INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
SERIES 8H
GAS - FIRED BOILER
3050579
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
_8_ _ _ _ _ - _ _ _ _
Heating Contractor
Boiler Serial Number
Installation Date
6_ _ _ _ _ _ _
Phone Number
Address
Commercial Boilers
Price - $5.00
8ꢀ4ꢀ602ꢀR3-6/ꢀ0
WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an knowledgeable, experienced,
and skilled installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efficiency.
Installation is not complete unless a pressure relief valve is installed into the tapping located on the top
of boiler - See the Water Trim and Piping Section of this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt
to disconnect any components of this 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.
Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,
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.
Failuretofollowallinstructionsintheproperordercancausepersonalinjuryordeath. Readallinstructions,
including all those contained in component manufacturers manuals which are provided with the boiler
before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or
liquids.
Do not operate boiler with control which has been subject to water.
All cover plates, enclosures and guards must be in place at all times.
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.
USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially
orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orifice sizing is indicated on the
rating label.
3
Table of Contents
I. Pre-Installation.............................................................6
II. Boiler Assembly...........................................................8
III. Gas Control System Assembly ..................................15
(Knockdown Boilers)
IV. Water Trim and Piping...............................................25
V. Gas Piping..................................................................29
VI. Venting.......................................................................31
VII. Electrical....................................................................34
VIII. System Start-up..........................................................52
IX. Service .......................................................................61
X. Repair Parts................................................................67
4
Figure ꢀ: Dimensional Data
Table ꢀ: Dimensional Data
Dimensions (Inches)
Recommended
Chimney Size
(Round)
Water
Content
(Gallons)
Approx.
Shipping
Weight (LB.)
Boiler
Model
D
E
A
B
C
USA
Canada
USA
Canada
805H
806H
807H
808H
809H
810H
20
10
7
8
24-13/16
27-13/16
28-13/16
30-13/16
33-1/2
24-13/16
25-3/4
16-1/8
18
16-1/8
16
7” dia. x 15 ft.
8” dia. x 15 ft.
8” dia. x 15 ft.
8” dia. x 15 ft.
10” dia. x 15 ft.
10” dia. x 15 ft.
11.9
13.9
15.9
17.9
19.9
21.9
705
785
23-3/4
27-1/2
31-1/4
35
11-7/8
13-3/4
15-5/8
17-1/2
19-3/8
9
25-3/4
18
16
890
9
26-11/16
26-7/16
26-7/16
20
16
1000
1100
1220
10
10
22
15
38-3/4
33-1/2
22
15
5
I. Pre-Installation
WARNING
2. USA, 808H-810H: for installation in room which is
large in comparison with size of boiler.
a. Front: 18”
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
b. Top: 51½”
c. Draft hood, rear, sides, and flue connector: 6”
3. Canada, 805H-810H:
A. 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 claim
for damage or shortage in shipment must be filed
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
a. Top and front: 18” (45.7 cm)
b. Flue, rear and sides: 6” (15.2 cm)
D. Provide clearance for servicing and proper operation
(following clearances are recommended and may be
reduced to minimum clearances shown above):
1. Single boiler, 805H-807H, Front/Top: 24” (61.0 cm)
2. Single boiler, 808H-810H, Front/Top: 48”
(122.0 cm)
B. Installation must conform to the requirements of
the authority having jurisdiction. In the absence of
such requirements, installation must conform to the
National Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or
CAN/CSA B149.1 Installation Codes. Where required
by the authority having jurisdiction, the installation
must conform to the Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
No CSD-1.
3. Multiple/modular boiler, USA /Canada, Sides: 1”
(2.5 cm)
E. Install boiler on level floor as close to chimney as
possible. For basement installation provide a solid base
such as concrete or masonry construction if floor is not
level or if water may be encountered on floor around
boiler.
F. Protect gas ignition system components from
water (dripping, spraying, rain, etc.) during boiler
operation and service (circulator replacement, control
replacement, etc.).
C. Provide clearance between combustible material and
boiler jacket (following clearances are minimums):
1. USA, 805H-807H: listed for Alcove installation
a. Front: 18”
G. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or the National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation; or CAN/
CSA B149.1, Venting Systems and Air Supply for
Appliances.
b. Top: 36”
c. Draft hood, rear, sides and flue connector: 6”
WARNING
Appliance is design certified for installation on
noncombustible flooring only. For installation
on combustible flooring only when installed on
special base listed in Table 2. Boiler must not be
installed on carpeting. When boiler is installed on
concrete which is over a material that is subject
to melting (PVC, PEX radiant tubing, etc.), the
special base must be used. A concrete pad is not
sufficient to protect combustible flooring.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
permanent openings not furnished with doors) are
considered part of space.
Table 2: Special Base Required for Installation on
Combustible Flooring
Volume [ft3] = Length [ft] x Width [ft] x Height [ft]
Boiler Model
805H
Special Base Part Number
61816055
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
806H
61816065
3. Determine type of space. Divide Volume by Total
Input.
807H
61816075
808H
61816085
a. If result is greater than or equal to 50 ft3 per
1,000 BtuH, space is considered an unconfined
space.
809H
61816095
810H
61816105
6
b. If result is less than 50 ft3 per 1,000 Btuh, space
i. Minimum free area of 1 square inch per
3,000 Btu per hour input of all equipment in
space.
is considered a confined space.
4. Determine building type. A building of unusually
ii. Free area shall not be less than the sum
of the areas of all vent connectors in the
confined space.
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and
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.
b. Weather-stripping has been added on openable
windows and doors, and
c. Caulking or sealants applied in joints around
window and door frames, between sole
plates and floors, between wall-ceiling joints,
between wall panels, at plumbing and electrical
penetrations, and at other openings.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be fixed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch mesh.
5. For boiler located in an unconfined space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air infiltration through cracks
around windows and doors.
6. For boiler located in an unconfined space in a
building of unusually tight construction or in
a confined space, provide outdoor air through
permanent opening(s) which communicate directly
or by duct with the outdoors or spaces (crawl or
attic) freely communicating with the outdoors.
Minimum dimension of air opening(s) is 3” (7.6
cm).
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
8. For Specially Engineered Installations. The above
requirements shall be permitted to be waived
where special engineering, consistent with good
engineering practice and approved by the authority
having jurisdiction, provides an adequate supply of
air for combustion, ventilation, and dilution of flue
gases.
a. Two permanent openings: Locate one opening
within 12 inches (30.5 cm) of top of space.
Locate remaining opening within 12 inches
(30.5 cm) of bottom of space. Size each opening
per following:
i. Direct communication with outdoors.
Minimum free area of each opening must be
1 square inch per 4,000 Btu per hour input
of all equipment in space.
ii. Vertical ducts. Minimum free area of each
opening must be 1 square inch per 4,000
Btu per hour input of all equipment in space.
Duct cross-sectional area shall be same as
opening free area.
WARNING
Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
iii. Horizontal ducts. Minimum free area of each
opening must be 1 square inch per 2,000
Btu per hour input of all equipment in space.
Duct cross-sectional area shall be same as
opening free area.
NOTICE
Mis-sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler
to the system. Modular/multiple boilers greatly
reduce the likelihood of boiler oversizing.
b. One permanent opening shall be permitted where
the boiler has clearances of at least 1” (2.5 cm)
from the sides and rear and 6” (15.2 cm) from
the front. Locate the opening within 12 inches
(30.5 cm) of top of space. Size opening per
following:
ꢁ
II. Boiler Assembly
A. Remove Crate
1. Remove all fasteners at crate skid.
2. Lift outside container and remove with all other
inside protective spacers and bracing.
B. Remove boiler from skid. See Figure 2. Exercise care
to avoid dropping boiler.
1. Place boiler in approximate location. Refer to
Section I: Pre-Installation. Remove base hold down
bolts.
2. Using pry bar under rear corner of Base End Panel,
raise boiler and install 1½” wood blocks under rear
corners. Install ¾” pipe roller between Base and
skid.
3. Remove 1½” wood blocks. Place 3” pipe roller on
floor behind skid.
4. Roll boiler off skid. Move skid out of way.
5. Roll boiler until 3” roller is located as shown. Use
pry bar to install wood blocks under front corners of
base. Remove 3” roller.
Figure 2: Skid Removal
Figure 3: Tapping Locations
Table 3: Purpose of Tappings
Tapping
Size
2”
Purpose
Supply
A
B
C
D
E
F
2”
Return
3/4”
3/4”
3/4”
3/4”
3/4”
Relief Valve
Limit
Auxiliary Limit
Washout
Drain
G
8
6. Lift boiler with pry bar. Remove wood blocks.
Lower boiler.
water pressure of at least 10 psi but less than 50 psi
gauge pressure.
6. Examine boiler for leaks or damage due to shipment
or handling.
C. For Packaged Boiler only, proceed to Paragraph E.
D. Test Section Assembly for leaks before connecting to
system and installing controls, trim and jacket. Refer to
Figure 3 and Table 3.
7. Remove plugs from Return Tapping B, Tapping C,
and Tapping E (if second limit or operating control
is used). Also remove fill valve and piping, purge
valve and piping, and pressure gauge.
1. Plug Tappings C & E (¾ NPT) and Return Tapping
B (2 NPT).
E. Install special base if installation is on combustible
flooring. See Figure 4. Floor shield adds 4¾” to boiler
height.
2. Insert ¾” NPT x ¼” NPT bushing in Tapping D.
Install pressure gauge capable of indicating 50 psi.
3. Insert 2” NPT x ¾” NPT bushing in Supply Tapping
A. Install purge valve with a hose that runs to a
drain.
1. Place special base on combustible floor with surface
marked “FRONT” in upward position.
2. Locate special base with spacing to combustible
materials as shown in Figure 4.
4. Connect fill valve and piping to Drain Tapping G.
3. Place boiler on special base. Boiler must rest inside
locating brackets. Boiler jacket panels will overhang
special base.
WARNING
Do not use air to leak test boiler.
4. Do not enclose boiler (including special base) on all
four sides. Models 805H - 807H may be enclosed
on three sides (alcove) while maintaining clearances
shown in Figure 4.
5. Fill boiler completely with water by venting air
through purge valve. Close purge valve and apply
Figure 4: Installation of Special Base for Combustible Flooring
ꢂ
Figure 5: General Assembly (Knockdown Boilers)
F. Move boiler to permanent location by sliding or
1. Attach Base Front Panel to Section Assembly using
¼” - 20 x 1¼” carriage bolts, washers and nuts.
walking. Do not drop.
For Packaged Boiler, proceed to Paragraph L.
2. Seal between top of Base Front Panel and Section
Assembly with furnace cement (shipped in
G. Confirm that one (1) Flue Baffle is properly
positioned in each Boiler Flueway. Tabs at the top
of each Flue Baffle should be resting on top row of Flue
Pins on each adjoining section.
Combination Boiler Parts and Control Carton).
3. Seal between top of Base Rear Panel and Section
Assembly with furnace cement.
K. Install Pilot/Main Burner Assembly. See Figure 7.
Assembly is located in Combination Boiler Parts and
Control Carton. Verify assembly is properly located
on support bracket in Base Rear Panel, seated on Main
Burner Orifice, and secured with hitch pin clip.
H. Install Canopy on section assembly. See Figure 5.
Canopy and hardware are located in Combination
Boiler Parts and Control Carton.
1. Position Canopy on top of Section Assembly. Locate
between end sections and sealing ledge on front and
back of each section.
L. Adjust Burner Air Shutters on all Burners. See
Figure 7. (On Packaged Boilers, Front Door and
Burner Access Panel(s) must be removed to make
adjustments.) Distance between front edge of Burner
Air Shutter and burner mounting ring should be
approximately 11/16”. To adjust this distance, loosen
screw at top of air shutter and slide into correct
position. Then tighten screw. (Replace Burner Access
Panel(s) and Front Door on Packaged Boilers.)
