUB BASE 6 EN 65 6 EN 6 EN A A d N 2 NIN A SINISI gt y la T 5 9 z os 2 3 2 3 Sizes One to Th W 9 e o n s 6 Sizes One to Five Per Boiler
152. r to drive off the dissolved gases which might otherwise corrode the boiler PURGE GAS PIPING OF AIR Check Manual Shut Off Valve s and Pilot Shut Off Valve s at boiler to see that they are closed Turn gas on at meter Disconnect Pilot Tubing at Pilot Shut Off Valve s open Pilot Valve s until gas flows from valve s KEEPING A CONSTANT CHECK DURING THE PURGING Close pilot valve s and reconnect the pilot tubing In Canada refer to applicable Installation Codes for purging procedure SINCE LIGHTING INSTRUCTIONS SHUTDOWN INSTRUCTIONS AND CONTROL SEQUENCE OF OPERATION VARY WITH GAS CONTROL SYSTEM INSTALLED REFERENCE SHOULD NEXT BE MADE TO THE APPLICABLE CONTROL SYSTEM EI Control System Page 46 EP Control System Page 52 THERM Control System Page 57 Check all electrical circuits and connections Then follow lighting instructions up to a point where the boiler is ready to light be achieved or if the condensate 18 returned to the boiler boil out the boiler using the surface blowoff connection See Fig 7 a Drain boiler until water is just visible in gauge glass Run temporary 1 pipe line from the surface blowoff connection to an open drain or some other location where hot water may be discharged safely Do not install valve in this line b Add an appropriate amount of recommended boil out compound c Start burner and operate sufficiently to boil the water without producing steam pressure Bo
153. rmocouple Control System Should a pilot failure on one Thermocouple Control System occur the other Thermocouple Control System would not be affected Thus main burners on the unaffected side would ignite on a call for heat and would continue to operate until the operating control was satisfied a LIGHTING INSTRUCTIONS 1 Make sure that all main manual and pilot valves have been off for at least five 5 minutes 2 Set operating and limit controls to desired setting 3 Open pilot valve 4 Depress button on pilot safety switch to which it is connected and hold lighted match on pilot Hold button in for at least one minute or until the pilot burner remains lit after the button 1s released Repeat for second pilot when boiler is so equipped 5 Open manual main shut off valve s 6 Turn on main electric switch NORMAL OPERATION SEQUENCE 5006B thru 5014B see Fig 46 5015B thru 5024B see Fig 47 57 SECTION IV OPERATION continued When operating control A calls for heat it energizes main gas valves B starting burner operation The burners will operate until operating control A is satisfied The high limit control C will stop burner operation in case of excessive steam pressure steam boiler or excessive boiler water temperature water boiler Low water cut off D will stop burner operation if the water level in boiler drops below the lowest safe level The pilot safety switch E
154. rranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE HEAT EXCHANGER IN A COMMERCIAL GRADE BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the owner is requested to complete and the Warranty Card provided with the product or register product online at wwvw burnhamcommercialcastiron com within ten days after the installation of the boiler although failure to comply with this request will not void the owner s rights under these warranties Upon discovery of a condibon believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor f this action is not possible or does not produce a prompt response the owner should write to Burnham Commercial P O Box 3939 Lancaster PA 17604 giving full particulars in support of tho claim Tho owner is required to make available for inspection by Burnham Commercial
