Burnham Pf 3 Series Installation And Operation Manual

: Burnham Burnham-Pf-3-Series-Installation-And-Operation-Manual-738091 burnham-pf-3-series-installation-and-operation-manual-738091 burnham pdf

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INSTALLATION
AND

OPERATING INSTRUCTIONS
FOR

PF-3 FORCED DRAFT
BOILER - BURNER UNITS
SECTION I - GENERAL INFORMATION - Page 3
SECTION I1 - INSTALLATION INSTRUCTIONS - Page 4
SECTION I11 - OPERATING AND SERVICE INSTRUCTIONS - Page 13
NOTE : For optimum performance and serviceability from this unit adhere to the following recommendations:
\

1-Clean Flueways a t least once a year-preferably
a t the end of heating season to remove soot and scale.
Inside of Firebox should also be cleaned a t the same time.
2-Have

Oil Burner and Controls checked a t least once a year o r as may be necessitated.

3-Retain your contractor o r a competent serviceman to assure that the unit is properly adjusted and main,tained.

IMPORTANT: BEFORE STARTING TO INSTALL THIS OIL HEATING UNIT, READ THESE
INSTRUCTIONS CAREFULLY. KEEP INSTRUCTIONS NEAR OIL HEATING UNIT FOR
REFERENCE BY OWNER AND SERVICEMAN.

F o r service and repairs to the heating plant, call your Heating Contractor.
provide series and size designation shown on rating plate.
Boiler Number

When seeking information on the boiler,

Type Firing

Type System

Heating Contractor
Address

-

.-

--Phone

BURNHAM CORPORATION
HYDRONICS DIVISION
Laneaster, Pennsylvania 17604
Wrm No. 62008E-1/81-1200f

No

,-

-.

FRONT VlEW
FLUSH JACKET

MODEL

'URN

1
A

/3"

\

SUPPLY

1
LE

LF

8" DIA. VENT

VENT
SIZE
DIAM.

1

DRAIN VALVE

PANEL

--- REMOVABLE

/ 1

SIDE VlEW EXTENDED JACKET

8" / 8" K.O.

OPENING,

Figure 1
Dimensional Data

NO. OF
SECTIONS

4 $ X 18

L-LF
---d

REAR VIEh'

% -1

TAPPING BELOW WATER
LINE ON STEAM
BOILERS

- 3411
UTILITY

DAMPER

SECTION THRU BOILER WITH FLUSH JACKET

DRAIN VALVE

2 vzrl
ALTERNATE
RETURN

DAMPER
POSITIONIN
BRACKET

&k

r FLUE OUTLET

SECTION I

GENERAL INFORMATION
I N S P E C T SHIPMENT carefully for any signs of dam@
PROVIDE CLEARANCE of a t least
on the
right side and back of the unit f o r cleaning of flues. Proage. All equipment is carefully masufactured, inspected
24"

and packed by experienced workmen. Our responsibility
ceases upon delivery of boiler to the carrier in good condition. Any claims f o r damage in shipment must be filed
immediately against the carrier by the consignee. No
claims for variances from, o r shortage in orders, will be
allowed by the manufacturer, unless presented within
sixty (60) days a f t e r receipt of goods.

vide a minimum of 20" clearance in front f o r servicing of
equipment, 30" if boiler is equipped with jacket extension.
If boiler is equipped with tanldess heater, additional
allowance may have to be made for installation and servicing of heater, see table below:

a

LOCATE BOILER so that smoke pipe connection to
chimney is short and direct. Floor construction should
have adequate load bearing characteristics to bear the
weight of the boiler filled with water. See table below.
ASSEMBLED
SECTION
WEIGHT
(LBS.)

BOILER
N 0.

WATER
CONTENT
FULL
(LBS.)

HEATER
CLEARANCE
INCHES

HEATER
N 0.

TOTAL
WEIGHT
(LBS.)

226

23

232

29

445

35

Table "B"

P F-34

800

276

1076

Distances a r e measured from front of flush jacket.