2. Fasten each end with ¼” - 20 x 1” carriage bolts,
washers and nuts.
3. Seal between Canopy and Section Assembly with
furnace cement.
I. Inspect joints between sections. They were factory
sealed. If any openings resulted during shipment or
handling, reseal with furnace cement. Confirm tie rods
are only hand tight to allow for thermal expansion.
For Packaged Boiler, proceed to Section IV: Water Trim
and Piping.
J. Install Base Front Panel. See Figure 5. Panel and
hardware located in Combination Boiler Parts and
Control Carton.
ꢀ0
Figure 6: Flame Roll-out Switch Installation
Figure ꢁ: Burner/Burner Access Panel Installation
ꢀꢀ
Combustible Clearance Label from Combination
Boiler Parts and Controls Carton. Attach to
Vestibule Panel in locations shown.
M. Attach Flame Roll-out Switch to Burner Access Panel.
See Figure 6. Flame Roll-out Switch and hardware
are located in Combination Boiler Parts and Control
Carton. Flame Roll-out Switch is a single use device
- do not test with heat - switch cannot be reset.
6. Attach Vestibule Panel to Left Side and Right Side
Panels.
1. Cut insulation from semicircular notch at right
end of the burner access panel. Models 808H
- 810H have two (2) burner access panels. Remove
insulation from notch of right side burner access
panel only.
7. Attach Lower Front Tie Bar to Left Side and Right
Side Panels.
8. Engage Upper Front Panel in slots on Left Side
and Right Side Panels. Place Top Panel in position.
Attach Top Panel to Left Side, Right Side and Upper
Rear Panels.
2. Attach Flame Roll-out Switch Mounting Bracket to
burner access panel with (1) #8 x ½” lg. sheet metal
screw.
9. Tighten all jacket screws.
10. Affix Lighting/Operating Instructions Label and
Wiring Diagram Label to inside of Front
3. Attach Flame Roll-out Switch to mounting bracket
with (1) #8 x ¾” lg. sheet metal screw.
Removable Door. Labels are located in
N. Install Burner Access Panel(s). Locate Burner Access
Panel(s) in Combination Boiler Parts and Control
Carton. Engage Burner Access Panel holes with
projections on Base Front Panel. See Figure 5.
Combination Boiler Parts and Control Carton.
Q. Install Junction Box. See Figure 8. Attach junction
box to inside of Left Side Panel with ¼” - 20 x ¼” lg.
machine screw (located in Combination Boiler Parts
and Control Carton).
O. Install Immersion Well(s).
1. Remove Immersion Well(s) from Combination
Boiler Parts and Control Carton..
R. Install Limit Control. Locate limit in Combination
Boiler Parts and Control Carton. Insert limit probe
into left immersion well as far as possible. Tighten set
screw.
2. Insert Immersion Well in Tapping D. See Figure 3.
3. If second limit or operating control is used, insert
immersion well in Tapping E. If vertical gas
piping is to be installed inside of boiler jacket, it
is recommended that second limit be installed in
system piping.
S. Install Auxiliary Limit or operating control (if used).
Insert control probe into right immersion well as far as
possible. Tighten set screw.
T. Install Gas Control Assembly. Refer to Section III,
P. Install Jacket. See Figure 8.
Gas Control System Assembly (Knockdown Boilers).
1. Locate four (4) Jacket Attachment Brackets in
Combination Boiler Parts and Control Carton.
Attach to Front Base Panel and Rear Base Panels
with #8 sheet metal screws. See Figure 5.
U. EP and OP System: See Figure 9.
1. Install pre-wired EP/OP Control Cabinet Assembly
to right front corner of jacket top panel.
2. Install Honeywell RM7890 Control (located in
RM7890 Control Carton).
2. Hang Left Side Panel and Right Side Panel onto
Jacket Attachment Brackets.
3. Remove RM7890’s Dust Cover. With a pair of side
cutters, carefully snip both wire leads to the brown
resistor labelled “JR2” and discard it. Replace Dust
Cover.
3. Attach Lower Rear Panel to Left and Right Side
Panels. Do not tighten sheet metal screws.
4. Attach Upper Rear Panel to Lower Rear Panel. Do
not install three (3) upper screws.
4. Install Honeywell R7847 Flame Amplifier.
5. Remove Rating Label from envelope marked
“RATING LABEL ENCLOSED”. Remove
5. Install heat shield.
ꢀ2
ꢀ3
Figure ꢂ: EP/OP Control Installation
ꢀ4
III. Gas Control System Assembly (Knockdown Boilers)
1. Install Gas Control Assembly on Manifold. See
A. 24V Standing Pilot Control System
Figure 14. Use thread (joint) compound (pipe dope)
resistant to action of liquefied petroleum gas.
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
2. Install pilot burner piping and controls. See Figure
14.
1. Install Gas Control Assembly on Manifold. See
Figure 10. Use thread (joint) compound (pipe dope)
resistant to action of liquefied petroleum gas.
3. Connect Thermocouple Lead to Gas Valve.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
2. Install pilot burner piping and controls. See Figure
10.
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
3. Connect Thermocouple Lead to Gas Valve.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
b. Attach transformer/control center to junction
box.
D. OP-CSD-1 Control System
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
b. Attach transformer/control center to junction
box.
1. Install Gas Control Assembly on Manifold. See
Figure 15. Use thread (joint) compound (pipe dope)
resistant to action of liquefied petroleum gas.
B. EI (Intermittent Ignition)
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
2. Mount pilot switch.
3. Install pilot burner piping and controls. See Figure
15.
1. Install Gas Control Assembly on Manifold. See
Figure 11. Use thread (joint) compound (pipe dope)
resistant to action of liquefied petroleum gas.
4. Connect Thermocouple lead to pilot switch.
5. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
2. Install pilot burner piping and controls.
a. Honeywell EI
i. USA - See Figure 12.
ii. Canada - See Figure 13.
6. Attach transformer/control center to junction box.
E. EP Control System
3. Install Ignition Module.
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
a. Attach Ignition Control Mounting Bracket to
Jacket Vestibule Panel using two (2) #8 x ½”
sheet metal screws.
1. Install Gas Control Assembly on Manifold. See
Figure 16.
b. Attach Honeywell Ignition Module to Mounting
Bracket using two (2) #8 x ½” sheet metal
screws.
2. Install pilot burner piping and controls. See Figure
16.
c. Connect pilot ground wire and ignitor/sensor
lead(s) to ignition module. Refer to “Section VII:
Electrical” for connection details.
3. Install Ignition Transformer.
a. Attach Ignition Transformer to Jacket Vestibule
Panel using four (4) #8 x ½” lg. sheet metal
screws.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box. See Figure 8.
b. Connect Ignition Lead from Pilot to Ignition
Transformer.
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
b. Attach transformer/control center to junction
box.
C. OP Control System
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
b. Attach transformer/control center to junction
box.
ꢀ5
b. Connect Ignition Lead from Pilot to Ignition
Transformer.
F. EP-CSD-1 Control System
Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
4. Mount Transformer (continuous circulation) or
Control Center (intermittent circulation) to Junction
Box.
1. Install Gas Control Assembly on Manifold. See
Figure 17.
a. Canada only - loop 4” nylon cable tie between
junction box and transformer/control center.
2. Install pilot burner piping and controls. See Figure
17.
b. Attach transformer/control center to junction
box.
3. Install Ignition Transformer.
a. Attach Ignition Transformer to Jacket Vestibule
Panel using four (4) #8 x ½” lg. sheet metal
screws.
ꢀ6
ꢀꢁ
ꢀ8
ꢀꢂ
20
2ꢀ
22
23
24
IV. Water Trim and Piping
WARNING
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can
lead to boiler failure. Burnham’s Warranty does not cover problems caused by oxygen contamination of
boiler water or scale (lime) build-up caused by frequent addition of water.
Table 4: Flow Rate, Temperature Rise, and
Pressure Drop
A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
Boiler
Pressure
Drop
Boiler Flow Rate Temp. Rise Min. Boiler
1. There are many possible causes of oxygen
contamination such as:
Model
(GPM)
Thru Boiler Piping NPT
a. Addition of excessive make-up water as a result
of system leaks.
21
14
10
20° F
30° F
40° F
1½”
1¼”
1¼”
3’
2’
1’
805H
b. Absorption through open tanks and fittings.
26
17
13
20° F
30° F
40° F
1½”
1½”
1¼”
3’
2’
1’
c. Oxygen permeable materials in the distribution
system.
806H
807H
808H
809H
810H
2. In order to insure long product life, oxygen sources
must be eliminated. This can be accomplished by
taking the following measures:
31
20
15
20° F
30° F
40° F
2”
1½”
1¼”
3’
2’
1’
36
24
18
20° F
30° F
40° F
2”
1½”
1½”
3’
2’
1’
a. Repairing system leaks to eliminate the need for
addition of make-up water.
b. Eliminating open tanks from the system.
40
27
20
20° F
30° F
40° F
2”
2”
1½”
3’
2’
1’
c. Eliminating and/or repairing fittings which allow
oxygen absorption.
45
30
22
20° F
30° F
40° F
2”
2”
1½”
3’
2’
1’
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
f. Use properly designed and operating air
elimination devices in water piping.
B. Design boiler piping and flow rate to obtain proper
temperature rise though the boiler. (See Table 4)
WARNING
Pressure relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut off
valves, plugs or caps. Consult Local Codes for
proper discharge piping arrangement.
C. Install Safety Relief Valve. See Figure 18.
Components are located in Water Trim Carton. Safety
Relief Valve must be installed with spindle in vertical
position.
1. Install ¾” NPT x 3½” lg. nipple in tapping “C”. See
Figure 3.
2. Install safety relief valve on ¾” NPT nipple.
Figure ꢀ8: Safety Relief Valve Installation
25
Figure ꢀꢂ: Drain Piping Installation
D. Install Drain Valve in rear of Left End Section,
Tapping “G”. See Figure 19. Components are located
in Water Trim Carton.
E. Install Temperature-Pressure Gauge. Components
are located in Water Trim Carton.
1. Standard Temperature - Pressure Gauge Piping. See
Figure 20.
Figure 2ꢀ: Alternate Temperature-Pressure Gauge
Installation
b. Install 2 NPT x ¾ NPT x 2 NPT Tee (provided)
or 2 NPT x 2 NPT x ¾ NPT Tee (installer
furnished). ¾ NPT leg should face forward.
c. Install ¾ NPT x ¼ NPT Bushing.
d. Insert Temperature-Pressure Gauge. Tighten
by applying pressure to square shank on back
of gauge. DO NOT APPLY PRESSURE ON
GAUGE CASE since this may ruin gauge
calibration.
F. Connect system supply and return piping to boiler.
See Figure 23. Also consult I=B=R Installation and
Piping Guides. Maintain minimum ½ inch clearance
from hot water piping to combustible materials.
1. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled
medium piped in parallel with heating boiler using
appropriate valves to prevent chilled medium from
entering boiler. See Figure 22. Also consult I=B=R
Installation and Piping Guides.
Figure 20: Temperature-Pressure Gauge
Installation
a. Install 2” NPT x 10” lg. nipple with gauge
tapping into Supply Tapping “A”. See Figure 3.
Gauge tapping should face forward.
b. Insert Temperature-Pressure Gauge. Tighten
by applying pressure to square shank on back
of gauge. DO NOT APPLY PRESSURE ON
GAUGE CASE since this may ruin gauge
calibration.
2. Alternate Temperature-Pressure Gauge Piping. See
Figure 21.
a. Install 2 NPT x 10” Nipple into Supply Tapping
“A”. See Figure 3.
