Burnham 805H, Installation, Operating And Service Instructions

Page 1: ...only be used by a qualified heating installer service technician BEFORE installing read all instructions in this manual and all other information shipped with the boiler Post all instructions and manu...

Page 2: ...should be made to the following Standards USA BOILERS A Current Edition of American National Standard ANSI NFPA 31 Installation of Oil Burning Equipment for recommended installation practices B Curren...

Page 3: ...othing 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...

Page 4: ...h cast iron section is permanently marked with the MAWP listed on the boiler s ASME Data Label The MAWP for all Series 8HE Boiler is 50 psi Water Only It is common and acceptable practice to install t...

Page 5: ...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 fr...

Page 6: ...e Installation 8 II Boiler Assembly 10 III Gas Control System Assembly 17 Knockdown Boilers IV Water Trim and Piping 24 V Gas Piping 28 VI Venting 30 VII Electrical 33 VIII System Start up 49 IX Servi...

Page 7: ...7 24 13 16 16 1 8 7 dia x 15 ft 11 9 600 610 806H 315 23 3 4 11 7 8 8 27 13 16 18 8 dia x 15 ft 13 9 690 700 807HE 340 27 1 2 13 3 4 8 27 13 16 18 8 dia x 15 ft 15 9 785 870 808HE 410 31 1 4 15 5 8 9...

Page 8: ...with size of boiler a Front 18 b Top 51 c Draft hood rear sides and flue connector 6 3 Canada 805H 810HE a Top and front 18 45 7 cm b Flue rear and sides 6 15 2 cm D Provide clearance for servicing an...

Page 9: ...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 i Minimum free area of 1 square inch per 3 00...

Page 10: ...rear corner of Base End Panel raise boiler and install 1 wood blocks under rear corners Install pipe roller between Base and skid 3 Remove 1 wood blocks Place 3 pipe roller on floor behind skid 4 Rol...

Page 11: ...less than 50 psi gauge pressure Figure 4 Installation of Special Base for Combustible Flooring 6 Examine boiler for leaks or damage due to shipment or handling 7 Remove plugs from Return Tapping B Ta...

Page 12: ...ated in Combination Boiler Parts and Control Carton 1 Attach Base Front Panel to Section Assembly using 20 x 1 carriage bolts washers and nuts 2 Seal between top of Base Front Panel and Section Assemb...

Page 13: ...13 Figure 6 Flame Roll out Switch Installation Figure 7 Burner Burner Access Panel Installation...

Page 14: ...rews 5 Remove Rating Label from envelope marked RATING LABEL ENCLOSED Remove Combustible Clearance Label from Combination Boiler Parts and Controls Carton Attach to Vestibule Panel in locations shown...

Page 15: ...15 Figure 8 Jacket Assembly...

Page 16: ...16 Figure 9 EP Control Installation...

Page 17: ...4 Mount Transformer continuous circulation or Control Center intermittent circulation to Junction Box See Figure 8 a Canada only loop 4 nylon cable tie between junction box and transformer control ce...

Page 18: ...18 Figure 10 Schematic Gas Piping 24V Standing Pilot 806H 807HE...

Page 19: ...19 Figure 11 Main Gas Piping Intermittent Ignition EI...

Page 20: ...20 Figure 12 Schematic Pilot Piping Honeywell EI USA...

Page 21: ...21 Figure 13 Schematic Pilot Piping Honeywell EI Canada Natural Gas 805H 810HE LP Gas 806H 807HE...

Page 22: ...22 Figure 14 Schematic Gas Piping EP Control System Natural Gas Only 806H 810HE...

Page 23: ...23 Figure 15 Schematic Gas Piping EP CSD 1 Control System 808HE 810HE...

Page 24: ...at 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 arran...

Page 25: ...ping See Figure 19 a Install 2 NPT x 10 Nipple into Supply Tapping A See Figure 3 Figure 18 Temperature Pressure Gauge Installation Figure 19 Alternate Temperature Pressure Gauge Installation b Instal...

Page 26: ...ty Burnham Commercial recommends maintaining temperature differential drop across the system at 40 F or less and return water temperature at minimum of 135 F Continued boiler operation for prolonged p...

Page 27: ...protection from low return water temperature 4 A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of installation 5 A start up strainer is reco...

Page 28: ...is not shown choose next higher value 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...

Page 29: ...6 0 78 1 0 3 1 0 824 0 44 23 1 11 5 5 3 2 1 0 97 1 4 4 1 1 1 049 0 56 29 4 14 7 6 8 2 6 1 23 1 8 5 3 1 1 380 0 74 38 6 19 3 8 9 3 5 1 6 2 3 6 9 Specific Gravity Correction Factor Specific Gravity Cor...

Page 30: ...rated 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 MOD...

Page 31: ...on 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...

Page 32: ...d to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range h...

Page 33: ...enced 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 Set heat anticipator to mat...

Page 34: ...is causes the damper to close When the damper blade reaches the fully closed position the damper motor is de energized POWER FAILURE The damper blade will stop in the position it was in when power fai...

