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Burnham 805B, Installation, Operating And Servicing Instructions, Page: 4 / 100

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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 .................................... 27

V.

Gas Piping ....................................................... 31

VI.

Venting ............................................................ 33

VII.

Electrical .......................................................... 36

VIII.

System Start-up ............................................... 59

IX.

Service ............................................................. 68

X.

Repair Parts ..................................................... 75

Summary of Contents for 805B

Page 1: ...s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e b m u N l e d o M r e l i o B r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I _ _ _ _ _ _ _ _...

Page 2: ...a i t n a t s b u s r o y r u j n i s u o i r e s e g a m a d E C I T O N n o s n o i t c u r t s n i l a i c e p s s e t a c i d n I e c n a n e t n i a m r o n o i t a r e p o n o i t a l l a t s n...

Page 3: ...c o l s l i a t e d d n a n w o d t u h s o t r e l i o b e h t e s u a c y a m h c i h w s e c i v e d y t e f a s h t i w d e i l p p u s s i r e l i o b s i h T g n i t a e h e h t y t i l i b i s...

Page 4: ...Pre Installation 6 II BoilerAssembly 8 III Gas Control System Assembly 15 KnockdownBoilers IV Water Trim and Piping 27 V GasPiping 31 VI Venting 33 VII Electrical 36 VIII System Start up 59 IX Servic...

Page 5: ...f 5 1 x a i d 9 9 5 1 5 7 8 B 8 0 8 4 1 1 3 8 5 5 1 9 6 1 3 1 0 3 6 1 1 1 6 2 0 2 6 1 t f 5 1 x a i d 9 9 7 1 0 8 9 B 9 0 8 5 3 2 1 7 1 0 1 2 1 3 3 6 1 7 6 2 2 2 5 1 t f 5 1 x a i d 0 1 9 9 1 0 8 0 1...

Page 6: ...hority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME No CSD 1 C Provide clearance between combustible mate...

Page 7: ...mum free area of 1 square inch per 3 000 Btu per hour input of all equipment in space ii Free area shall not be less than the sum of the areas of all vent connectors in the confined space Alternate me...

Page 8: ...hold down bolts 2 Using pry bar under 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...

Page 9: ...s e t k a e l o t r i a e s u t o n o D 5 Fill boiler completely with water by venting air through purge valve Close purge valve and apply water pressure of at least 10 psi but less than 50 psi gauge...

Page 10: ...ds are only hand tight to allow for thermal expansion I Install Base Front Panel See Figure 5 Panel and hardware located in Combination Boiler Parts and Control Carton 1 Attach Base Front Panel to Sec...

Page 11: ...11 Figure 6 Flame Roll out Switch Installation Figure 7 Burner Burner Access Panel Installation...

Page 12: ...ld 1 Cut insulation from semicircular notch at right end of the burner access panel Models 808B 810B have two 2 burner access panels Remove insulation from notch of right side burner access panel only...

Page 13: ...13 Figure 8 Jacket Assembly...

Page 14: ...14 Figure 9 EP OP Control Installation...

Page 15: ...lon cable tie between junction box and transformer control center b Attach transformer control center to junction box C OPControlSystem Install Gas Control System All components are located in Combina...

Page 16: ...piping and controls See Figure 19 3 InstallIgnitionTransformer a Attach Ignition Transformer to Jacket Vestibule Panel using four 4 8 x lg sheet metal screws b Connect Ignition Lead from Pilot to Igni...

Page 17: ...17 Figure 10 Schematic Gas Piping 24V Standing Pilot 806B 807B...

Page 18: ...18 Figure 11 Main Gas Piping Intermittent Ignition EI...

Page 19: ...19 Figure 12 Schematic Pilot Piping Honeywell EI USA...

Page 20: ...20 Figure 13 Schematic Pilot Piping Honeywell EI Canada Natural Gas 805B 810B LP Gas 806B 807B...

Page 21: ...21 Figure 14 Schematic Pilot Piping Johnson EI USA...

Page 22: ...22 Figure 15 Schematic Pilot Piping Johnson EI Canada Natural Gas 805B 810B LP Gas 806B 807B...