Figure 22: Recommended Piping for Combination
Heating & Cooling (Refrigeration) System
26
2. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
flow control valves to prevent gravity circulation of
boiler water during cooling system operation.
at 40°F or less, and return water temperature at
minimum of 135°F.
Continued boiler operation for prolonged periods of
time under conditions when temperature differential
across the system exceeds 40°F and/or return water
temperature stays below 135°F, may result in
premature boiler failure due to flue gas condensation
and/or thermal shock.
3. The piping diagrams shown (Figure 23, Detail “A”
and Detail “B”) are recommended for optimum
operation and long term reliability.
Pump flow rates and minimum boiler supply and
return pipe sizes are shown in Table 4.
Burnham Commercial recommends maintaining
temperature differential (drop) across the system
Figure 23: Recommended Boiler Piping for Circulator Zoned Heating Systems
Detail “B”: Primary/Secondary Piping
with By-Pass
Detail “A”: Blend Pump Piping
2ꢁ
a. A boiler by-pass is recommended for any
installation for improved system temperature
balance, while serving to protect the boiler from
sustained condensing operation. The by-pass
also provides some measure of low return water
temperature protection by reducing flow through
the boiler. See Figure 23.
continuously run below 135°F for extended
periods (due to low temperature applications
like snowmelt, heat pump systems or others),
primary/secondary boiler piping with a three-
way valve and return temperature sensor is
recommended. Refer to Burnham RTC Return
Temperature Control Manual and Tekmar Essay
#021 “Mixing Methods and Sizing of Variable
Speed Injection Pumps” for more information on
mixing devices and boiler protection from low
return water temperature.
b. A blend pump is recommended to divert hot
supply water into the return when system return
temperatures can periodically dip below 135°F
or when delta T’s rise beyond 40°F because of
control schemes that shut off zone pumps for
extended periods. See Figure 23, Detail “A”.
4. A hot water boiler installed above radiation level
must be provided with a low water cutoff device as
part of installation.
c. Primary/secondary piping with a by-pass is
recommended to provide two points of mixing
when dual temperature systems are used (i.e.
baseboard and radiant heat, outdoor reset
and domestic hot water production, systems
incorporating night setback or multiple zone
pumps on clock schedules). See Figure 23,
Detail “B”.
5. A start-up strainer is recommended for all
installations (new and replacement alike) to prevent
system debris and sediment from ending up in the
boilers where it will inhibit heat transfer and may
eventually cause a cast iron section to crack from
overheating.
G. Alliance SL™ Water Heater (if used). Refer to
Alliance SL™ Installation, Operating and Service
Instructions for additional information. Install in same
manner as space heating zone.
d. If system three-way valves are used for
temperature modulation, or if the system will
WARNING
Burnham Commercial recommends maintaining temperature differential (drop) across the system at
40°F or less and return water temperature at minimum of ꢀ35°F.
Continued boiler operation for prolonged periods of time under conditions when temperature differential
acrossthesystemexceeds40°Fand/orreturnwatertemperaturestaysbelowꢀ35°F,mayresultinpremature
boiler failure due to flue gas condensation and/or thermal shock.
If the above conditions exist, to protect a boiler from sustained flue gas condensation and/or thermal
shock,theabove-recommendedtemperaturesmaybemaintainedbyemployingcommonindustry-accepted
mixing methods to provide boiler protection.
Some common methods are boiler by-pass piping, blend pumps, primary secondary piping with a by-
pass, mixing valves and/or variable speed injection pumps.
28
V. Gas Piping
WARNING
4. Specific gravity of gas. Gas piping systems for
gas with a specific gravity of 0.70 or less can be
sized directly from Table 6, unless authority having
jurisdiction specifies a gravity factor be applied.
For specific gravity greater than 0.70, apply gravity
factor from Table 8. If exact specific gravity is not
shown choose next higher value.
Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.
For materials or conditions other than those listed
above, refer to the National Fuel Gas Code,
NFPA 54/ANSI Z223.1 and/or CAN/CSA B149.1
Installation Codes, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
An additional gas pressure regulator may be
needed. Consult gas supplier.
A. Size gas Piping. Design system to provide adequate gas
supply to boiler. Consider these factors:
1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum allowable gas valve inlet pressure is
indicated on rating label.
WARNING
Failure to use proper thread compounds on all
gas connectors may result in leaks of flammable
gas.
2. Maximum gas demand. Table 5 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).
WARNING
Gas supply to boiler and system must be
absolutely shut off prior to installing or servicing
boiler gas piping.
3. Length of piping and number of fittings. Refer to
Table 6 for maximum capacity of Schedule 40 pipe.
Table 7 lists equivalent length for standard fittings.
B. Connect boiler gas valve to gas supply system.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow the National
Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or
CAN/CSA B149.1 Installation Codes.
Table 5: Rated Input
Rated Capacity
Gas
Boiler
Model
(cubic feet per hour)
Connection
Size
2. Use thread (joint) compound (pipe dope) resistant to
Natural
252
LP / Propane
100.8
action of liquefied petroleum gas.
805H
806H
807H
808H
809H
810H
1
1
1
1
1
1
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas valve and
outside jacket. See Figure 24.
315
126
374
149.6
433
173.2
4. All above ground gas piping upstream from
manual gas valve must be electrically continuous
and bonded to a grounding electrode. Do not use
gas piping as a grounding electrode. Refer to the
National Electrical Code, ANSI/NFPA 70 and/or
CSA C22.1 Electrical Code.
491
196.4
550
220
NOTICE
USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially
orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orifice sizing is indicated on the
rating label. High altitude boiler models are identifiable by the model number’s tenth digit on the rating label.
(4=2000’ - 4500’, 5= 2000’ - 5000’)
2ꢂ
Table 6: Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0.5 psig or Less
Length
(Feet)
0.3 Inch w.c. Pressure Drop
0.5 Inch w.c. Pressure Drop
½
132
92
73
63
56
50
46
43
40
38
¾
278
190
152
130
115
105
96
1
1¼
1,050
730
590
500
440
400
370
350
320
305
½
175
120
97
¾
1
1¼
1,400
950
770
660
580
530
490
460
430
400
10
20
30
40
50
60
70
80
90
100
520
350
285
245
215
195
180
170
160
150
360
250
200
170
151
138
125
118
110
103
680
465
375
320
285
260
240
220
205
195
82
73
66
61
90
57
84
53
79
50
Table 7: Equivalent Lengths of Standard Pipe Fittings & Valves
Valves (Fully Open)
Threaded Fittings
90° Tee, Flow
Pipe
Size
I.D.
(Inches)
Swing
Check
90°
Elbow
45°
Elbow
90° Tee, Flow
Gate
Globe
Angle
Through Run Through Branch
½”
¾”
0.622
0.824
1.049
1.380
0.35
0.44
0.56
0.74
18.6
23.1
29.4
38.6
9.3
4.3
5.3
6.8
8.9
1.6
0.78
0.97
1.23
1.6
1.0
1.4
1.8
2.3
3.1
4.1
5.3
6.9
11.5
14.7
19.3
2.1
1”
2.6
1¼”
3.5
Table 8: Specific Gravity Correction Factors
WARNING
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
Do not use matches, candles, open flames, or
other ignition source.
0.50
0.55
0.60
0.65
0.70
0.75
0.80
1.10
1.04
1.00
0.96
0.93
0.90
0.87
1.30
1.40
1.50
1.60
1.70
---
1.07
1.04
1.00
0.97
0.94
---
---
---
C. Pressure Test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
1. Protect boiler gas valve. For all testing over ½ psig,
boiler and its individual shut-off valve must be
disconnected from gas supply piping. For testing at
½ psig or less, isolate boiler from gas supply piping
by closing boiler’s individual manual shut-off valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonflammable
solution.
Figure 24: Recommended Gas Piping
30
VI. Venting
1. Uncoil power cord.
A. Install vent system in accordance with local building
codes; or local authority having jurisdiction; or
National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part
7, Venting of Equipment and/or CAN/CSA B149.1,
Venting Systems and Air Supply for Appliances. Install
any of the following for this Series 8H Category I, draft
hood equipped appliance:
2. Position mounting bracket onto lower edge of Draft
Hood skirt. Locate center tooth (with #10 sheet
metal screw) on outside and other two teeth inside
Draft Hood skirt. See Figure 25.
3. Slide mounting bracket tight against lower edge of
Draft Hood skirt. Position #10 sheet metal screw
above skirt’s stiffening rib.
1. Type B or Type L gas vent. Install in accordance
with listing and manufacturer’s instructions.
4. Secure bracket in position by tightening #10 sheet
metal screw against outer surface of Draft Hood
skirt.
2. Masonry or metal chimney. Build and install in
accordance with local building codes; or local
authority having jurisdiction; or Standard for
Chimneys, Fireplaces, Vents, and Solid Fuel
Burning Appliances, ANSI/NFPA 211 and/or
National Building Code of Canada.
5. Insert excess power cord through Jacket Right Side
Panel hole. Remove slack.
6. Position strain relief bushing around power cord.
Pinch bushing’s two halves together and snap back
into hole in Jacket Right Side Panel.
Masonry chimney must be lined with approved
clay flue lining or listed chimney lining system
except as provided in ANSI Z223.1/NFPA 54,
Paragraph 7.5.4(a): Exception: Where permitted by
the authority having jurisdiction, existing chimneys
shall be permitted to have their use continued when
an appliance is replaced by an appliance of similar
type, input rating, and efficiency.
7. Verify power cord, mounting bracket, and Blocked
Vent Switch are secure and located as shown in
Figure 25.
WARNING
Do not operate boiler without Blocked Vent Switch
Properly installed.
3. Single wall metal vent. Allowed by ANSI Z223.1/
NFPA 54 under very restrictive conditions.
B. Inspect chimney and remove any obstructions or
restrictions. Clean chimney if previously used for solid
or liquid fuel-burning appliances or fireplaces.
DANGER
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.
C. Install Draft Hood on canopy outlet. Maintain height
from Jacket Top Panel to Draft Hood skirt as shown
in Figure 1. DO NOT ALTER, CUT, OR MODIFY
DRAFT HOOD.
WARNING
Do not alter boiler draft hood or place any
obstruction or non-approved damper in the
breeching or vent system. Flue gas spillage can
occur. Unsafe boiler operation will occur.
D. Install Blocked Vent Switch. The Blocked Vent
Switch Assembly consists of a strain relief bushing,
power cord, and switch attached to mounting bracket.
On Packaged boilers, the assembly is shipped attached
to top of boiler. On Knocked Down boilers, the
assembly is located in Combination Boiler Parts and
Control Carton.
Figure 25: Blocked Vent Switch Installation
3ꢀ
2. Where two or more appliances vent into a common
vent, the area of the common vent should at least
equal the area of the largest vent plus 50 % of the
area of the additional vents. Do not connect the
vent of this appliance into any portion of mechanical
draft system operating under positive pressure.
E. Boiler Equipped With Vent Damper. See Figure 26.
1. Open Vent Damper Carton and remove Installation
Instructions. Read Installation Instructions
thoroughly before proceeding.
CAUTION
3. Vent connector should have the greatest possible
initial rise above the draft hood consistent with the
head room available and the required clearance from
adjacent combustible building structure.
Do not use one vent damper to control two or
more heating appliances.
2. Vent damper must be same size as draft hood
outlet. See Figure 1. Unpack vent damper carefully.
Forcing vent damper open or closed may damage
gear train and void warranty. Vent damper assembly
includes pre-wired connection harness with
polarized plug.
4. Install vent connector above bottom of chimney to
prevent blockage - inspect chimney for obstructions
or restrictions and remove - clean chimney if
necessary.
5. Vent connector should slope upward from draft hood
to chimney not less than one inch in four feet. No
portion of vent connector should run downward or
have dips or sags. Vent connector must be securely
supported.