Page 35: ...y 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...

Page 36: ...36 Figure 27 Wiring Diagram Standing Pilot 24V Continuous Circulation 806H 807HE...

Page 37: ...37 Figure 28 Wiring Diagram Standing Pilot 24V Intermittent Circulation 806H 807HE...

Page 38: ...ain burner operation when excessive flue gas spillage occurs Circulator continues to operate and Vent Damper if used remains open with call for heat If blocked vent switch is activated do not attempt...

Page 39: ...39 Figure 29 Wiring Diagram Honeywell EI USA Canada 805 Only with Hydrostat 3200 Control...

Page 40: ...40 Figure 30 Wiring Diagram Honeywell EI USA Continuous Circulation 806 810...

Page 41: ...41 Figure 31 Wiring Diagram Honeywell EI USA Intermittent Circulation 806 810...

Page 42: ...42 Figure 32 Wiring Diagram Honeywell EI Canada Continuous Circulation Natural 806H 810HE LP 806H 807HE...

Page 43: ...43 Figure 33 Wiring Diagram Honeywell EI Canada Intermittent Circulation Natural 806H 810HE LP 806H 807HE...

Page 44: ...culator 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 excessi...

Page 45: ...45 Figure 34 Wiring Diagram EP Ignition System Natural Gas Only Continuous Circulation EP CSD 1 Natural Gas USA Only 808HE 810HE...

Page 46: ...46 Figure 35 Wiring Diagram EP Ignition System Natural Gas Only Intermittent Circulation EP CSD 1 Natural Gas USA Only 808HE 810HE...

Page 47: ...ure 36 McDonnell Miller 751P MT 120V L W C O Wiring for Boilers with 24V Limit Circuits 806H 810HE Figure 37 McDonnell Miller 751P MT 120V L W C O Wiring for Boilers with 120V Limit Circuits EP 808HE...

Page 48: ...38 Hydrolevel OEM 170 550 650 750 120V L W C O Wiring for Boilers with 24V Limit Circuits 806H 810HE Figure 39 Hydrolevel OEM 170 550 650 750 120V L W C O Wiring for Boilers with 120V Limit Circuits 8...

Page 49: ...low from bucket until discharge from hose is bubble free for 30 seconds 8 Close the open zone valve or shut off valve for the zone being purged of air then open the zone valve or shut off valve for th...

Page 50: ...50 Figure 40 Lighting Instructions 24V Standing Pilot...

Page 51: ...51 Figure 41 Operating Instructions EI...

Page 52: ...52 Figure 42 Operating Instructions EP...

Page 53: ...controls to lowest setting 3 Remove burner access panel s 4 Open manual pilot valve s 5 Turn on main electric switch 6 Reset safety switch on flame safeguard relay 7 Intermittent electric ignition rec...

Page 54: ...air injection Adjust primary air as follows Figure 45 Honeywell Q3481B Pilot Flame 24V Electronic Ignition Figure 44 Honeywell Q314 Pilot Flame 24V Standing Pilot Figure 46 Honeywell Q179C Pilot Flam...

Page 55: ...inimum gas supply pressure listed on rating label contact gas supplier for assistance 3 Clock gas meter for at least 30 seconds Use Table 12 to determine gas flow rate in Cubic Feet per Hour 4 Determi...

Page 56: ...sition Q Install Front Removable Panel 1 Engage top flange longer of 2 flanges behind Upper Front Panel 2 Swing lower portion of door toward boiler 3 Lower door to engage bottom flange behind Lower Fr...

Page 57: ...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 48 E Clean Boiler Flueways See Figure 48 1 Shut down gas...

Page 58: ...es and secured with hitch pin clips Verify Main Burner with Pilot Bracket is in proper location See Table 13 H Lubrication Manufacturers Instruction should be followed on all parts installed on boiler...

Page 59: ...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 w...

Page 60: ...rol remains in wait mode When the fault corrects control resumes normal operation after one minute delay Check transformer and AC line for proper input voltage to the control Check with full system lo...

Page 61: ...61 Honeywell EI Trouble Shooting Guide...

Page 62: ...717 293 5803 X Repair Parts r e l i o b n o n o i t a m r o f n i g n i k e e s n e h W r o t c a r t n o c g n i t a e h r u o y l l a c r e l i o b o t s r i a p e r r o e c i v r e s r o F l e b a...

Page 63: ...1 6171609 1 6171610 1 1A Left End Section 7171601 1 1 1 1 1 1 1B Intermediate Section 7171603 3 4 5 6 7 8 1C Right End Section 7171602 1 1 1 1 1 1 1D Tie Rod 80861032 1 80861033 1 80861013 1 80861034...

Page 64: ...ntity 805H 806H 807HE 808HE 809HE 810HE 2 Canopy 2A Canopy 6111605 1 6111606 1 61116071 1 6111608 1 61116091 1 61116110 1 2B Bolt Carriage 20 x 1 80860115 2 2 2 2 2 2 2C Washer Flat 80860603 2 2 2 2 2...