Page 23: ...23 Figure 16 Schematic Gas Piping OP Control System 806B 810B...

Page 24: ...24 Figure 17 Schematic Gas Piping OP CSD 1 Control System 808B 810B...

Page 25: ...25 Figure 18 Schematic Gas Piping EP Control System Natural Gas Only 806B 810B...

Page 26: ...26 Figure 19 Schematic Gas Piping EP CSD 1 Control System 808B 810B...

Page 27: ...t l u s e r y a m r e l i o b e p i p y l r e p o r p o t e r u l i a F e r u t c u r t s r e l i o b l e e t s d n a n o r i f o n o i s o r r o c e s u a c l l i w r e t a w r e l i o b f o n o i t...

Page 28: ...um inchclearancefromhot 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 b...

Page 29: ...29 Figure 22 Temperature Pressure Gauge Installation Figure 23 Alternate Temperature Pressure Gauge Installation Figure 24 Recommended Piping for Combination Heating Cooling Refrigeration System...

Page 30: ...30 Figure 25 Recommended Boiler Piping for Circulator Zoned Heating Systems...

Page 31: ...t compound pipe dope resistant to action of liquefied petroleum gas 3 Install sediment trap ground joint union and manual shut off valve upstream of boiler gas valve and outside jacket See Figure 26 4...

Page 32: ...8 0 h t g n e L t e e F p o r D e r u s s e r P c w h c n i 3 0 p o r D e r u s s e r P c w h c n i 5 0 1 1 1 1 0 1 2 3 1 8 7 2 0 2 5 0 5 0 1 5 7 1 0 6 3 0 8 6 0 0 4 1 0 2 2 9 0 9 1 0 5 3 0 3 7 0 2 1...

Page 33: ...Hood skirt Locate center tooth with 10 sheet metal screw on outside and other two teeth inside Draft Hood skirt See Figure 27 3 Slide mounting bracket tight against lower edge of Draft Hood skirt Posi...

Page 34: ...of this appliance into any portion of mechanical draft system operating under positive pressure 3 Vent connector should have the greatest possible initial rise above the draft hood consistent with th...

Page 35: ...s outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should...

Page 36: ...e n o n a h t e r o m m o r f e b y a m r e w o p l a c i r t c e l E k r o w l a c i r t c e l e y n a g n i t p m e t t a t c e n n o c s i d d e s u f d e z i s y l r e p o r p a h t i w d e t c e...

Page 37: ...he damper blade reaches the fully closed position the damper motor is de energized POWERFAILURE Thedamperbladewillstopin the position it was in when power failed Combustion can never take place unless...

Page 38: ...ner gas flow should pilot burner flame extinguish Circulator continues to operate and Vent Damper if used remains open with call for heat Table 10 Sequence of Operation and Wiring Diagrams m e t s y S...

Page 39: ...39 Figure 31 Wiring Diagram Standing Pilot 24 USA and Canada Continuous Circulation...

Page 40: ...40 Figure 32 Wiring Diagram Standing Pilot 24V USA and Canada Intermittent Circulation...

Page 41: ...additionalcontrol information 3 ElectronicallySupervisedStandingPilot OP CSD 1 Sequence of Operation a NormalOperation i Thermostat or operating control calls for heat ii Terminal 6ofRM7890CBurnerCont...

Page 42: ...42 Figure 33 Wiring Diagram OP OP CSD 1 Ignition System Continuous Circulation...

Page 43: ...43 Figure 34 Wiring Diagram OP OP CSD 1 Ignition System Intermittent Circulation...

Page 44: ...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 45: ...45 Figure 35 Wiring Diagram Honeywell EI USA Continuous Circulation...

Page 46: ...46 Figure 36 Wiring Diagram Honeywell EI USA Intermittent Circulation...

Page 47: ...47 Figure 37 Wiring Diagram Honeywell EI Canada Continuous Circulation...

Page 48: ...48 Figure 38 Wiring Diagram Honeywell EI Canada Intermittent Circulation...

Page 49: ...main burner operation when excessive flue gas spillage occurs Circulator continues to operate Vent Damper if used remains open with call for heat If blocked vent switch is activated do not attempt to...