155. rvice Record Service Performed Section VI Repair Parts Index 74 Repair Parts Index Table 2A 76 Series 5B Base Parts 5006B Thru 5014B Table 2B 77 Series 5B Base Parts 50158 Thru 50268 Table 3A 80 Series 5B Integral Canopy Draft Hoods Boiler Sizes 5006B Thru 5010B Table 3B 81 Series 5B Section Replacement Chart Table 3C 82 Series 5B Base Pilot Assemblies Table 4A 84 Series 5B Jackets 5006B Thru 5015B Table 4B 85 Series 5B Jackets 5006B Thru 5015B Table 4C 86 Series 5B Jackets 5016B Thru 5026B Table 4D 87 Series 5B Jackets 5016B Thru 5026B Table 4E 87 Complete Jackets Table 4F 88 Water Trim Table 4G 89 Steam Trim cista 90 7000DERHC Gas Train El 50068 thru 50098 USA 91 V88A Gas Train USA Honeywell 92 V88A Gas Train Canada Natural Gas Only Gas Train 93 Fluid Power Gas Train USA 94 Diaphragm Valve LO HI LO Gas Train USA Natural Gas Only Gas Train Honeywell 95 Diaphragm Valve LO HI LO Gas Train Canada Natural Gas Only Gas Train 2 96 Fluid Power Gas Train Canada Honeywell 97 Ignition Module 58610 and Support Bracket El Control System Ignition Module 108 APPENDIX B TABLES continued Table Number Page Number Description Section VI Repair Parts continued Penn Johnson Control System Penn Pilot Solenoid Valve Ass y Maxitrol Pilot Reg Penn Pilot Solenoid Valve Ass y Control Assembly Honeywell Q3481 Pilot Ass y Honeywell Q179C Pilo
156. sed by water side clogging due to dirty systems or corrosion products from the system Any damage resulting from natural disaster m Damage or malfunction due to the lack of required maintenance outlined in the Installation and Operating Manuals furnished with the unit 6 Exclusive Remedy Burnham Commercial obligation for any breach of these warranties is limited to the repair or replacement of its parts not including labor in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall Burnham Commercial be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time Burnham Commercial liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the commercial grade boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 8 Limitation of Warrantios Those warranties sot forth tho entire obligation of Burnham Commercial with respect to amy defect in a commercial grade boiler parts or accessories and Burnham Commercial shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set forth herein These wa
157. service is dependent on a Required supply of gas in cu ft hr input of boiler in BTUH heat value of gas BTU cu ft b Allowable loss of pressure in piping to obtain minimum input pressure indicated on rating label of boiler c Length of piping in feet and number of elbows for practical purposes each 90 elbow can be considered as the following equivalent in length of straight pipe 34 24ft 2 5 2 ft 1 2 6 ft 2 12 6 2 ft 1 1 4 3 5 32 7 7 ft 1 127 4 0 ft 4 10 1 ft Specific gravity of gas In the absence of requirements of the authority having jurisdiction the tables below may be used to size natural gas supply piping A pipe thread compound resistant to the action of liquefied petroleum gases must be used on all threaded joints in the gas piping Pressure testing of the Gas Supply Piping Boiler and its connections is required before placing the boiler in operation The boiler and shutoff valve must be disconnected from the gas supply piping system during any pressure testing at pressures greater than gt psig The boiler must be isolated from the gas supply piping system during any pressure testing at pressures equal to or less than psig WITH GAS SUPPLY OFF and Service Piping connected to the boiler open Manual Valve s and pilot valve s at end of Gas Train s and reduce pressure to lb gage pressure Using soap solution or other approved method check gas tr