3. Mount vent damper assembly on draft hood without
modification to either (Refer to instructions packed
with vent damper for specific instructions). Vent
damper position indicator to be visible to users.
6. Use thimble where vent connector enters masonry
chimney - keep vent connector flush with inside of
flue liner.
WARNING
Provide adequate clearance for servicing -
provide 6” minimum clearance between damper
and combustible construction.
7. Do not install Non-listed (AGA, CGA, CSA, ETL,
or UL) vent damper or other obstruction in vent
pipe.
8. Locate Boiler as close to Chimney as possible
consistent with necessary clearances. See Section I:
Pre-Installation.
F. Install Vent Connector from draft hood or vent
damper to chimney. See Figure 27.
1. Do not connect into same leg of chimney serving an
open fireplace.
Figure 26: Vent Damper Installation
32
9. Design vent system for sea level input.
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
10. Provide adequate ventilation of Boiler Room. See
Section I: Pre-Installation.
11. Never pass any portion of vent system through a
circulating air duct or plenum.
WARNING
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
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 to it.
5. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
G. If an Existing Boiler is Removed:
At the time of removal of an existing boiler,
the following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the other
appliances remaining connected to the common
venting system are not in operation:
6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
condition of use.
1. Seal any unused openings in the common venting
system.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of
the common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 7 and Part 11 in the National Fuel Gas Code,
NFPA 54/ANSI Z223.1.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, or other
deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
Figure 2ꢁ: Typical Vent System
33
VII. Electrical
DANGER
Positively assure all electrical connections are unpowered before attempting installation or service of
electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock
once power is turned off.
WARNING
Failure to properly wire electrical connections to the boiler may result in serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempting any
electrical work.
Each boiler must be protected with a properly sized fused disconnect.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with
a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls
used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.
2. Remove factory installed Jumper Plug from Vent
Damper Receptacle on Vestibule Wiring Harness
and discard.
A. Install Boiler Wiring
1. Knockdown boilers only. Locate wiring harnesses
in Combination Boiler Parts and Control Carton.
Refer to Table 10 and connect wiring as shown on
the appropriate wiring diagram.
3. Plug Vent Damper Harness Plug into Vent Damper
Receptacle. See Figure 26.
C. Install thermostat. Locate on inside wall
approximately 4 feet above floor. Do not install on
outside wall, near fireplace, or where influenced
by drafts or restricted air flow, hot or cold pipes,
lighting fixtures, television, or sunlight. Allow free air
movement by avoiding placement of furniture near
thermostat.
2. Connect supply wiring and electrically ground boiler
in accordance with requirements of authority having
jurisdiction, or in absence of such requirements the
National Electrical Code, ANSI/NFPA 70 and/or
CSA C22.1 Electrical Code.
B. Wire Vent Damper (if used; required on 805H,
optional on 806H - 810H). See Figure 26.
Set heat anticipator to match control system
requirements. Refer to Table 9.
1. Attach Vent Damper Harness to mounting hole in
Jacket Left Side Panel. Install Cable Clamp around
flexible conduit and attach to Jacket Top Panel.
D. Wire thermostat. Provide Class II circuit between
thermostat and boiler. Refer to appropriate wiring
diagram for control system being used.
Figure 28: Vent Damper Schematic Wiring Diagram
34
through Terminal 2 and the damper motor is de-
energized.
E. Alliance SL™ Water Heater (if used). May be used
with Intermittent Circulation only.
5. When the call for heat is satisfied, the damper
relay coil is de-energized - closing contacts which
energize the damper motor. This causes the damper
to close. When the damper blade reaches the fully
closed position, the damper motor is de-energized.
Refer to Alliance SL™ Installation, Operating
and Service Instructions for wiring, piping and
additional information.
F. Vent Damper Sequence of Operation. See Figure 28
for schematic wiring diagram.
POWER FAILURE - The damper blade will stop in the
position it was in when power failed. (Combustion
can never take place unless the damper blade is in
the fully open position).
1. The Vent Damper is continuously powered at
Terminal 1.
2. When there is a call for heat, the damper relay coil
is energized through Terminal 5 if all limits ahead of
the damper are satisfied.
G. Sequence of Operation and Wiring. Refer to Table
10 for the appropriate control system.
3. The relay coil closes contacts which energize the
damper motor, causing the damper to open.
H. Optional Low-Water Cut-Off Wiring. See Figures 45
through 48.
4. When the damper blade reaches the fully open
position, power is sent back to the ignition circuit
Table ꢂ: Heat Anticipator Settings
Heat Anticipator Setting *
Control System
24V Standing Pilot
24V Electronic Ignition
Continuous Circulation
Intermittent Circulation
0.3
1.1
USA: 0.9
0.3
Canada: 1.2
* If room is heated above thermostat temperature setting, reduce heat anticipator setting by 0.1 or
0.2 amps. If boiler short cycles without room reaching desired temperature, increase heat anticipator
by 0.1 or 0.2 amps.
35
Table 10: Sequence of Operation and Wiring Diagrams
Wiring Diagram Figure
Sequence of
Operation
Ignition System
Country
Fuel
Boiler Sizes
6 & 7 Sect.
Continuous
Intermittent
Natural Gas
LP Gas
USA &
Canada
Standing Pilot (24V)
Figure 29
Figure 30
Page 36
Natural Gas
LP Gas
Standing Pilot
(OP - 120V)
USA &
Canada
6 - 10 Sect.
8 - 10 Sec.
5 - 10 Sect.
Figure 31
Figure 31
Figure 33
Figure 32
Figure 32
Figure 34
Page 39
Page 39
Standing Pilot
(OP-CSD-1 - 120V
USA
USA
LP Gas
Natural Gas
LP Gas
Intermittent Ignition
(Honeywell EI - 24V)
Page 42
Natural Gas
LP Gas
5 - 10 Sect.
5 - 7 Sect.
6 - 10 Sect.
Canada
Figure 35
Figure 37
Figure 36
Figure 38
Natural Gas
LP Gas
Page 47
Page 47
Intermittent Ignition
(EP - 120V)
USA &
Canada
Not Available
Intermittent Ignition
(EP-CSD-1 - 120V)
USA
Natural Gas
8 - 10 Sect.
Figure 37
Figure 38
1. Standing Pilot (24) Sequence of Operation
a. Normal Operation
Circulator continues to operate and Vent
Damper (if used) remains open with call
for heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.
i. Thermostat or operating control calls for
heat. Vent Damper (if used) opens.
ii. Gas valves are energized allowing main gas
flow and ignition of main burners.
iii. Flame Roll-out Switch: Automatically
interrupts main burner operation when
flames or excessive heat are present in
vestibule. Circulator continues to operate
and Vent Damper (if used) remains open
with call for heat. Control is single use
device. If flame roll-out switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and replace flame
roll-out switch.
iii. Call or heat ends. Gas valves are de-
energized, extinguishing main flame. Vent
Damper (if used) closes.
b. Safety Shutdown
i. Limit: Automatically interrupts main burner
operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat, Vent Damper (if used)
closes. Normal operation resumes when
water temperature falls below set point.
iv. Thermocouple: Senses pilot flame and
causes gas valves to turn off main burner
and pilot burner gas flow should pilot burner
flame extinguish. Circulator continues to
operate and Vent Damper (if used) remains
open with call for heat.
ii. Blocked Vent Switch: Automatically
interrupts main burner operation when
excessive flue gas spillage occurs.
36
Figure 2ꢂ: Wiring Diagram, Standing Pilot (24V), USA and Canada, Continuous Circulation
3ꢁ
Figure 30: Wiring Diagram, Standing Pilot (24V), USA and Canada, Intermittent Circulation
38
2. Electronically Supervised Standing Pilot (OP)
Sequence of Operation
3. ElectronicallySupervisedStandingPilot(OP-CSD-1)
Sequence of Operation
a. Normal Operation
a. Normal Operation
i. Thermostat or operating control calls for
heat.
i. Thermostat or operating control calls for
heat.
ii. Terminal #6 of RM7890C Burner Control
is energized, initiating a microcomputer
monitored circuit test.
ii. Terminal #6 of RM7890C Burner Control
is energized, initiating a microcomputer
monitored circuit test.
iii. Pilot Flame Establishing Period (PFEP)
begins.
iii. Pilot Flame Establishing Period (PFEP)
begins.
iv. After pilot flame is proven, terminal #9 of
RM7890C is energized, allowing main gas
flow and ignition of main burners. “Main”
gas light will be illuminated.
iv. After pilot flame is proven, terminal #9 of
RM7890C is energized, allowing main gas
flow and ignition of main burners. “Main”
gas light will be illuminated.
v. Call for heat ends. Terminal #6 of
RM7890C is de-energized, in turn de-
energizing gas valves and extinguishing
main flame. “Main” gas light is de-
energized.
v. Call for heat ends. Terminal #6 of
RM7890C is de-energized, in turn de-
energizing gas valves and extinguishing
main flame. “Main” gas light is de-
energized.
b. Safety Shutdown
b. Safety Shutdown
i. Limit: Automatically interrupts main burner
operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat. Normal operation
resumes when water temperature falls below
set point.
i. Limit: Automatically interrupts main burner
operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat. Normal operation
resumes when water temperature falls below
set point.
ii. Blocked Vent Switch: Automatically
interrupts main burner operation when
excessive flue gas spillage occurs.
ii. Blocked Vent Switch: Automatically
interrupts main burner operation when
excessive flue gas spillage occurs.
Circulator continues to operate with call for
heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.
Circulator continues to operate with call for
heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.
iii. Flame Roll-out Switch: Automatically
interrupts main burner operation when
flames or excessive heat are present in
vestibule. Circulator continues to operate
with call for heat. Control is single use
device. If flame roll-out switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and replace flame
roll-out switch.
iii. Flame Roll-out Switch: Automatically
interrupts main burner operation when
flames or excessive heat are present in
vestibule. Circulator continues to operate
with call for heat. Control is single use
device. If flame roll-out switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and replace flame
roll-out switch.
iv. RM7890C Burner Control: Automatically
interrupts main burner operation if a pilot
flame is not detected during the four or ten
second pilot flame establishing period. The
RM7890C will lockout or recycle based
on jumper settings. “Alarm” light will be
illuminated. Refer to instructions supplied
with RM7890C for additional control
information.
iv. RM7890C Burner Control: Automatically
interrupts main burner operation if a pilot
flame is not detected during the four or ten
second pilot flame establishing period. The
RM7890C will lockout or recycle based
on jumper settings. “Alarm” light will be
illuminated. Refer to instructions supplied
with RM7890C for additional control
information.
v. Pilot Safety Switch: Automatically de-
energizes main gas valve and interrupts pilot
gas supply if pilot flame is not detected at
any time.
3ꢂ
Figure 3ꢀ: Wiring Diagram, OP/OP-CSD-ꢀ Ignition System, Continuous Circulation
40
Figure 32: Wiring Diagram, OP/OP-CSD-ꢀ Ignition System, Intermittent Circulation
4ꢀ
4. Honeywell EI Sequence of Operation
a. Normal Operation
Circulator continues to operate and Vent
Damper (if used) remains open with call
for heat. If blocked vent switch is activated
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.
i. Thermostat or operating control calls for
heat. Vent Damper (if used) opens.
ii. Ignition Module Terminals PV, MV/PV
and the Ignition Terminal are energized.
Terminals PV and MV/PV power the Pilot
Valve in the Gas Valve supplying gas to
the Pilot. The Ignition Terminal supplies
voltage to the Ignition Electrode creating an
electric spark to ignite the Pilot.
iii. The sensing Circuit between the Q348
Pilot Burner and the IGNITION MODULE
proves the presence of the Pilot Flame
Electronically and the Ignition Terminal is
de-energized.
iii. Flame Roll-out switch: Automatically
interrupts main burner operation when
flames or excessive heat are present in
vestibule. Circulator continues to operate,
Vent Damper (if used) remains open with
call for heat. Control is single use device.