Page 50: ...50 Figure 39 Wiring Diagram Johnson EI USA Continuous Circulation...

Page 51: ...51 Figure 40 Wiring Diagram Johnson EI USA Intermittent Circulation...

Page 52: ...52 Figure 41 Wiring diagram Johnson EI Canada Continuous Circulation...

Page 53: ...53 Figure 42 Wiring Diagram Johnson EI Canada Intermittent Circulation...

Page 54: ...or continues to operate with call for heat Normal operation resumes when water temperature falls below set point ii BlockedVentSwitch Automatically interrupts main burner operation when excessive flue...

Page 55: ...55 Figure 43 Wiring Diagram EP EP CSD 1 Ignition System USA Continuous Circulation...

Page 56: ...56 Figure 44 Wiring Diagram EP EP CSD 1 Ignition System USA Intermittent Circulation...

Page 57: ...57 Figure 46 McDonnell Miller PS 851 120V L W C O Wiring for Boilers with 120V Limit Circuits OP EP Figure 45 McDonnell Miller PS 851 120V L W C O Wiring for Boilers with 24V Limit Circuits...

Page 58: ...58 Figure 47 Hydrolevel OEM 170 550 650 750 120V L W C O Wiring for Boilers with 24V Limit Circuits Figure 48 Hydrolevel OEM 170 550 650 750 120V L W C O Wiring for Boilers with 120V Limit Circuits...

Page 59: ...other components are leak free Eliminate any leaks 8 Purge gas line of air Table 11 Lighting and Operating Instructions 1 Close full port ball valve in boiler supply piping 2 Isolate all zones by clo...

Page 60: ...60 Figure 49 Lighting Instructions 24V Standing Pilot...

Page 61: ...61 Figure 50 Operating Instructions EI...

Page 62: ...62 Figure 51 Lighting Instructions OP...

Page 63: ...63 Figure 52 Operating Instructions EP...

Page 64: ...r e t f a d e t h g i l s n i a m e r t o l i p l i t n u r o e t u n i m e n o t s a e l g n i d n a t s g n i n i a m e r r o f t a e p e R d e s a e l e r s i n o t t u b s t o l i p 6 h c t i w s...

Page 65: ...Johnson J991 Pilot Flame 24V Electronic Ignition I Checkpilotburnerflameandmainburnerflames through observation port 1 Check pilot flame Refer to Table 11 for appropriate pilot detail 2 Adjust thermos...

Page 66: ...eading Main burners should reignite 4 Adjust thermostat to lowest setting Adjust limit to desired setting M Adjust gas input rate to boiler Natural Gas 1 Adjust thermostat to highest setting 2 Check m...

Page 67: ...al regulations P CheckDamperOperation Ifboilerisequippedwith vent damper vent damper must be in open position when boiler main burners are operating Start boiler refer to instructions on damper to det...

Page 68: ...ft Hood 3 Remove Jacket Top Panel 4 Remove Canopy from top of boiler 5 Thoroughly clean flueways with flue brush removing all scale and soot See Figure 60 6 Clean boiler heating surface accessible fro...

Page 69: ...thing 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...

Page 70: ...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 Ori...

Page 71: ...71 Honeywell EI Trouble Shooting Guide...

Page 72: ...72 Johnson EI Trouble Shooting Guide...

Page 73: ...73...

Page 74: ...74 SERVICE RECORD DATE SERVICE PERFORMED...

Page 75: ...lesale 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...

Page 76: ...E t f e L 1 0 6 1 7 1 7 1 1 1 1 1 1 B 1 n o i t c e S e t a i d e m r e t n I 3 0 6 1 7 1 7 3 4 5 6 7 8 C 1 n o i t c e S d n E t h g i R 2 0 6 1 7 1 7 1 1 1 1 1 1 D 1 d o R e i T 2 3 0 1 6 8 0 8 1 d...

Page 77: ...9 0 8 B 0 1 8 y p o n a C 2 A 2 y p o n a C 5 0 6 1 1 1 6 1 6 0 6 1 1 1 6 1 7 0 6 1 1 1 6 1 8 0 6 1 1 1 6 1 9 0 6 1 1 1 6 1 0 1 6 1 1 1 6 1 B 2 1 x 0 2 e g a i r r a C t l o B 5 1 1 0 6 8 0 8 2 2 2 2...