158. shed on Water Boiler Ordered With Two Tankless Heaters One Per Boiler 1 E kumain 4 ge 1 ese pog U HCP Tapped NPT Heater Cover Plate Not Furnished on Water Boiler Ordered With Tankless Heater s One Per Boiler 2 pps mima nee pose sr 0 e INSPECT SHIPMENT carefully for any signs of damage All equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of Boiler to carrier in good condition Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within sixty 60 days after receipt of equipment SECTION I EQUIPMENT CHECK LIST Page 5 SECTION II GENERAL INFORMATION Page 10 SECTION III INSTALLATION INSTRUCTIONS Page 11 SECTION IV OPERATION Page 43 SECTION V SERVICE Page 64 SERVICE RECORDS Pages 73 110 111 SECTION VI REPAIR PARTS Page 74 APPENDIX A FIGURES Page 105 APPENDIX B TABLES Page 108 VIVO IVNOISN3WIG L 213 Q31V CTI NNI sm S ANA LNONA AJIA LAJT O3llddns AB 03n LON nino LON 50 3 H10 I
159. stall Boiler Drain Valve into one of unused return equally applicable to the second set 2M tapping Mat mas PRESSURE TESTING of gas service piping must be can also be installed in return piping preferably done before connecting to the boiler gas train Test for in leg of tee that 1s located in line with return ti Boil leaks by introducing from an isolated source air or inert gas to the piping Piping shall withstand 3 PSI 35 CONNECT PIPING TO BUILT IN HEATER S IF gage pressure for a period of not less than 10 minutes USED see Fig 30 top left side of this page without showing any drop in pressure 34 50 55 65 70 SECTION INSTALLATION INSTRUCTIONS continued 37 A DRIP LEG SHOULD BE PROVIDED IN THE VERTICAL DROP TO EACH GAS TRAIN see Fig 1 An additional Manual Shut off valve and ground joint union as show in Fig 1 should be installed in the piping to each gas train for ease of servicing CONNECT GAS SERVICE FROM METER TO GAS TRAIN in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements to the USA National Fuel Gas Code ANSI Z223 1 CANADA Installation Codes for Natural and LP Gas Burning Appliances and Equipment CAN B149 1 amp 227 The size of the gas train s has no criteria as to the size of the service from the meter to the gas train s Sizing of the
160. t Ass y Miscellaneous Tables Rear Cover 98 99 100 101 102 103 104 108 109 Pilotstat L62GB amp Support Bracket Thermocouple Control System Transformer Penn H91WG 5 Pilot Solenoid Valve and Pilot Line Regulator El Control System USA 5010B 5026B Natural Gas Canada 5006B 5026B Natural Gas Transformer and Pilot Line Regulator Thermocouple Control System Canada Transformer Penn H91WA 4 Pilot Solenoid Valve and Pilot Line Regulator EP Control System Control Assembly amp Mounting Bracket EP Control Systems Control System Honeywell 33481 Pilot Assembly EP Control System Pilot Assembly Appendix B Tables Limited Warranty for Commercial Grade Boilers and Parts Accessories 109 110 SERVICE RECORD SERVICE PERFORMED SERVICE RECORD SERVICE PERFORMED 111 Limited Warranty For Commercial Grade Boilers Using Cast Iron Carbon Steel or Stainless Steel Heat Exchangers and Parts Accessories Subject to the terms and conditions set forth below Burnham Commercial Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and or accessories manufactured and shipped on or after October 1 2009 ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS AND PARTS ACCESSORIES SUPPLIED BY BURNHAM COMMERCIAL Burnham Commercial warrants to the or