If flame roll-out switch is activated, do not
attempt to place boiler in operation. Correct
cause of spillage and replace flame roll-out
switch.
iv. Pilot
iv. Terminals MV and MV/PV of the
IGNITION MODULE are energized and
supply power to the Main Gas Valve. The
Gas Valve is energized allowing main gas
flow, and ignition of Main Burners.
v. Call for heat ends. Ignition module is de-
energized, de-energizing gas valve, and
extinguishing pilot and main flame. Vent
Damper (if used) closes.
–
Pilot failure can occur during the start-up or
the operating cycle of the boiler. Any pilot
failure of the Q348 Electronic Pilot, after
ignition of pilot flame will close the main
gas valve in 0.8 seconds.
–
For approximately 90 seconds after failure
of the Q348 pilot, the module through the
ignition terminal will try to reestablish
pilot flame. If no pilot flame can be sensed
by the flame rod circuit, terminals PV and
MV/PV are de-energized and the module
will lock out on safety. Five to six minutes
after shutdown, the IGNITION MODULE
restarts the 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.
b. Safety Shutdown
i. Limit: Automatically interrupts power
to the Ignition Module and Gas Valve(s),
extinguishing pilot and main flame, when
water temperature exceeds set point.
Maximum allowable temperature is 250°F.
Circulator continues to operate with call for
heat, Vent Damper (if used) closes. Normal
operation resumes when water temperature
falls below set point.
ii. Blocked Vent Switch: Automatically
interrupts main burner operation when
excessive flue gas spillage occurs.
c. Trouble Shooting Guide. See Page 66.
42
Figure 33: Wiring Diagram, Honeywell EI, USA, Continuous Circulation
43
Figure 34: Wiring Diagram, Honeywell EI, USA, Intermittent Circulation
44
Figure 35: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation
45
Figure 36: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation
46
ii. Blocked Vent Switch: Automatically
interrupts main burner operation when
excessive flue gas spillage occurs.
6. Electronically Supervised Intermittent Ignition
(EP/EP-CSD-1) Sequence of Operation
a. Normal Operation
Circulator continues to operate with call for
heat. If blocked vent switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and reset blocked
vent switch.
i. Thermostat or operating control calls for
heat.
ii. Terminal #6 of RM7890A Burner Control
is energized, initiating a microcomputer
monitored circuit test.
iii. Flame Roll-out Switch: Automatically
interrupts main burner operation when
flames or excessive heat are present in
vestibule. Circulator continues to operate
with call for heat. Control is single use
device. If flame roll-out switch is activated,
do not attempt to place boiler in operation.
Correct cause of spillage and replace flame
roll-out switch.
iv. RM7890A Burner Control: Automatically
interrupts main burner operation if a pilot
flame is not detected during the four or ten
second pilot flame establishing period. The
RM7890A will lockout or recycle based
on jumper settings. “Alarm” light will be
illuminated. Refer to instructions supplied
with RM7890A for additional control
information.
iii. The pilot valve (terminal 8) and ignition
transformer (terminal 10) are energized.
The pilot valve opens and the ignition
electrode sparks, igniting the pilot.
iv. After the pilot flame is proven, the ignition
terminal (10) is de-energized and the main
valve terminal (9) is energized, allowing
main gas flow and ignition of main burners.
“Main” gas light will be illuminated.
v. When the call for heat ends, terminal #6
is de-energized, extinguishing the pilot
and main flames. “Main” gas light is de-
energized.
b. Safety Shutdown
i. Limit: Automatically interrupts main burner
operation when water temperature exceeds
set point. Maximum allowable temperature
is 250°F. Circulator continues to operate
with call for heat. Normal operation
resumes when water temperature falls below
set point.
4ꢁ
Figure 3ꢁ: Wiring Diagram, EP/EP-CSD-ꢀ Ignition System, USA, Continuous Circulation
48
Figure 38: Wiring Diagram, EP/EP-CSD-ꢀ Ignition System, USA, Intermittent Circulation
4ꢂ
Figure 3ꢂ: McDonnell & Miller ꢁ50P-MT (ꢀ20V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits
Figure 40: McDonnell & Miller ꢁ50P-MT (ꢀ20V) L.W.C.O. Wiring for Boilers with ꢀ20V Limit Circuits (OP & EP)
50
Figure 4ꢀ: Hydrolevel OEM - ꢀꢁ0/550/650/ꢁ50 (ꢀ20V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits
Figure 42: Hydrolevel OEM - ꢀꢁ0/550/650/ꢁ50 (ꢀ20V) L.W.C.O. Wiring for Boilers with ꢀ20V Limit Circuits
5ꢀ
VIII. System Start-Up
WARNING
9. Close purge valve, continue filling the system
until the pressure gauge reads the desired cold fill
pressure. Close fill valve.
Completely read, understand and follow all
instructions in this manual before attempting
start-up.
(Note - If make-up water line is equipped with
pressure reducing valve, adjust pressure reducing
valve to desired cold fill pressure. Follow fill valve
manufacturer’s instructions).
A. Safe operation and other performance criteria were met
with the gas manifold and control assembly provided
on boiler when boiler underwent tests specified in
American National Standard for Gas-Fired Low-
Pressure Steam and Hot Water Boilers, ANSI Z21.13.
10. Open isolation valve in boiler supply piping.
11. Remove hose from purge valve.
F. Confirm that the boiler and system have no water
leaks.
B. Check Main Burners. Main burners must be properly
located on support bracket in Base Rear Panel, seated
on Main Burner Orifices, and secured with hitch pin
clips.
G. Prepare to check operation.
1. Obtain gas heating value (in Btu per cubic foot)
from gas supplier.
C. Verify that the venting, water piping, gas piping
and electrical system are installed properly. Refer to
installation instructions contained in this manual.
2. Connect manometer to pressure tap on gas valve.
Use 1/8 NPT tapping provided.
3. Temporarily turn off all other gas-fired appliances.
D. Confirm all electrical, water and gas supplies
are turned off at the source and that vent is clear of
obstructions.
4. Turn on gas supply to the boiler gas piping.
5. Confirm that the supply pressure to the gas valve is
14 in. w.c. or less.
E. FILL ENTIRE HEATING SYSTEM WITH WATER
and vent air from system. Use following procedure on
a Series Loop or multi-zoned system installed as per
Figure 23 to remove air from system when filling.
6. Open the field installed manual gas shut-off valve
located upstream of the gas valve on the boiler.
7. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method. Check that boiler gas piping, valves, and
all other components are leak free. Eliminate any
leaks.
WARNING
The maximum operating pressure of this boiler is
50 psig. Never exceed this pressure. Do not plug
or modify pressure relief valve.
8. Purge gas line of air.
H. Follow Lighting or Operating Instructions to place
boiler in operation. Refer to label on inside of Front
Removable Panel or appropriate Figure as listed in
Table 11.
1. Close full port ball valve in boiler supply piping.
2. Isolate all zones by closing zone valves or shut-off
valves in supply and return of each zone(s).
3. Attach a hose to the vertical purge valve located
prior to the full port ball valve in the system supply
piping. (Note - Terminate hose in five gallon bucket
at a suitable floor drain or outdoor area).
DANGER
Do not use matches, candles, open flames or
other ignition source to check for leaks.
4. Starting with one circuit at a time, open zone valve
or shut-off valve in system supply and return piping.
Table ꢀꢀ: Lighting and Operating Instructions
5. Open purge valve.
Lighting or
Pilot Flame
6. Open fill valve (Make-up water line should be
located directly after full port ball valve in system
supply piping between air scoop and expansion
tank).
Ignition System
Operating
Instructions
Figure 43
Illustration
Standing Pilot (24)
Honeywell EI
OP
Figure 48
Figure 49
Figure 50
Figure 51
Figure 50
Figure 51
Figure 44
Figure 45
Figure 46
7. Allow water to overflow from bucket until discharge
from hose is bubble free for 30 seconds.
EP
8. Close the open zone valve or shut-off valve for the
zone being purged of air, then open the zone valve
or shut-off valve for the next zone to be purged.
Repeat this step until all zones have been purged. At
OP-CSD-1
EP-CSD-1
Figure 47
completion, open all zone valves or shut-off valves.
52
Figure 43: Lighting Instructions (24V Standing Pilot)
53
Figure 44: Operating Instructions (EI)
54
Figure 45: Lighting Instructions (OP)
55
Figure 46: Operating Instructions (EP)
56
BOILER OPERATING INSTRUCTIONS
TO SHUT DOWN:
1. Close manual main shut-off valve(s) and pilot
valve(s).
2. Turn off main electric switch.
TO START UP:
1. Make sure that both the main manual and the pilot
valve(s) have been off for at least five minutes.
2. Turn room thermostat and all operating controls to
lowest setting.
3. Remove burner access panel(s).
4. Open manual pilot valve(s).
NOTE:
Item (5) applies only to boilers with standing pilot
safety switch(es).
5. Depress button on standing pilot safety switch and
hold lighted match to pilot, holding button in for at
least one minute or until pilot remains lighted after
button is released. Repeat for remaining standing
pilots.
6. Turn on main electric switch.
7. Reset safety switch on flame safeguard relay.
8. Immediately light constant burning rectification pilot(s)
Q179D with a lighted match. If pilot is not lighted
in 15 seconds, Step (7) must be repeated. Electric
pilot valve(s) are automatic, opening after Step (7).
(“OP” System).
8a. Intermittent electric ignition rectification pilot(s)
Q179C light up automatically when thermostat or
operating control calls for heat. (“EP” System).
9. Replace burner access panel(s).
10. Open manual main shut-off valve(s).
11. Adjust room thermostat and operating controls to
desired setting.
Figure 4ꢁ: Lighting / Operating Instructions (OP/EP-CSD-ꢀ)
5ꢁ
Figure 48: Honeywell Q3ꢀ4 Pilot Flame
(24V Standing Pilot)
Figure 50: Honeywell QꢀꢁꢂD Pilot Flame (OP)
Figure 5ꢀ: Honeywell QꢀꢁꢂC Pilot Flame (EP)
Figure 4ꢂ: Honeywell Q348 Pilot Flame
(24V Electronic Ignition)
I. Check pilot burner flame and main burner flames
through observation port.
1. Check pilot flame. Refer to Table 11 for appropriate
pilot detail.
2. Adjust thermostat to highest setting.
3. Check main burner flames. See Figure 52. Flame
should have clearly defined inner cones with no
yellow tipping. Orange-yellow streaks caused
by dust should not be confused with true yellow
tipping.
Yellow-tipping indicates lack of primary air.
Improper burner alignment on Main Burner Orifice
will also affect primary air injection. Adjust primary
air as follows:
Figure 52: Main Burner Flame
58
3. Clock gas meter for at least 30 seconds. Use Table
12 to determine gas flow rate in Cubic Feet per
Hour.
CAUTION
Avoid operating this boiler in an environment
where saw dust, loose insulation fibers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.
Table ꢀ2: Input Rate
Size of Gas Meter Dial
Seconds
for One
Revolution
One-Half
Cu. Ft.
One
Cu. Ft.
Two
Cu. Ft.
Five
Cu. Ft.
30
32
34
36
40
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
60
56
53
50
45
47
45
43
41
39
37
36
35
33
32
31
30
29
29
29
28
26
25
24
24
23
22
120
113
106
100
90
95
90
86
82
78
75
72
69
67
64
62
60
58
56
54
53
51
50
48
47
46
45
240
225
212
200
180
189
180
172
164
157
150
144
138
133
129
124
120
116
112
109
106
103
100
97
600
563
529
500
450
474
450
430
410
391
375
360
346
333
321
310
300
290
281
273
265
257
250
243
237
231
225
a. Loosen lock screw.
b. Close air adjustment until yellow tips appear on
flames.
c. Slowly open air adjustment until clearly defined
inner cones are visible.
d. Tighten lock screw.