P F-35

1000

335

1335

P F-36

1200

402

1602

@
CHIMNEY OR VENT. The P F - 3 series boiler is
designed for forced-draft firing and may be used with a

P F-37

1400

465

1865

conventional natural d r a f t stack o r a stub vent (see Figure 3 ) . See Fig. 1 for the proper vent size. Draft controls a r e not normally required, although they may be
used on installations where a natural d r a f t stack is used
or on multiple boiler installations with a common stack.
The boiler is provided with a breeching damper which
should be secured in the open position unless high breeching d r a f t makes burner adjustment difficult.

Table "A"
A boiler foundation similar to the one shown in Figure 2 is recommended if the boiler room floor is not Perfectly level, weak, uneven o r if a water condition exists.
If t h e boiler is s e t on a combustible floor, a 1" thick layer
of foil-faced insulation or equivalent should be placed
beneath the boiler foil side up.

rl
44.

@
AIR FOR COMBUSTION AND VENTILATION
must be provided. If natural ventilation is inadequate,
provide a screened opening from the boiler room to the
outside, which is based on one square inch free afea per
3000 btuh input. If other a i r consuming appliances are
near the boiler the a i r inlet should be larger. Consult
respective manufacturers.

50.

114 X 4 STEEL PLATE

/

Figure 2 - SUGGESTED BOILER
FOUNDATION

3

Figure 3 - ARRANGEMENT FOR
STUB VENT

SECTION I1
INSTALLATION INSTRUCTIONS

a

ket to the lower nipple port in Front Section using

Place boiler assembly on foundation provided. Shim
if necessary. The tie rod nuts should then be loosened
until finger tight.

3/8" Hex Hd. Cap Screws and Flat Washers (if

furnished). Snug all screws before final tightening.
b. Attach the Tapped Heater Cover Plate with Rubber
Gasket to the upper nipple port in Front Section
using 3/8" Hex Hd. Cap Screws and Flat Washers
(if furnished). Snug all screws before final tighting.

"INSTALLATION OF BUILT-IN HEATERS AND
HEATER OPENING COVER PLATES"

@
INSTALLATION OF BUILT-IN DOMESTIC WATER HEATER if furnished.
a. Slip Rubber Gasket over Heater Coil and place
against Heater Mounting Plate so that holes in
Gasket are in line with holes in Heater Mounting
Plate.
b. Install Built-in Heater Coil through openihg in
Front Section into the upper nipple port for water
boilers or the lower nipple port for steam boilers.
(See Fig. 4).
c. Secure the Heater Mounting Plate with 3 / 8 Hex
Head Cap Screws and Flat Washers (if furnished).
Snug all screws before final tightening.
d. Attach the Tapped Heater Cover Plate with Rubber
Gasket to the remaining opening in the Front Section. Secure with 3/8" Hex Hd. Cap Screws and
Flat Washers (if furnished). Snug all screws before
tightening.

@
TEST BOILER FOR LEAKS before installing controls, trim, and jacket, and before connecting to heating
system.
a. Install Pressure Gauge ( a t least 30 P.S.I. capacity),
a hose to the City Water and a valve in one of the
supply tappings. Plug remainder of tappings.
b. Fill Boiler with water and apply a pressure of a t
least 10 pounds but no more than 50 pounds gauge
pressure.
c. Examine Boiler carefully inside and outside for leaks
or damage due to shipment or handling.
DRAIN WATER FROM BOILER. Remove gauge,
valve and plugs from those tappings to be used. Leave
other tappings plugged or bushed according to Figure 4.

@
INSTALLMENT O F HEATER OPENING COVER
PLATES if Built-in Domestic Water Heater is not fur-

@
INSPECT JOINTS BETWEEN SECTIONS. All
joints are factory sealed. If there are any spaces due to

nished. (Steam and Water Boilers). See Figure l.
a. Attach Blank Heater Cover Plate with Rubber Gas-

LOCATION
ON BOILER
A

SIZE
(INCHES)

shipment or handling, seal them with silastic sealant.