Page 78: ...b m e s s A l e n a P s s e c c A r e n r u B 4 5 0 6 1 8 1 6 1 4 6 0 6 1 8 1 6 1 4 7 0 6 1 8 1 6 1 4 8 0 6 1 8 1 6 2 4 9 0 6 1 8 1 6 2 4 0 1 6 1 8 1 6 2 F 3 t e k c a r B t n e m h c a t t A t e k c...

Page 79: ...o l i P h t i w r e n r u B n i a M 3 0 6 1 3 2 8 1 1 1 1 1 P E t e k c a r B t o l i P h t i w r e n r u B n i a M C 4 d l o f i n a M 1 5 0 6 1 2 2 8 1 1 6 0 6 1 2 2 8 1 1 7 0 6 1 2 2 8 1 1 8 0 6 1...

Page 80: ...l e w y e n o H e v l a V s a G d i o n e l o S 5 3 2 0 6 6 1 8 B 7 0 8 B 6 0 8 1 T P N 1 2 3 0 1 A 5 9 2 8 V l l e w y e n o H e v l a V s a G d i o n e l o S 6 3 2 0 6 6 1 8 B 0 1 8 B 8 0 8 C T P N...

Page 81: ...a M e v l a V T P N 1 2 0 3 0 4 0 5 o C a r B n o C 5 1 6 2 2 8 1 D 8 1 x 8 1 1 0 1 2 2 6 5 o C a r B n o C e v l a V f f o t u h S t s e T k a e L 9 7 6 2 2 8 2 E 8 1 g u l P e p i P 4 9 5 3 0 6 6 0...

Page 82: ...e b o R e v l a V s a G 1 5 1 0 6 6 1 8 B 0 1 8 B 5 0 8 1 T P N 1 s a G P L P L C H R E D 0 0 0 7 w a h s t r e b o R e v l a V s a G 8 5 1 0 6 6 1 8 B 0 1 8 B 5 0 8 A S U B 7 0 8 B 5 0 8 a d a n a C...

Page 83: ...6 0 8 1 T P N 1 2 3 0 1 A 5 9 2 8 V l l e w y e n o H e v l a V s a G d i o n e l o S 6 3 2 0 6 6 1 8 B 0 1 8 B 8 0 8 C T P N 1 M 0 0 2 n e k i l l i M n a m w e N e v l a V f f O t u h S l a u n a M...

Page 84: ...l a u n a M e v l a V T P N 1 2 0 3 0 4 0 5 o C a r B n o C 5 1 6 2 2 8 1 D 8 1 x 8 1 1 0 1 2 2 6 5 o C a r B n o C e v l a V f f o t u h S t s e T k a e L 9 7 6 2 2 8 2 E 8 1 g u l P e p i P 4 9 5 3...

Page 85: ...L 8 2 8 3 A 4 1 3 Q l l e w y e n o H r e n r u B t o l i P 4 3 0 6 3 2 8 B d a e L g L 6 3 w 6 9 9 1 A 9 0 3 Q l l e w y e n o H e l p u o c o m r e h T 4 0 0 6 3 2 8 C e b u T D O n o i n U n o i s...

Page 86: ...i t c e S 0 1 5 A s a G l a r u t a N 2 0 0 1 A 8 4 3 Q l l e w y e n o H r e n r u B t o l i P U 2 7 0 6 3 2 8 B 0 1 8 B 5 0 8 1 s a G P L 0 1 0 1 A 8 4 3 Q l l e w y e n o H r e n r u B t o l i P 1...

Page 87: ...r p m o C s s a r B 8 0 0 6 3 2 8 B 7 0 8 B 5 0 8 1 E L 2 P x e s s E e v l a V f f o t u h S 5 4 6 2 2 8 B 0 1 8 B 8 0 8 1 F e l b a e l l a M T P N 8 1 e e T e p i P 5 0 0 1 0 6 6 0 8 G d a e H q S...