161. tall heat shield optional INSTALLATION OF PILOT PIPING Install the 91 4 pilot solenoid valve in the bottom center knockout of the J box using conduit fittings furnished see Fig 35 Install RV 12LT regulator Packed in Gas Train Carton and 1 8 tee in the 1 4 OD pilot tubing as shown in Fig 35 INSTALLATION OF BLEED PIPING Using OD aluminum tubing install a bleed line on both diaphragm valves connect together see Fig 35 and on USA boilers run tubing to bleed line protruding from inside base see Fig 35 On boilers installed in Canada run bleed line to outdoors 37 SECTION INSTALLATION INSTRUCTIONS continued DUST COVER CAPTIVE SECURING SCREWS NL LL CLIP JR2 RESISTOR WIRE DUST cover ADS AND PLE AMPLIFIER USI COMI DISCARD HONEYWELL ET poa RM7890 OPTIONAL CONTROL HEAT SHIELD 220 4 T P N 70116003 HONEYWELL Q7800 CONTROL CABINET COVER SUB BASE 8 x Le CONTROL CABINET SHEET TYPE B FIG 34 INSTALLATION OF EP CONTROL PANEL PILOT TUBING PENN H91WA 4 SOLENOID VALVE COMP NUTS WITH ATTACHED SLEEVES MALE COMP ADAPTERS BLEED LINE USA SHOWN RV 12 LT REGULATOR CANADA VENT TO OUTDOORS IGNITION ELECTRODE LEAD Df CES IGNITION ELECTRODE PILOT BURNER FLAME ELECTRODE PILOT BRACKET MANUAL L FLAME ELECTRODE LEAD SHUT
162. tallation of EP Mounting Bracket and Controls Fig 35 38 Pilot Piping EP Control System 105 Description Section Ill Installation Instructions continued Fig 36 40 Pilot Piping Thermocouple Control System Canada Only Fig 37 40 Installation of Pilot Safety Switch Thermocouple Control System Fig 38 41 Single Vent System Fig 39 41 Manifold Vent System Section IV Operation Fig 40 47 Schematic Wiring Diagram El Control System Robertshaw7000 Gas Valve USA 5006B Thru 5009B Fig 41 48 Schematic Wiring Diagram El Control System V88 Gas Train USA 5010B Thru 5014B Canada 5006B Thru 5014B Fig 42 49 Schematic Wiring Diagram 5015B Thru 5026B Section Boilers El Control System Fig 43 50 Ladder Wiring Diagram 5015B Thru 5026B Section Boilers El Control System Fig 44 54 Wiring Diagram 5006B Thru 5014B Section Boilers EP Control System Fig 45 55 Wiring Diagram 5015B Thru 5026B Section Boilers EP Control System Fig 46 58 Wiring Diagram 5006B Thru 5014B Section Boilers Thermocouple Control System Canada Only Fig 47 59 Wiring Diagram 5015B Thru 5024B Section Boilers Thermocouple Control System Canada Only Fig 48 61 V8944B Combination Valve Fig 49 62 Low Fire Adjustment V4062 Actuator Fig 50 62 Low Fire Adjustment V9055A Actuator Section V Service Fig 51 64 Removal of Jacket Front Panel Fig 52 66 Attachment of Flue Covers Fig 53 66 Cleaning of Flueways Fig 54 1 68 Pilot Locations Fig
163. tely Pressure Gauge before the control can be mounted Unions are furnished with the 67BC 2 Low Water Cut Off for ease of installation 1 pipe tappings have been provided in the End Sections for other FIG 27 STEAM TRIM AND CONTROLS leveled for proper operation It is level when the leveling indicator hangs freely with its pointer directly over the index mark inside the back of the case Level the controller by carefully bending the steam trap siphon loop Install Pressure Safety Valve with fittings furnished into 172 pipe tapping in upper corner of End Section see Fig 12 DO NOTINSTALLA SHUTOFF VALVE BETWEEN SAFETY VALVE AND BOILER If this boiler tapping is to be used as Surface Blowoff replace ell with tee and plug open end of tee or valve off opening Pressure Safety Valve must be in leg of tee and in a vertical position with handle up Install Boiler Drain Valve and 3 x 92 Bushing into one of the two return tappings The drain valve may also be installed in return piping but it must be installed in the leg of a tee so that it is directly opposite and as close as possible to the return tapping The leg of the tee must be at least 175 pipe size 31 yz Nd SONILLI MOOH MOIND HLIM 440 100 d3JIVM MOI W 9 ON 2 TISNNOGOW 1 311 1 4 55386 14544 86 0v1 TI3MA3NOH SNOILONUMLSNI OLNI AIS