WATER 'ONTRoL

1

SAFETY RELIEF USED

Iml

LlMlT CONTROL OR COMBINATION
HlGH LlMlT AND CIRCULATOR
CONTROL (FOR INSTALLATIONS
WITHOUT TANKLESS WATER H E A T E R )

1 1

COMBINATION HlGH LIMIT, LOW LlMlT
AND CIRCULATOR CONTROL (FOR
INSTALLATIONS WITH TANKLESS
HEATER)

COMBINATION PRESSURE AND
TEMPERATURE GAUGE

D

I
1

AUXILIARY LlMlT CONTROL (WHEN
NEEDED-TEQUIRES ADDITIONAL
TAPPED HEATER OPENING COVER
P
~
O
TANKLESS HEATER)

BUSH TO 1/4"

-

PRESSURETROL-

OR OPTIONAL CONTROLS

WATER HEATER
(OPTIONAL)=

d

(11/2
1/2

NOT USED

H

3/4

AUXILIARY TAPPING

,3'

SUPPLY

STEAM PRESSURE GAUGE

U

IN BACK SECTION

T

1nw OR9UI V U k E
r n w ~ A m w s ~ w

NOT USED

F
G

A

STEAM BOILER

GAUGE GLASS AND LOW WATER
CUT-OFF
-

-

AUXILIARY TAPPING-BELOW
NORMAL WATER LINE

I
Fig. 4
4

WATER BOILER

(1) INSTALL

CAST IRON CLEANOUT COVERS to
x 2%'' long bolts provided. The bolts
the boiler with
should be anchored to the slots in the cleanout openings
of the sections with the head of the bolt and a washer
inside and a washer and n u t outside. See Figure 5. The
covers a r e placed on the bolts.and secured with washers
and nuts.

CLEANOUT

x"

COVER 7

r

COVER GASKET

INSULATION

CLEANOUT NUT
AND WASHER
WASHERS
TOP VIEW

CLEANOUT COVER ASSEMBLY

'@

Fig. 5

F L U E COLLAR should be assembled next. Clean
the ground surface on the flue collar and the mating
ground surface on the back section with a wire brush.
Then using a cartridge of silastic sealant provided, apply
a smooth 1/4" diameter bead of sealant to the ground surface on the back section. Place the collar on the back
section and position the damper bracket on the collar as,
shown in Figure 1. Secure the collar with the 5/16"
bolts provided.

@ INSTALL BURNER PLATE a s follows:

@)

CONNECT SUPPLY AND RETURN P I P I N G TO
HEATING SYSTEM.
NOTE-If
jacket extension (special order only) is to be
installed now or in the future, return piping connected
to front section must pass thru opening provided in extension, see Fig. 1. In addition, fittings used to connect
circulator in this return (water boiler) must be selected
so t h a t circulator does not extend beyond sides of flush
jacket.
a. If boiler is equipped with tankless heater, hot and
cold water lines must be routed thru opening provided in Jacket Extension Top Panel. Refer to FIG.
18 f o r Tankless Heater Piping.
b. All Piping must be installed so a s to provide clearance f o r running the Smokepipe a s direct a s possible
between the Boiler and Chimney.
c. With Forced Circulation HOT WATER HEATING,
consult I-B-R Installation and Piping Guide No. 200.
N O T E : When Hot Water Heating Boilers are connected to Heating Coils located in Air Handling
Units where they may be exposed to refrigerated
a i r circulation, the Boiler Piping System must be
equipped with Flow Control Valve or other automatic means to prevent gravity circulation of the
Boiler Water during Cooling Cycle.
d. With STEAM HEATING, see Figures 7 and 8.
Consult I-B-R Piping Guide No. 200.
e. With COMBINATION HEATING AND COOLING
(REFRIGERATION) SYSTEMS having the same
Distributing Units, Piping and Circulator, see Figure 6. NOTE: Valves must be installed in each
Supply and Return Branch to the Heating Boiler
and Water Chiller so a s to prevent circulation of
Chilled Water through the Boiler o r Heated Water
through the Chiller.
Hm