Page 88: ...o s n h o J r e n r u B t o l i P d a e L n o i t i n g I s e d u l c n I 0 5 0 6 3 2 8 B 0 1 8 B 5 0 8 1 s a G P L D 0 4 8 9 W Y L 1 9 9 J n o s n h o J r e n r u B t o l i P d a e L n o i t i n g I...

Page 89: ...G 4 5 0 6 3 1 6 1 E e b u T D O n o i n U n o i s s e r p m o C s s a r B 8 0 0 6 3 2 8 B 7 0 8 B 5 0 8 1 F L 2 P x e s s E e v l a V f f o t u h S 5 4 6 2 2 8 B 0 1 8 B 8 0 8 1 G e l b a e l l a M T...

Page 90: ...l F 1 6 5 2 6 3 1 7 1 D 6 5 3 7 3 l l e w y e n o H r o t c e n n o C h a j a R 1 2 0 6 3 2 8 1 E y l b m e s s A e r i W d n u o r G 9 5 2 6 3 1 6 1 F e b u T D O n o i n U n o i s s e r p m o C s s...

Page 91: ...e h T 4 0 0 6 3 2 8 1 C g L t f 4 0 2 0 8 9 2 1 R l l e w y e n o H d a e L d o R e m a l F 1 6 5 2 6 3 1 7 1 D 6 5 3 7 3 l l e w y e n o H r o t c e n n o C h a j a R 1 2 0 6 3 2 8 1 E y l b m e s s...

Page 92: ...a r B 8 0 0 6 3 2 8 B 7 0 8 B 6 0 8 a d a n a C A S U B 0 1 8 B 8 0 8 y l n O A S U 1 G L 2 P x e s s E e v l a V f f o t u h S 5 4 6 2 2 8 B 0 1 8 B 8 0 8 y l n O a d a n a C 1 H e l b a e l l a M T...

Page 93: ...y e n o H d a e L n o i t i n g I 7 4 2 6 3 1 7 1 E y l b m e s s A e r i W d n u o r G 9 5 2 6 3 1 6 1 F n o i s s e r p m o C s s a r B e b u T D O 4 1 g n i l p u o C 8 0 0 6 3 2 8 1 G 8 1 x 8 1 k...

Page 94: ...94...

Page 95: ...B 6 l e n a P r a e R r e p p U t e k c a J 5 5 0 6 1 4 0 6 1 5 6 0 6 1 4 0 6 1 5 7 0 6 1 4 0 6 1 5 8 0 6 1 4 0 6 1 5 9 0 6 1 4 0 6 1 5 0 1 6 1 4 0 6 1 C 6 l e n a P r a e R r e w o L t e k c a J 6 5...

Page 96: ...4 0 6 1 1 1 1 1 1 G 6 l e n a P e d i S t h g i R t e k c a J 2 0 6 1 4 0 6 1 1 1 1 1 1 H 6 l e n a P e l u b i t s e V t e k c a J 3 5 0 6 1 4 0 6 1 3 6 0 6 1 4 0 6 1 3 7 0 6 1 4 0 6 1 3 8 0 6 1 4 0...

Page 97: ...97...

Page 98: ...e v l a V n i a r D 1 6 0 3 0 6 6 0 8 1 1 1 1 1 1 1 E 3 x T P N e l p p i N 8 3 0 0 0 6 6 0 8 1 1 1 1 1 1 2 E T P N g n i l p u o C 1 6 5 2 0 6 6 0 8 1 1 1 1 1 1 F y l b m e s s A t n e m e c a l p e...

Page 99: ...1 1 9 0 6 1 1 1 8 1 1 B 8 7 r e p m a D t n e V c i t a m o t u A 7 S K P G V R l a k i f f E 6 4 1 6 1 1 8 1 8 r e p m a D t n e V c i t a m o t u A 8 S K P G V R l a k i f f E 7 4 1 6 1 1 8 1 9 r e...

Page 100: ...arranty statements Burnham Commercial hereby warrants to the original owner Owner of each Series 5B 8B V9 and V11 commercial cast iron boiler a Boiler manufactured by Burnham Commercial as follows Fir...

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