164. terminal R Jumper terminal R to W This will prevent the actuator from going to the high fire position TO SERIES 90 4 Energize the system and light the main burner 5 PROPORTIONING a blade no more than 3 16 inch wide to turn LINE VOLTAGE the low fire adjusting screw for the desired low POWER SUPPLY fire position DO NOT PUSH INWARD ON CONNECTIONS SCREW 6 Shut down the burner and then restart Repeat several times to be sure the low fire setting 1s that desired and suitable for correct burner light DO NOT MAKE ANY oft CONNECTIONS 7 Turn off power supply Remove R W jumper TO MESE TERMINALS and reconnect the lead to terminal R on the GROUND SCREW V9055A AUXILIARY SWITCH i SWITCH confused with true yellow tipping SWITCH probe see Fig 56 thru 59 LOW FIRE ADJUSTMENT V9055A ACTUATOR CONTROLLER 5 Use a Phillips screwdriver or standard type with 8 Replace the wiring compartment cover 12 MAIN BURNER FLAMES should have a clearly defined inner cone see Fig 55 with no yellow tipping Orange yellow streak caused by dust should not be ADJUSTING SCREW 13 CHECK PILOT FLAME Flame should be a blue FOR AUXILIARY medium hard flame enveloping approximately 3 8 of the end of the thermocouple flame sensor or sensing SECTION IV OPERATION continued 14 CHECK THERMOSTAT OPERATION Raise and 15 16 lower thermostat setting as required to start and stop b
165. termittent electrically ignited pilot The RM7890A Relay Module Primary Control is a non programming amplifying relay which when used with the 179 Pilot provides solid state electronic Flame Safeguard Protection that will not allow the main gas valves to open on call for heat for that will shut down main burners within 0 8 second if pilot flame is not proved Relay Module will lockout on safety shutdown within 15 seconds if there is a pilot flame failure on start or if during the run cycle pilot flame is not re established Since 8 terminal in the Relay Module is de energized at end of safety switch timing a solenoid valve in the pilot line will close and thus 100 shut off is achieved a OPERATING INSTRUCTIONS 1 Make sure Manual Main Shut off Valve and all Pilot Valves have been off for at least five minutes 2 Set Operating and Limit Controls to desired settings 3 Turn Manual Main Shut off Valve and Pilot Valve to Open Position 4 Turn on Main Electric Switch and Service Switch Pilot will automatically light main burners SEQUENCE OF OPERATION EP See Fig 44 b NORMAL OPERATION 5006B thru 5014B 1 When the operating control calls for heat terminal 6 of RM7890A Relay is energized 2 Acomponent check circuit in the RM7890A Relay is activated which checks the electronic network in the relay 3 Terminals 8 and 10 of the relay are energized Terminal 88 opens pilot line sol
166. tlet of regulator USA boilers and using OD aluminum tubing connect outlet of tee to connection on pilot safety switch see Fig 36 Using 4 OD aluminum tubing connect the outlet of the pilot safety switch to the tubing or fitting connected to the pilot burner see Fig 36 Connect Q309 thermocouple to pilot safety switch Connect power supply fused disconnect switch service switch primary and secondary of Gas Valve Transformer gas valves and other controls see Fig s 46 and 47 for wiring type and connections to be made All wiring must be adequately supported and strain relief provided All wiring including ground connections must comply with the requirements of the authority having jurisdiction and in the absence of such to the National Electrical Code ANSI NFPA No 70 2005 INSTALLATION OF GAS VALVE TRANSFORMER AND COMPLETION OF WIRING Attach the bracket for mounting of the junction box to the lower front corner of the Jacket Upper End Panel using two 10 32 15 MS and nuts Mount junction box to bracket using 8 SMS see Fig 36 Install Transformer on junction box SECTION INSTALLATION INSTRUCTIONS continued THERMOCOUPLE CONTROL SYSTEM CANADA ONLY COMPRESSION NUT W ATTACHED SLEEVE BLEED LINE PILOT TUBING VENT TO OUTDOORS THERMOCOUPLE LEAD THERMOCOUPLE PILOT BURNER PILOT BRACKET RV 12LT REGULATOR MANUAL SHUT OFF PILOT SAFETY SWITCH VALVE