ARE CLOSED IN WINTER AND OPEN IN SUMMER
ARE OPEN IN WINTER AND CLOSED IN SUMMER

n
I

WATER
I
c
CHILLER -

I

rSHUT-

SHUT- OFF

OFF

VALVE

Clean the
ground surface on the burner plate and the mating surface on the front section with a wire brush. Then using
a cartridge of sealant provided, apply a smooth
diameter bead of sealant to the ground surface of the front
section. Secure the burner plate to the f r o n t section with
the 5 / 1 6 x 1" long bolts provided. Draw-up the bolts
until the burner plate makes contact with the front
section.

HEATING
A

s"

SUPPLY MAIN
TO COMBINED
HEATING 8
COOLING
SYSTEM

I

d
[AIR

I
f"
'1

BOILER
CUSHION TANK

I

, , .;;;;;

RETURN MAIN

CIRCULATOR

FROM
COMBlNECl
H F A T I NM
G
- I3
COOLING

RECOMMENDED
PIPING FOR COMBINATION
HEATING 8 COOLING IREFRIGERATION) SYSTEMS

IMPORTANT-THIS
BOILER DOES NOT REQUIRE
A COMBUSTION CHAMBER OR SEPARATE SMOKEHOOD.

Fig. 6

STEAM SUPPLY MAIN -SLOPE DOWN FROM
HIGH POINT ABOVE BOILER AN0 DRIP ENDS
OF MCllNS INTO WET RETURN

LOW POINT OF SUPPLY MAIN TO BE NOT
LESS THAN 2 9 ' ABOVE WATER LlNE

PIPE

DISCHARGE

TO

DRAIN

CLOSE
KEEP STEAM BOILERS FILLED
T O NORMAL WATER LlNE
1
W

2"
4"

-

.

OR SHOULOER

NIPPLE

L

PREFERRED HARTFORO RETURN
CONNECTION ' GRAVITY RETURN

GRAVITY RETURN
PUMP RETURN

STEAM - WET RETURN
PITCH DOWN TO BOILER

Fig.

7

Minimum P i p i n g Recommendations

4 and 5 Section Steam B o i l e r s

4" SUPPLY MAIN TO B E TAKEN
WADER VERTICALLY OR AT 45'

4" HEADER -24.

MIN.

ABOVE

WATERLINE

PREFERRED

-

HARTFORD RETURN

CLOSE OR SHOULDER NIPPLE

KEEP STEAM BOILERS FILLED
TO NORMAL WATER LlNE

2"
4.

OFF TOP
ANGLE.

+

PREFERRED HARTFORD RETURN
CONNECTION - GRAVITY RETURN

GRAVITY RETURN
PUMP RETURN

STEAM - W E T RETURN
PITCH DOWN TO BOILER

PROVIDE DRAIN COCKS FOR
FLUSHING BOILER AND SYSTEM

Fig.

8

Minimum P i p i n g Recommendations
6 and 7 Section Steam B o i l e r s

6

OF

@

@.

I

D

FRONT PANEL FILLER

PIECE

@)

PANEL

1

RlGHT HAND '%

LUWtK

PANEL

UPPER
RlGHT HAND

ATTACH RATING PLATE
HERE USING S.M.S.

TOP
PANEL

Fig. 9

FLUSH JACKET ASSEMBLY

3
'

@

INSTALL UPPER RlGHT HAND SlDE
PANEL BY SLIDING DOWN UNTIL
BOTTOM FLANGE IS FULLY SEATED
BEHIND LOWER RlGHT HAND SlDE
PANEL. ATTACH TO FLANGES ON
FRONT AND REAR PANELS WITH S.M.S.
LEAVING UPPER FRONT HOLE VOlD
UNTIL INSTALLATION OF TOP PANEL.

REAR PANEL IN POSITION AND
ATTACH LEFT AND LOWER RlGHT HAND
SlDE PANELS TO FLANGES ON REAR
PANEL WlTH S.M.S.