4. Adjust thermostat to normal setting.
J. Check thermostat or operating control operation.
Raise and lower temperature setting to start and stop
boiler operation.
K. Check ignition system shut-off.
1. Standing Pilot (24V): Disconnect thermocouple
lead at Gas Valve. Gas Valve must close and pilot
and main burners extinguish. If not, replace the gas
valve.
2. Honeywell EI: Disconnect ignitor/sensor cable from
ignition module. Gas valve must close and pilot and
main burners extinguish. If not, measure voltage
across gas valve terminals “TH” and “TR”.
a. If voltage is not present, replace gas valve.
b. If voltage is present, replace ignition module.
3. EP and OP: Refer to instructions supplied with the
Honeywell RM7890 Burner Control.
L. Check Limit(s).
1. Adjust thermostat to highest setting.
95
2. Observe temperature gauge. When temperature
exceeds limit set point main burners should
extinguish.
92
90
3. Adjust limit to setting above observed reading. Main
burners should reignite.
4. Determine Input Rate. Multiply gas flow rate by gas
heating value.
4. Adjust thermostat to lowest setting. Adjust limit to
desired setting.
Warning
M. Adjust gas input rate to boiler. Natural Gas.
Failure to properly adjust gas input rate will result
in over firing or under firing of the appliance.
Improper and unsafe boiler operation may result.
1. Adjust thermostat to highest setting.
2. Check manifold gas pressure. Manifold pressure
is listed on rating label. Adjust gas valve pressure
regulator as necessary (turn adjustment screw
counterclockwise to decrease manifold pressure, or
clockwise to increase manifold pressure). If pressure
can not be attained, check gas valve inlet pressure.
If less than minimum gas supply pressure listed on
rating label, contact gas supplier for assistance.
5. Compare measured input rate to input rate stated on
rating label.
a. Boiler must not be overfired. Reduce input rate
by decreasing manifold pressure. Do not reduce
more than 0.3 inch w.c. If boiler is still overfired,
contact your Burnham distributor or Regional
Office for replacement Gas Orifices.
5ꢂ
b. Increase input rate if less than 98% of rating
plate input. Increase manifold gas pressure no
more than 0.3 inch w.c. If measured input rate is
still less than 98% of rated input:
reworked system should be boiled out, and then
thoroughly flushed. A qualified water treatment
chemical specialist should be consulted for
recommendations regarding appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.
i. Remove Main Burners per procedure in
Section IX: Service.
ii. Remove gas orifices. Drill one (1) drill size
larger (drill size is stamped on orifice, or see
Key No. 4E).
iii. Reinstall gas orifices and main burners.
Measure input rate.
P. Check Damper Operation - If boiler is equipped with
vent damper, vent damper must be in open position
when boiler main burners are operating. Start boiler,
refer to instructions on damper to determine if damper
is in full open position.
6. Recheck Main Burner Flame.
Q. Install Front Removable Panel.
7. Return other gas-fired appliances to previous
1. Engage top flange (longer of 2 flanges) behind
conditions of use.
Upper Front Panel.
N. Adjust gas input rate to boiler. LP/Propane.
2. Swing lower portion of door toward boiler.
1. Set thermostat to highest setting.
3. Lower door to engage bottom flange behind Lower
2. Adjust tank regulator for gas valve inlet pressure of
13.5 inches w.c. or less.
Front Tie Bar.
R. Combustion Chamber Burn-Off
3. Gas valve has step opening regulator which initially
opens to 1.4 or 2.5 inch w.c. and steps to full
1. The mineral wool combustion chamber panels
contain a cornstarch based binder that must be
burned out at installation to prevent odors during
subsequent boiler operation.
pressure after approximately 30 seconds. Check
manifold pressure after step has occurred. Adjust gas
valve pressure regulator as necessary for 10.0 inches
w.c. (turn adjustment screw counterclockwise to
decrease manifold pressure, or clockwise to increase
manifold pressure). If 10.0 inches w.c. can not be
attained, check gas valve inlet pressure. If less than
11.0 inches w.c., contact gas supplier for assistance.
2. Ventilate the boiler room, set the high limit to its
maximum setting, set the thermostat to call for heat.
3. Allow the boiler to fire for at least an hour or until
the odor from the cornstarch has dissipated.
4. Return the high limit and thermostat to their desired
settings.
O. Clean Heating System
Oil, grease, and other foreign materials which
accumulate in new hot water boilers and a new or
S. Review User’s Information Manual and system
operation with owner or operator.
60
IX. Service
WARNING
Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service
agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a
legible condition.
Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and
liquids.
Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air.
The service instructions contained in this manual are in addition to the instructions provided by the
manufacturer of the boiler components. Follow component manufacturer’s instructions. Component
manufacturer’s instructions were provided with the boiler. Contact component manufacturer for replace-
ment if instructions are missing. Do not install, start up, operate, maintain or service this boiler without
reading and understanding all of the component instructions. Do not allow the boiler to operate with
altered, disconnected or jumpered components. Only use replacement components identical to those
originally supplied by Burnham Commercial.
A. General. Inspection and service must be conducted
annually. Turn off electrical power and gas supply while
conducting service or maintenance. Follow instructions
TO TURN OFF GAS TO APPLIANCE. See Lighting/
Operating Instructions on inside of Front Removable
Door.
4. Remove burner access panel(s).
5. Mark location of Main Burner with Pilot Bracket on
manifold.
6. Remove hitch pin clips from Main Burner Orifices.
7. Hold Main Burner on throat. Lift slightly to raise
rear of burner. Push to rear of boiler until burner
clears Main Burner Orifice. Lift burners out.
WARNING
8. Check burners to be sure they do not contain foreign
matter or restrictions. Clean burners with a soft
bristle brush, blow any dirt out with compressed air
or use a vacuum cleaner. See Figure 53.
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.
E. Clean Boiler Flueways. See Figure 53.
B. Maintenance of Low Water Cut-off (if used). Follow
1. Shut down gas boiler in accordance with Lighting/
Operating Instructions on inside of Front Removable
Door. Close Manual Shut-off Valve.
instructions provided with low water cut-off.
C. Vent System. Check for:
1. obstructions
2. Disconnect vent system. Remove Draft Hood.
3. Remove Jacket Top Panel.
2. accumulations of soot
3. deterioration of vent pipe or vent accessories due to
condensation or other reasons
4. Remove Canopy from top of boiler.
5. Lift Flue Baffles out of flueways. Remove any
4. proper support—no sags, particularly in horizontal
runs
accumulated scale or soot.
6. Thoroughly clean flueways with flue brush,
5. tightness of joints. Remove all accumulations of
soot with wire brush and vacuum
removing all scale and soot. See Figure 53.
7. Clean boiler heating surface accessible from
combustion chamber with straight handle wire
brush.
Remove all obstructions. Replace all deteriorated parts
and support properly. Seal all joints.
8. Reinsert Blue Baffles into flueways. See Figure 53
for correct baffle orientation. Tabs at top of each
baffle should rest o top of Flue Pins.
D. Remove Main Burners for cleaning, changing orifice
plugs, or repairs.
1. Shut down gas boiler in accordance with Lighting/
Operating Instructions on inside of Front Removable
Door. Close Manual Shut-off Valve.
9. Install Canopy. See Section II: Boiler Assembly,
Paragraph G.
10. Install Jacket Top Panel, Draft Hood, Vent Damper
(if used) and Vent System.
2. Remove Front Removable Door. Raise Lower Front
Tie Bar.
3. Disconnect ignition system.
6ꢀ
Important Product Safety Information
Refractory Ceramic Fiber Product
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 about 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
2. Long sleeved, loose fitting clothing
3. Gloves
4. 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 United
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.
62
Figure 53: Boiler Flueway Cleaning
F. Clean Combustion Chamber by vacuuming. Exercise
care to avoid damaging Base Insulation.
G. Install Burners by reversing procedures used to
remove burners. Verify Main Burners are properly
located on support bracket in Base Rear Panel, seated
on Main Burner Orifices, and secured with hitch pin
clips. Verify Main Burner with Pilot Bracket is in
proper location. See Table 13.
Table ꢀ3: Pilot Burner Location
Boiler Model
805H
Pilot Located Between Burners*
4 & 5
5 & 6
6 & 7
6 & 7
7 & 8
8 & 9
806H
807H
H. Lubrication. Manufacturers Instruction should be
followed on all parts installed on boiler requiring
lubrication. This includes type of lubricant to be used,
frequency of lubrication, and points to lubricate.
808H
809H
810H
* Burners numbered left to right as viewed from front of boiler.
I. Check operation. Refer to Section VIII: System Start-
up.
63
Honeywell EI Ignition Module Yellow LED Flame Codes
Yellow LED
Indicates
Recommended Service Action
N/A
Flash Codea
Heartbeat
Normal Flame Signal
Weak Flame Signal -
System will operate reliably but flame signal is less than
desired.
Note: This indication may flash temporarily during or
shortly after lightoff on some applications.
Perform routine maintenance to
assure optimum flame signal.
2
Marginal Flame Signal (less than 1.1 µA) -
System may not operate reliably over time. Service call
recommended.
Note: This indication may flash temporarily during or
shortly after lightoff on some applications.
Check gas supply, pilot burner, flame
sense wiring, contamination of flame rod,
burner ground connection.
1
No Flame or Flame Signal -
below minimum threshold for system operation.
OFF
N/A
aFlash Code Descriptions
- Heartbeat: Constant ½ second bright, ½ second dim cycles.
- The flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then repeats
sequence.
64
Honeywell EI Ignition Module Green LED Status Codes
Green LED
Flash Code
Indicates
Next System Action
Recommended Service Action
(X + Y)a
OFF
No “Call for Heat”
N/A
N/A
N/A
None
None
None
Startup - Flame sense
calibration
Flash Fast
Heartbeat Normal operation
If system fails to light on next trial for
ignition check gas supply, pilot burner,
spark and flame sense wiring, flame rod
contamination or out of position, burner
ground connection.
5 minute Retry Delay-
Pilot flame not detected
during trial for ignition
Initiate new trial for ignition after
retry delay completed.
2
3
If system fails to light on next trial
for ignition check gas supply, pilot
burner, flame sense wiring, flame rod
contamination, burner ground connection.
Initiate new trial for ignition. Flash
code will remain through the ignition
trial until flame is proved.
Recycle- Flame failed
during run
If situation self corrects within 10
seconds, control returns to normal
Check for pilot flame. Replace gas valve
Flame sensed out of
sequence
sequence. If flame out of sequence if pilot flame present. If no pilot flame,
remains longer than 10 seconds, cycle “Call for Heat.” If error repeats,
4
control goes to Flash code 6+4 (see replace control.
below)
Control remains in wait mode.
Flame sense leakage to When the fault corrects, control
Check flame sense lead wire for damage
or shorting. Check that flame rod is in
proper position. Check flame rod ceramic
for cracks, damage or tracking.
7
8
ground
resumes normal operation after a
one minute delay.
Control remains in wait mode.
When the fault corrects, control
Check transformer and AC line for proper
input voltage to the control. Check with
full system load on the transformer.
Low secondary voltage
supply- (below 15.5 Vac) resumes normal operation after one
minute delay.
Check gas supply, pilot burner, spark
and flame sense wiring, flame rod
contamination or out of position, burner
ground connection.
5 minute Retry Delay-
Initiate new trial for ignition after
On every third retry on
retry delay completed.
same “Call for Heat”
6 + 2
6 + 3
On every 6th flame
Check gas supply, pilot burner, flame
sense wiring, contamination of flame rod,
burner ground connection.
