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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 Boiler Serial Number Installation Date
_8_ _ _ _ _ - _ _ _ _ 6_ _ _ _ _ _ _
Heating Contractor Phone Number
Address
Commercial Boilers
www.burnhamcommercialcastiron.com
Price - $5.00
84 602 R3-6/ 0
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IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment must be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boil
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WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. 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 boil
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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 ...............................................
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Figure : Dimensional Data Table : Dimensional Data Dimensions (Inches) Recommended Water Approx. Boiler D E Chimney Size Content Shipping Model A B C (Round) (Gallons) Weight (LB.) USA Canada USA Canada 805H 20 10 7 24-13/16 24-13/16 16-1/8 16-1/8 7” dia. x 15 ft. 11.9 705 806H 23-3/4 11-7/8 8 27-13/16 25-3/4 18 16 8” dia. x 15 ft. 13.9 785 807H 27-1/2 13-3/4 9 28-13/16 25-3/4 18 16 8” dia. x 15 ft. 15.9 890 808H 31-1/4 15-5/8 9 30-13/16 26-11/16 20 16 8” dia. x 15 ft. 17.9 1000 809H 35 1
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I. Pre-Installation 2. USA, 808H-810H: for installation in room which is WARNING large in comparison with size of boiler. a. Front: 18” Carefully read all instructions before installing b. Top: 51½” boiler. Failure to follow all instructions in proper order can cause personal injury or death. c. Draft hood, rear, sides, and flue connector: 6” 3. Canada, 805H-810H: A. Inspect shipment carefully for any signs of damage. a. Top and front: 18” (45.7 cm) All equipment is carefully manufac
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3 b. If result is less than 50 ft per 1,000 Btuh, space i. Minimum free area of 1 square inch per is considered a confined space. 3,000 Btu per hour input of all equipment in space. 4. Determine building type. A building of unusually ii. Free area shall not be less than the sum tight construction has the following characteristics: of the areas of all vent connectors in the a. Walls and ceiling exposed to outside atmosphere confined space. have a continuous water vapor retarder with a Alt
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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 roll
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6. Lift boiler with pry bar. Remove wood blocks. water pressure of at least 10 psi but less than 50 psi Lower boiler. gauge pressure. 6. Examine boiler for leaks or damage due to shipment C. For Packaged Boiler only, proceed to Paragraph E. or handling. D. Test Section Assembly for leaks before connecting to 7. Remove plugs from Return Tapping B, Tapping C, system and installing controls, trim and jacket. Refer to and Tapping E (if second limit or operating control Figure 3 and Table 3.
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Figure 5: General Assembly (Knockdown Boilers) F. Move boiler to permanent location by sliding or 1. Attach Base Front Panel to Section Assembly using walking. Do not drop. ¼” - 20 x 1¼” carriage bolts, washers and nuts. 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 Combination Boiler Parts and Control Carton). positioned in each Boiler
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Figure 6: Flame Roll-out Switch Installation Figure : Burner/Burner Access Panel Installation
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Combustible Clearance Label from Combination M. Attach Flame Roll-out Switch to Burner Access Panel. Boiler Parts and Controls Carton. Attach to See Figure 6. Flame Roll-out Switch and hardware Vestibule Panel in locations shown. are located in Combination Boiler Parts and Control Carton. Flame Roll-out Switch is a single use device 6. Attach Vestibule Panel to Left Side and Right Side - do not test with heat - switch cannot be reset. Panels. 1. Cut insulation from semicircular notch at
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3 Figure 8: Jacket Assembly
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Figure : EP/OP Control Installation 4
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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) Install Gas Control System. All components are resistant to action of liquefied petroleum gas. located in Combination Boiler Parts and Control 2. Install pilot burner piping and controls. See Figure Carton. 14. 1. Install Gas Control Assembly on Manifold. See 3. Connect Thermocouple Lead to Gas
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b. Connect Ignition Lead from Pilot to Ignition F. EP-CSD-1 Control System Transformer. Install Gas Control System. All components are 4. Mount Transformer (continuous circulation) or located in Combination Boiler Parts and Control Control Center (intermittent circulation) to Junction Carton. Box. 1. Install Gas Control Assembly on Manifold. See a. Canada only - loop 4” nylon cable tie between Figure 17. junction box and transformer/control center. 2. Install pilot burner piping and co
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Figure 0: Schematic Gas Piping, 24V Standing Pilot, 806H & 80H
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8 Figure : Main Gas Piping, Intermittent Ignition (EI)
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Figure 2: Schematic Pilot Piping (Honeywell EI), USA
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20 Figure 3: Schematic Pilot Piping (Honeywell EI) Canada: Natural Gas, 805H - 80H; LP Gas, 806H - 80H