@ PLACE

@ FLANGE
ASSEMBLE LOWER RIGHT HAND SlDE PANEL
ON FRONT PANEL WITH S.M.S.

REAR
PANEL

S-.

INSTALL TOP PANEL WlTH FLANGES
POSITIONED OUTSIDE REAR AND SlDE
PANELS. SECURE WlTH S.M.S.

-----k?

INSTALL FRONT PANEL FILLER
PIECE BELOW BURNER PLATE
POSITIONING BEHIND FLANGE.

PLACE FRONT PANEL IN POSITION BY SLIDING DOWN BEHIND
BURNER PLATE FLANGE. ASSEMBLE TO FRONT PANEL FILLER
&
PIECE WITH S.M.S.

WATER PLATE USING S.M.S.

@IATTACH LOWEST

@ASSEMBLE LEFT HAND SIDE
PANEL TO FLANGE ON FRONT
PANEL WITH S.M.S. LEAVING
UPPER HOLE VOlD UNTIL
INSTALLATION OF TOP PANEL.
I" BLOCKS UNDER REAR OF
SlDE PANELS WILL FACILITATE
ASSEMBLY.

NECESSARY KNOCKOUTS.
DO NOT TIGHTEN ANY S.M.S.
UNTIL ALL PANELS HAVE BEEN
INSTALLED.

@ REMOVE

INSTALL FLUSH JACKET in accordance with
Fig. 9. Refer to Figure 4 for knockouts to be removed.

@)

@

INSTALLATION O F TRIM AND CONTROLS
FOR WATER BOILERS. (See Figure 4 for Control
Locations.)
a. Screw COMBINATION ALTITUDE GAUGE AND
THERMOMETER into %" tapping. Tighten by
wrench applied to square shank back of gauge. DO
NOT APPLY PRESSURE ON GAUGE CASE since
this may destroy calibration of gauge.
b. R E L I E F VALVE-Install in 1" Tapping next to 3"
Supply Tapping in Front Section using fittings provided.
CAUTION : Safety Relief Valve should be piped to
and open drain-full
size of discharge outlet on
Relief Valve and without any provision of "shut-off"
between the Relief Valve and discharge into drain.
c. Install Hydronic Controls in their designated tappings.

@
INSTALLATION O F TRIM AND
FOR STEAM BOILERS. (See Figure

CONTROLS
4 for control

locations.)
a. Screw Combination Pressure Vacuum Gauge into
designated $" tapping. Tighten by wrench applied
to square shank on back of gauge. Do not apply
pressure on gauge case since this may destroy calibration of gauge.
b. SAFETY VALVE. Install in 1" Tapping next to 3"
Supply Tapping in Front Section.
CAUTION: Safety Valve should be piped to a n
open drain-full size of discharge outlet on Safety
Valve and without any provision of "shut-off" between the Safety Valve and discharge into drain.
c. Install Pressure Limit Control with 1/4" Pig Tail
Syphon into Heater Cover Plate Tapping bushed 3/4"
to G".
d. Install Operating Control (supplied with Tankless
Heater equipped boilers only) in designated tapping.
e. Install Gauge Glass and Low Water Cut-off (if furnished) in y2" tappings on left side of Front Section.

@)

INSTALL SMOKEPIPE so t h a t connection to
Chimney or vent is short and direct.

a. Install in accordance with LOCAL F I R E ORINANCES.
b. Smokepipe must not be smaller than the 8" dia. flue
collar. See Fig. 1.
For Stub Vent installation see Fig. 3, if connected
to chimney.
c. Do not connect into same leg of Chimney serving an
open fireplace.
d. Inspect Chimney for obstructions o r restrictions
which should be removed. Clean Chimney if necessary.
e. Smokepipe should slope upward from Boiler to
Chimney not less than one inch in four feet. Smokepipe must be securely supported so a s to maintain,
proper clearances from combustible materials and
to prevent separation of joints.
f. Insert Smokepipe into but not beyond inside wall of
Chimney Flue Lining. Pipe should be installed
above the extreme bottom of Chimney so as to prevent stoppage.
y. Seal between Smokepipe and Chimney connection to
prevent draft leakage.