167. uiessy jexoeJg uonduoseq 08 9991 86109108 10681109 LHVd 0 SINN M3MOS HOVW Z X 01 z WISIN 13345 2 1 x 8 HOLIMS 4 5 10114 4443 88 LYOddNS FINGOW Q1OJINVW SLYWd MIVd33 NOILO3S IO3INVA 98 SECTION VI REPAIR PARTS continued FOR LOW VOLTAGE WIRE USE AeSF ADAPTER W HEYCO STRAIN RELIEF SR 6P 4 CONNECTOR 4 X 4 JUNCTION BOX 2 INSULATING BUSHING CONDUIT LOCK NUT 2 REQ D 1 x 1 LG CONDUIT NIPPLE 4 FRDM 0 2 TUBE X BRASS COMPRESSION VALVE _ Ej NUTS W ATTACHED SLEEVE RET Them o n SEES mam 3 2040 CX 1 D D ALUMINUM TUBING D D TUBE X MP T BRASS MP T PIPE PLUG COMPRESSION ADAPTERS i 1 NP T MALLEABLE TEE REMOVE FOR CANADA ee 1 0 0 ALUMINUM TUBING TO PILOT BURNER TRANSFORMER PENN H91WG PILOT SOLENOID VALVE amp PILOT LINE REGULATOR EI CONTROL SYSTEM U S A 5010B 5026B NAT GAS CANADA 5006B 5026B NAT GAS PART NO ITEM 7136001 1 J Box Mounting Bracket 24V 100 VA Transformer 120 60HZ Primary 80160016 2 Penn Y64T22 0 Plate Mounted 822666 3 Penn Pilot Solenoid Valve H91WG 6 9220005 dn er eee w orange spring 4 to 8 WC 8136037 Heyco A25F Strain Relief
168. urners CHECK HIGH LIMIT CONTROL Jumper Thermostat terminals or thermostat connections in Limit Control Allow burners to operate until shutdown by limit REMOVE JUMPER TEST IGNITION SYSTEM SAFETY SHUT OFF DEVICE AS FOLLOWS Place the boiler into operation by following the appropriate lighting instructions in this manual Proceed with test as follows a Thermocouple Pilot System Using a 3 8 wrench loosen the thermocouple lead at the gas valve Main gas and pilot gas must shut off If not replace gas valve b EI Pilot System Carefully remove ignitor sensor wire from ignition module Main gas and pilot gas must shut off immediately If not replace the module c EP Pilot Systems Carefully remove the flame rod wire from terminal 11 on the RM7890 Control Main gas and pilot gas must shut off If not replace the RM7890 Control 17 COMBUSTION CHAMBER BURN OFF a 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 b Ventilate the boiler room set the high limit to its maximum setting set the thermostat to call for heat Allow the boiler to fire for at least an hour or until the odor from the cornstarch has dissipated c Return the high limit and thermostat to their desired settings A CAUTION Avoid operating this boiler in an environment where saw dust loose insulation fibers dry wall d
169. ust 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 63 SECTION V SERVICE ADANGER This boiler used flammable gas high voltage electricity moving parts and very hot water under high pressure Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service More than one gas shut off valve and electrical disconnect switch are used on the boiler Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service Do not attempt any service work if gas is present in the air in the vicinity of the boiler Never modify remove or tamper with any control device ZA WARNING This boiler must only be serviced and repaired by skilled and experienced service technicians If any controls are replaced they must be replaced with identical models Read understand and follow all the instructions and warnings contained in all the sections of this manual If any electrical wires are disconnected during service clearly label the wires and assure that the wires are reconnected properly NEVER operate boiler without all sight glasses and brackets in place and securely fastened and sealed Very HOT combustion gas may cause burn injury Read understand and follow all the instructions and warnings contain
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