5 minute retry delay, then initiate
failure during run on the
new trial for ignition.
same “Call for Heat”
Control waits until flame is no
Check for pilot flame. Replace gas valve
if pilot flame present. If no pilot flame,
cycle “Call for Heat.” If error repeats,
replace control.
Flame sensed out of
sequence- longer than
10 seconds
longer sensed and then goes to
soft lockout. Flash code continues.
Control auto resets from soft
lockout after one hour.
6 + 4
Soft lockout due to error
detected during self
check sequences
Control auto resets from soft
lockout after one hour.
Reset by cycling “Call for Heat.” If error
repeats, replace the control
ON
aFlash Code Descriptions:
-
-
-
Flash Fast: rapid blinking
Heartbeat: Constant ½ second bright, ½ second dim cycles.
A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then
repeats the sequence.
-
X + Y flash codes signify that the LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at
2 Hz, remains off for three seconds, and then repeats the sequence.
65
Honeywell EI Trouble Shooting Guide
66
X. Repair Parts
All Series 8H Repair Parts may be obtained through your local Burnham Wholesale distributor. Should
you require assistance in locating a Burnham Distributor in your area, or have questions regarding the
availability of Burnham products or repair parts, please contact Burnham Customer Service at:
(717) 481-8400 or Fax (717) 481-8408.
6ꢁ
Quantity
Item No.
Description
Part No.
805H
806H
807H
808H
809H
810H
ꢀ. Heat Exchanger Assembly
6171605
6171606
6171607
6171608
6171609
6171610
7171601
7171603
7171602
80861032
80861033
80861013
80861034
80861035
80861036
80860600
80860400
7066002
7111622
1
---
---
---
---
---
1
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
1
1
Complete (Less Flue Baffles)
---
---
---
1
---
---
1
---
1
1A
1B
1C
Left End Section
1
Intermediate Section
Right End Section
3
4
5
6
7
8
1
1
1
1
1
1
1
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
4
---
---
---
---
4
1D
Tie Rod
---
---
---
4
---
---
4
---
4
1E
1F
1G
1H
Washer
4
Nut
4
4
4
4
4
4
Slip Nipple, 3”
Flue Baffle
8
10
5
12
6
14
7
16
8
18
9
4
68
Quantity
Item No.
Description
Part No.
805H
806H
807H
808H
809H
810H
2. Canopy
6111605
6111606
6111607
6111608
6111609
6111610
80860115
80860603
80860407
1
---
---
---
---
---
2
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
2
2A
Canopy
---
---
---
2
---
---
2
---
2
2B
2C
2D
Bolt, Carriage, ¼ - 20 x 1”
Washer, ¼” Flat
2
2
2
2
2
2
2
Nut, ¼” - 20
2
2
2
2
2
2
6ꢂ
Quantity
Item
No.
Description
Part No.
805H
806H
807H
808H
809H
810H
3. Base Assembly
3A
Base End Panel
7181601
61816052
61816062
61816072
61816082
61816092
61816102
61816051
61816061
61816071
61816081
61816091
61816101
61816053
61816063
61816073
61816083
61816093
61816103
61816054
61816064
61816074
61816084
61816094
61816104
7041601
2
2
2
---
2
2
---
---
2
2
---
---
---
2
2
---
---
---
---
2
2
---
---
---
---
---
2
---
---
---
---
---
1
---
---
---
---
---
1
3B
Base Channel Assembly
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
3C
3D
3E
Base Rear Panel Assembly
Base Front Panel Assembly
Burner Access Panel Assembly
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
2
---
---
---
---
---
2
---
---
---
---
---
2
---
---
---
---
---
4
---
---
---
---
4
---
---
---
4
---
---
4
---
4
3F
3G
3H
3J
Jacket Attachment Bracket
Bolt, Carriage, ¼ - 20 x 1¼”
Washer, ¼” Flat
4
80860106
80860603
80860407
80860700
80861302
80861311
80860000
80860600
80860403
80860702
4
4
4
4
4
4
4
4
4
4
4
4
Nut, ¼ - 20
4
4
4
4
4
4
3K
3L
Screw, Self Tapping, ¼ - 20 x ½”
Screw, Cap, Hex Head, 5/16” - 18 x ¾”
Screw, Cap, Hex Head, 5/16 - 18 x 1¼”
Screw, Sheet Metal, #8 x ½”
Washer, 3/8” Flat
3
4
4
5
5
6
2
2
2
2
2
2
3M
3N
3P
3Q
3R
6
6
6
6
6
6
8
8
8
8
8
8
6
6
6
6
6
6
Nut, 5/16”
6
6
6
6
6
6
Screw, Self Tapping, ¼ - 20 x ¾”
10
10
10
10
10
10
ꢁ0
Quantity
Item
No.
Description
Part No.
805H
806H
807H
808H
809H
810H
4. Manifold and Main Burners
4A
Main Burner
8231602
8231601
8231604
8
---
1
10
1
12
1
15
1
17
1
19
1
Main Burner with Pilot Bracket, Standing Pilot (24V)
Main burner with Pilot Bracket, Honeywell EI
Main Burner with Pilot Bracket, OP
Main burner with Pilot Bracket, EP
1
1
1
1
1
4B
8231603
---
1
1
1
1
1
82216051
82216061
82216071
82216081
82216091
82216101
---
1
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
1
4C
Manifold
---
---
---
1
---
---
1
---
1
4D
4E
4F
Pipe Plug, 1/8 NPT (Included with 4C)
Main Burner Orifice, #39 (Natural Gas Only *
Main Burner Orifice, #53 (LP/Propane Only) *
Hitch Pin Clip
1
822603
9
11
13
13
16
16
18
18
20
20
8226002
822604
9
11
* Main burner orifice sizes shown for normal altitude (0-2000 feet). For High Altitude consult factory.
ꢁꢀ
Item
No.
Description
Part No.
Size
Quantity
5-ꢀ Gas Train -- Standing Pilot (24V, OP)
24V: USA & Canada, 6 & ꢁ Section, Natural & LP Gas
OP: USA & Canada, 6 - ꢀ0 Section, Natural & LP Gas
Gas Valve, Robertshaw 7000ERHC-S7C, Natural Gas, 1” NPT
Gas Valve, Robertshaw 7000ERHC-LP-S7C, LP Gas, 1” NPT
Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT
Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT
81660156
A
B
806H - 810H
1
81660157
81660235
81660236
806H-807H
808H-810H
1
1
808H-810H
Canada Only
C
D
Lubricated Manual Shut-Off Valve, Newman-Milliken 200M, 1” NPT
822619
1
Hex Bushing, 1” NPT x ¾” NPT
Nipple, ¾” NPT x 2” Lg.
806600501
806600003
806600004
806601512
806601513
806H & 807H
806H & 807H
808H-810H
1
USA: 1
Canada: 2
E
F
Nipple, 1” NPT x 2” Lg.
Street Elbow, 1” NPT x ¾” NPT
Street Elbow, 1¼” NPT x 1” NPT
806H - 807H
808H - 810H
1
ꢁ2
Item
No.
Description
Part No.
Quantity
5-2 Gas Train -- Standing Pilot (OP-CSD-ꢀ)
OP-CSD-ꢀ: USA Only, 8-ꢀ0 Section, LP Gas Only
A
B
C
D
E
F
Gas Valve, Robertshaw 7000GVERHC-S7C, LP Gas, 1” NPT
81660271
81660236
822615
1
1
1
2
2
1
2
1
1
1
1
1
Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT
Lubricated Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT
Leak Test/Shut-off Valve, Conbraco #56-221-01, 1/8” x 1/8”
Pipe Plug, 1/8”
822679
806603594
806600520
806600004
806601514
806600033
806602502
6136230
Hex Bushing, 1/4” x 1/8”
G
H
J
Nipple, 1” x 2” Long
Street Elbow, 90° x 1”
Close Nipple, 1”
K
L
Malleable Coupling, 1-1/4” x 1”
Wiring Harness, Gas Valve to Solenoid Valve
Pilot Outlet Plug, Honeywell #394424
M
8226051
ꢁ3
Item
No.
Description
Part No.
Size
Quantity
5-3 Gas Train -- Intermittent Ignition (EI)
USA: 5 - ꢀ0 Section, Natural and LP Gas
Canada: 5 - ꢀ0 Section, Natural Gas
5 - ꢁ Section, LP Gas
Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT
81660151
81660158
805H-810H
A
1
USA: 805H-810H
Canada: 805H-807H
Gas Valve, Robertshaw 7000DERHC-LP, LP Gas, 1” NPT
B
C
Lubricated Manual Shut-Off Valve, Newman-Milliken 200M, 1” NPT
Nipple, 1’ NPT x 2” Lg.
822619
808H-810H
Canada Only
1
1
806600004
806601514
806601513
Street Elbow, 1” NPT
805H-807H
808H-810H
D
Street Elbow, 1¼” NPT x 1” NPT
ꢁ4
Item
No.
Description
Part No.
Size
Quantity
5-4 Gas Train -- Intermittent Ignition (EP)
USA & Canada: 6 - ꢀ0 Section, Natural Gas Only
A
Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT
81660168
81660235
81660236
806H-810H
806H-807H
808H-810H
1
1
Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT
Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT
B
808H-810H
Canada Only
C
D
Lubricated Manual Shut-Off Valve, Newman-Milliken 200M, 1” NPT
822619
1
Hex Bushing, 1” NPT x ¾” NPT
Nipple, ¾” NPT x 2” Lg.
806600501
806600003
806H & 807H
806H & 807H
1
1
E
F
USA: 1
Canada: 2
Nipple, 1” NPT x 2” Lg.
806600004
808H-810H
Street Elbow, 1” NPT x ¾” NPT
Street Elbow, 1¼” NPT x 1” NPT
806601512
806601513
806H & 807H
808H-810H
1
ꢁ5
Item
No.
Description
Part No.
Quantity
5-5 Gas Train -- Intermittent Ignition (EP-CSD-ꢀ)
USA Only: 8 - ꢀ0 Section, Natural Gas Only
A
B
C
D
E
F
Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT
81660168
81660236
822615
1
1
1
2
2
1
2
1
1
1
1
1
Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT
Lubricated Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT
Leak Test/Shut-Off Valve, Conbraco #56-221-01, 1/8” x 1/8”
Pipe Plug, 1/8”
822679
806603594
806600520
806600004
806601514
806600033
806602502
6136230
Hex Bushing, 1/4” x 1/8”
G
H
J
Nipple, 1” x 2” Long
Street Elbow, 90° x 1”
Close Nipple, 1”
K
L
Malleable Coupling, 1-1/4” x 1”
Wiring Harness, Gas Valve to Solenoid Valve
Pilot Outlet Plug, Honeywell #394424
M
8226051
ꢁ6
Item
No.
Description
Part No.
Size
Quantity
5-6 Pilot Assembly and Piping -- Standing Pilot (24V)
USA & Canada: 6 & ꢁ Section, Natural and LP Gas
Pilot Burner, Honeywell Q314A3687, Natural Gas
8236033
8236034
8236004
8236008
A
Pilot Burner, Honeywell Q314A3828, LP Gas
Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead
Brass Compression Union, 1/4” OD Tube
All
1
B
C
806H & 807H
1
1
Canada: 806H & 807H
Natural Gas Only
D
E
Regulator, Maxitrol RV12LT, Natural Gas
8226005
822630
Canada: 806H & 807H
Natural Gas Only
Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT
2
ꢁꢁ
Item
No.
Description
Part No.