.

0

INSTALL ROOM THERMOSTAT on an inside
wall about four feet above floor. Never install Thermos t a t on an outside wail or where i t will be influenced by
drafts, hot or cold water pipes, lighting fixtures, television, rays of the sun, or near a fireplace. Keep large
furniture away from Thermostat so there will be free
movement of room a i r around this Control.

@
OIL BURNER INSTALLATION. Bolt burner to
mounting plate with nuts and washers packed in boiler
parts carton. R E F E R TO BURNER INSTALLATION
and SERVICE MANUAL form No. 52004.

@)

BOILER with JACKET EXTENSION refer to
Figure 10 for assembly instructions.
h

INSTALL ELECTRIC WIRING in accordance with
NATIONAL ELECTRICAL CODE and Local Regulations.
a. A separate ELECTRICAL CIRCUIT should be run
from Meter with a Fused Disconnect Switch in
this Circuit.
See Figures 11 thru 17 for appropriate wiring diagram.

I

\

BOTTOM

FRONT

TIE

THE BOTTOM FRONT
TIE PANEL TO THE EXTENSION
SIDE PANELS WITH THE FOUR
LONG SHEET METAL SCREWS.

@ ASSEMBLE

TO INSTALL THE FRONT DOOR
'PANEL ,ENGAGE THE BOTTOM
FLANGE FIRST, FULLY SEAT
THE TOP OF PANEL WHILE
HOLDING DOWN THE DOOR
LATCH AND RELEASE LATCH
TO SECURE PANEL IN POSITION.

PANEL

THE EXTENSION TOP PANEL IN
POSITION WlTH THE FLANGES EXTENDING
DOWN OVER THE EXTENSION SlDE PANELS.
SECURE WlTH THE SIX SHORT S.M.S.

@ PLACE

Fig. 10

THE TWO EXTENSION
SlDE PANELS WlTH THE NOTCHED
EDGE INSERTED BETWEEN THE
FLUSH JACKET SlDE AND FRONT
PANELS. TIGHTEN SCREWS TO
HOLD PANELS IN PLACE.

@ ASSEMBLE

FLUSH JACKET
-

Jacket Extension Assembly

8

RIGHT
HAND
SlDE
PANEL

ALL FLUSH JACKET SCREWS ATTACHING
SlDE PANELS TO THE FRONT PANEL
MUST BE LOOSENED.

LOW WATER
CUTOFF

HOT
LlNE
NEUTRAL

n

HONEYWELL PA 4 0 4 A
PRESSURE L I M I T
CONTROL

=

1

'

E$go'S:D
I

0

-

V

I I

?o
TFOI.

; W-

SWITCH

THERMOSTAT

O

-

FO

HONEYWELL R 8 1 8 4
PRIMARY CONTROL

',

1

I,(/I

.,-...a,.-. ...
IMC U t L A T

IGNITIONTRANSFORMER

VALVE

Fig. 11
O I L BURNER

SEQUENCE OF OPERATION
When the thermostat calls for heat, i t energizes the cad cell protectorelay, bringing on the burner. The burner will
operate until the thermostat is satisfied or the limit setting on ,the high limit is reached. When the high limit control
restores the circuit on a drop in pressure, the burner will start if the thermostat is still calling for heat. The low water
cut-off will stop the burner if the water level in the boiler drops too low.
On burner start, if the cad cell does not see flame within approximately 45 seconds, protectorelay will lock out on safety
and must be reset before burner can be restarted.

No. 1 Wiring Diagram for Steam Boilers Less Heater
LOW WATER
CUTOFF

HONEYWELL PA 4 0 4 A
PRESSURE L I M I T
CONTROL

b

THERMOSTAT

-

Q ?

HOT
LlNE
NEUTRAL

-

I

0

-

E~~oS
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