Page 65: ...1816103 1 3E Burner Access Panel Assembly 61816054 1 61816064 1 61816074 1 61816084 2 61816094 2 61816104 2 3F Jacket Attachment Bracket 7041601 4 4 4 4 4 4 3G Bolt Carriage 20 x 1 80860106 4 4 4 4 4...

Page 66: ...r with Pilot Bracket EP 8231603 1 1 1 1 1 4C Manifold 82216051 1 82216061 1 82216071 1 82216081 1 82216091 1 82216101 1 4D Pipe Plug 1 8 NPT Included with 4C 1 1 1 1 1 1 4E Main Burner Orifice 39 Natu...

Page 67: ...B Solenoid Gas Valve Honeywell V8295A1024 NPT 81660235 806H 807HE 1 Solenoid Gas Valve Honeywell V8295A1032 1 NPT 81660236 808HE 810HE 1 C Manual Shut Off Valve Conbraco 50GB501A 1 NPT 822615 808HE 8...

Page 68: ...LP Gas A Gas Valve Robertshaw 7000DERHC Natural Gas 1 NPT 81660151 805H 810HE 1 Gas Valve Robertshaw 7000DERHC LP LP Gas 1 NPT 81660158 USA 805H 810HE Canada 805H 807HE B Manual Shut Off Valve Conbrac...

Page 69: ...lve Honeywell V8295A1024 NPT 81660235 806H 807HE 1 Solenoid Gas Valve Honeywell V8295A1032 1 NPT 81660236 808HE 810HE C Manual Shut Off Valve Conbraco 50GB501A 1 NPT 822615 806H 810HE 1 D Hex Bushing...

Page 70: ...81660236 1 C Manual Shut Off Valve Conbraco 50 403 02 1 NPT 822615 1 D Leak Test Shut Off Valve Conbraco 50GB501A 1 8 x 1 8 822679 2 E Pipe Plug 1 8 806603594 2 F Hex Bushing 1 4 x 1 8 806600520 1 G...

Page 71: ...Natural Gas 8236033 807HE 1 Pilot Burner Honeywell Q314A3828 LP Gas 8236034 B Thermocouple Honeywell Q309A1996 w 36 Lg Lead 8236004 C Brass Compression Union 1 4 OD Tube 8236008 806H 807HE 1 D Regula...

Page 72: ...embly and Piping Intermittent Ignition Honeywell EI USA 5 10 Section Natural and LP Gas A Pilot Burner Honeywell Q3481B1206 Natural Gas 103704 01 805H 810HE 1 Pilot Burner Honeywell Q3481B1420 LP Gas...

Page 73: ...1 C Shut Off Valve Essex P2L 822645 808HE 810HE 1 D Pipe Tee 1 8 NPT Malleable 806601005 E Pipe Plug 1 8 NPT Sq Head 806603508 F Brass Compression Adapter 1 4 OD Tube x 1 8 NPT 822630 807HE Natural Ga...

Page 74: ...ling 1 4 OD Tube 8236008 806H 807HE USA Canada 808HE 810HE USA Only 1 G Shut Off Valve Essex P2L 822645 808HE 810HE Canada Only 1 H Pipe Tee 1 8 NPT Malleable 806601005 J Pipe Plug 1 8 NPT Sq Head 806...

Page 75: ...gnition Lead Honeywell R1061012 3 Ft Lg 7136247 1 E Ground Wire Assembly 6136259 1 F Brass Compression Coupling 1 4 OD Tube 8236008 1 G Conbraco Leak Test Shut Off Cock 1 8 x 1 8 822679 1 H Brass Comp...

Page 76: ...76...

Page 77: ...11 1 7201613 1 7201615 1 7201617 1 6C Jacket Upper Rear Panel 70416056 1 70416066 1 70416076 1 70416086 1 70416096 1 70416106 1 6D Jacket Upper Rear Panel Insulation 72016059 1 72016069 1 72016079 1 7...

Page 78: ...78...

Page 79: ...ket Right Side Panel Lower Corner Insulation Piece 72016012 1 1 1 1 1 1 6Q Jacket Vestibule Panel 70416055 1 70416065 1 70416075 1 70416085 1 70416095 1 70416105 1 6R Jacket Vestibule Panel Upper Insu...

Page 80: ...60302 1 1 1 1 1 1 D1 Nipple NPT x 3 806600038 1 1 1 1 1 1 E Drain Valve NPT Conbraco 35 302 03 806603061 1 1 1 1 1 1 E1 Nipple NPT x 3 806600038 1 1 1 1 1 1 E2 Coupling NPT 806602561 1 1 1 1 1 1 F Blo...

Page 81: ...nd Automatic Vent Damper 8A Draft Hood 8111605 1 8111604 1 1 8111602 1 8111601 1 1 8B Automatic Vent Damper 7 Effikal RVGP 7 8116324 1 Automatic Vent Damper 8 Effikal RVGP 8 8116325 1 1 Automatic Vent...

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