Size
Quantity
5-ꢁ Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) USA
5 - ꢀ0 Section, Natural and LP Gas
Pilot Burner, Honeywell Q348A1002, Natural Gas
Pilot Burner, Honeywell Q348A1010, LP Gas
Igniter/Sensor Cable, 36” Lg., Honeywell 394803-2
Ground Wire Assembly
8236072U
8236081
8236121
6136054
8236008
A
1
B
C
D
805H-810H
1
1
Brass Compression Union, 1/4” OD Tube
ꢁ8
Item
No.
Description
Part No.
Size
Quantity
5-8 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) Canada
5 - ꢀ0 Section, Natural Gas
5 - ꢁ Section, LP Gas
Pilot Burner, Honeywell Q348A1002, Natural Gas
Pilot Burner, Honeywell Q348A1010, LP Gas
Igniter/Sensor Cable, 36” Lg., Honeywell 394800-36
Ground Wire Assembly
8236072U
8236081
8236084
6136054
8236008
822645
805H-810H
805H-807H
A
1
B
C
D
E
F
All
1
1
Brass Compression Union, 1/4” OD Tube
Shut-Off Valve, Essex P2L
805H-807H
Pipe Tee, 1/8” NPT, Malleable
806601005
806603508
808H-810H
1
G
Pipe Plug, 1/8” NPT, Sq. Head
805H-807H Natural Gas
808H-810H Natural Gas
805H-807H LP Gas
2
3
1
H
Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT
822630
J
K
L
Solenoid Gas Valve, Johnson H91WG-6
Junction Box, 4” Sq. x 1-1/2” Deep
Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg.
Conduit Locknut, 1/2”
822666
8136259
8136019
8136220
8136034
1
All
M
N
2
1
Plastic Insulating Bushing, 1/2”
805H-810H
Natural Gas Only
P
Regulator, Maxitrol RV12LT, Natural Gas
8226005
1
ꢁꢂ
Item
No.
Description
Part No.
Size
Quantity
5-ꢂ Pilot Assembly and Piping -- Standing Pilot (OP)
USA & Canada: 6 - ꢀ0 Section, Natural and LP Gas
Pilot Burner, Honeywell Q179D1008, Natural Gas
8236025
6236039
8236004
71362561
8236021
6136259
A
Pilot Burner, Honeywell Q179D1008 w/388146KD Orifice, LP Gas
Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead
Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg.
Rajah Connector, Honeywell 37356
B
C
D
E
806H-810H
1
Ground Wire Assembly
USA: 806H-810H
Canada: 806H & 807H
F
Brass Compression Union, 1/4” OD Tube
Regulator, Maxitrol RV12LT, Natural Gas
8236008
8226005
1
1
Canada: 806H-810H
Natural Gas Only
G
H
J
Pipe Tee, 1/8” NPT, Malleable
Pipe Plug, 1/8” NPT, Sq. Head
Shut-Off Valve, Essex P2L
806601005
806603508
822645
808H-810H
Canada Only
1
K
806H & 807H
Natural Gas
2
L
Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT
822630
808H-810H Natural Gas
806H-810H LP Gas
3
1
80
Item
No.
Description
Part No.
Size
Quantity
5-ꢀ0 Pilot Assembly and Piping -- Standing Pilot (OP-CSD-ꢀ)
USA Only: 8 - ꢀ0 Section, LP Gas Only
A
B
C
D
E
Pilot Burner, Honeywell Q179D1008 w/388146KD Orifice, LP Gas
6236039
8236004
71362561
8236021
6136259
1
1
1
1
1
Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead
Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg.
Rajah Connector, Honeywell 37356
Ground Wire Assembly
808H-810H
F
Brass Compression Union, 1/4” OD Tube
8236008
1
G
H
J
Regulator, Maxitrol RV12LT, Natural / LPGas
Pilot Switch, Johnson L62-GB-3C
8226005
80160138
822679
1
1
1
2
Conbraco Leak Test / Shut-Off Valve, 1/8” x 1/8”
Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT
K
822630
8ꢀ
Item
No.
Description
Part No.
Size
Quantity
5-ꢀꢀ Pilot Assembly and Piping -- Intermittent Ignition (EP)
USA & Canada: 6 - ꢀ0 Section, Natural Gas Only
A
B
C
D
E
Pilot Burner, Honeywell Q179C1009, Natural Gas
8236017
71362561
8236021
7136247
6136259
1
1
2
1
1
Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg.
Rajah Connector, Honeywell 37356
Ignition Lead, Honeywell R1061012, 3 Ft. Lg.
Ground Wire Assembly
806H-810H
806H & 807H
USA & Canada
808H-810H
F
Brass Compression Coupling, 1/4” OD Tube
8236008
1
1
USA Only
G
H
J
Shut-Off Valve, Essex P2L
Pipe Tee, 1/8” NPT, Malleable
Pipe Plug, 1/8” NPT, Sq. Head
822645
808H-810H
Canada Only
806601005
806603508
806H & 807H
Canada Only
2
3
K
Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT
822630
808H-810H
Canada Only
L
M
N
P
Solenoid Gas Valve, Johnson H91WA-4
Junction Box, 4” Sq. x 1-1/2” Deep
Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg.
Conduit Locknut, 1/2”
822662
8136259
8136019
8136220
8136034
1
1
1
2
1
806H-810H
Q
Plastic Insulating Bushing, 1/2”
806H-810H
Canada Only
R
Regulator, Maxitrol RV12LT, Natural / LP Gas
8226005
1
82
Item
No.
Description
Part No.
Size
Quantity
5-ꢀ2 Pilot Assembly and Piping -- Intermittent Ignition (EP-CSD-ꢀ)
USA Only: ꢀ0 Section, Natural Gas Only
A
B
C
D
E
F
Pilot Burner, Honeywell Q179C1009, Natural Gas
Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg.
Rajah Connector, Honeywell 37356
8236017
71362561
8236021
7136247
6136259
8236008
822679
1
1
2
1
1
1
1
2
1
1
1
2
1
Ignition Lead, Honeywell R1061012, 3 Ft. Lg.
Ground Wire Assembly
Brass Compression Coupling, 1/4” OD Tube
Conbraco Leak Test / Shut-Off Cock, 1/8” x 1/8”
Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT
Solenoid Gas Valve, Johnson H91WA-4
Junction Box, 4” Sq. x 1-1/2” Deep
G
H
J
808H-810H
822630
822662
K
L
8136259
8136019
8136220
8136034
Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg.
Conduit Locknut, 1/2”
M
N
Plastic Insulating Bushing, 1/2”
P
Regulator, Maxitrol RV12LT, Natural / LP Gas
8226005
1
83
84
Quantity
Item
No.
Description
Part No.
805H
806H
807H
808H
809H
810H
6. Jacket
60416111
60416121
60416131
60416141
60416151
60416161
70416053
70416063
70416073
70416083
70416093
70416103
72016058
72016068
72016078
72016088
72016098
72016108
70416056
70416066
70416076
70416086
70416096
70416106
72016059
72016069
72016079
72016089
72016099
72016109
60416056
60416066
60416076
60416086
60416096
60416106
70416051
70416061
70416071
70416081
70416091
70416101
1
---
----
---
---
---
1
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
6
Complete
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
6A
6B
6C
6D
6E
6F
Jacket Top Panel
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
Jacket Top Panel Insulation
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
Jacket Upper Rear Panel
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
Jacket Upper Rear Panel Insulation
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
Jacket Lower Rear Panel
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
---
---
---
---
Jacket Upper Front Panel
---
---
---
---
---
---
85
Quantity
Item
No.
Description
Part No.
805H
806H
807H
808H
809H
810H
6. Jacket (Continued)
7041605
7041606
1
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
7041607
---
---
---
---
1
6G
Jacket Front Removable Panel
7041608
---
---
---
1
7041609
---
---
1
7041610
---
1
6H
6J
Jacket Left Side Panel
6041601
1
Jacket Left Side Panel Main Insulation Piece
Jacket Left Side Panel Upper Corner Insulation Piece
Jacket Left Side Panel Lower Corner Insulation Piece
Jacket Right Side Panel
72016021
72016023
72016022
6041602
1
1
1
1
1
1
6K
6L
1
1
1
1
1
1
1
1
1
1
1
1
6M
6N
6P
1
1
1
1
1
1
Jacket Right Side Panel Main Insulation Piece
Jacket Right Side Panel Lower Corner Insulation Piece
72016011
72016012
70416055
70416065
70416075
70416085
70416095
70416105
72016057
72016067
72016077
72016087
72016097
72016107
72016056
72016066
72016076
72016086
72016096
72016106
70416052
70416062
70416072
70416082
70416092
70416102
1
1
1
1
1
1
1
1
1
1
1
1
1
---
1
---
---
1
---
---
---
1
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
6Q
6R
6S
6T
Jacket Vestibule Panel
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
Jacket Vestibule Panel Upper Insulation Piece
Jacket Vestibule Panel Lower Insulation Piece
Jacket Lower Front Tie Bar
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
1
---
---
---
---
---
---
---
---
---
---
---
---
---
---
---
86
Quantity
805H 806H 807H 808H 809H 810H
Item
No.
Description
Part No.
ꢁ. Trim and Miscellaneous Controls
Limit, 140-220°F, Honeywell
L4080D1218 (EI & Standing Pilot);
L4080B1212 (EP * OP)
80160251
80160474
1
1
1
1
1
1
A
Immersion Well, ¾” NPT x 1½” Insul. Depth
80160426
80160703
80160452
100282-01
8061601
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
B
B1
C
Limit, Manual Reset, Honeywell L4006E1133
Immersion Well, ¾” NPT x 3” Insul. Depth
Temperature - Pressure Gauge
Nipple, 2 NPT x 10” w/Gauge Tapping
Safety Relief Valve, ¾ NPT, 50 psi
Nipple, ¾ NPT x 3½”
C1
D
81660302
806600038
806603061
806600038
806602561
6016058
D1
E
Drain Valve, ¾ NPT, Conbraco 35-302-03
Nipple, ¾ NPT x 3½”
E1
E2
F
Coupling, ¾ NPT
Blocked Vent Switch Replacement Assembly
Flame Roll-out Switch
G
80160044
7181612
G1
H
Flame Roll-out Switch Mounting Bracket
Junction Box
8136010
Control Center, Honeywell R8285D500
(Intermittent Circulation builds)
J
80160155U
1
1
1
1
1
1
K
L
Transformer, 50VA (Continuous Circulation builds)
Ignition Module, Honeywell S8610M3009
80160249
100958-01
81316010
81316011
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
---
1
---
1
---
1
Vestibule Wiring Harness, Complete with Vent Damper Bypass
Plug (EI and Standing Pilot) (Not Depicted)
M
---
---
---
8ꢁ
Quantity
Item
No.
Description
Part No.
805H
806H
807H
808H
809H
810H
8. Draft Hood and Automatic Vent Damper
8111605
8111604
8111607
8111603
8111608
8111602
8111608
8111601
8111609
1
---
1*
---
---
---
1*
---
---
---
---
---
1*
---
---
---
---
---
---
---
1*
---
---
---
---
---
---
---
1*
---
---
---
---
---
---
---
---
1**
---
---
---
---
---
---
8A
Draft Hood
1**
---
---
---
---
1**
---
---
1**
1**
Automatic Vent Damper, 7”
Effikal RVGP-7
8116324
8116325
8116326
8116327
1
---
1
---
---
1
---
---
1
---
---
---
1
---
---
---
1
Automatic Vent Damper, 8”
Effikal RVGP-8
---
---
---
8B
Automatic Vent Damper, 9”
Effikal RVGP-9
---
---
Automatic Vent Damper, 10”
Effikal RVGP-10
---
---
All components for use in both USA and Canada, unless marked with * for USA Only or ** for Canada Only.
88
SERVICE RECORD
DATE
SERVICE PERFORMED
8ꢂ
SERVICE RECORD
DATE
SERVICE PERFORMED
ꢂ0
SERVICE RECORD
DATE
SERVICE PERFORMED
ꢂꢀ
|