Burnham Series 5B Boiler Installation Operating Instructions

2015-06-08

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DNAGNITAREPO,NOITALLATSNI

ROFSNOITCURTSNIECIVRES

B5SEIRES

DERIF-SAG

RELIOB

8141302R18 - 1/15 PRICE - $5.00

Commercial Boilers

www.burnhamcommercial.com

3050579

This manual must only be used by a qualied heating installer/service technician.

BEFORE installing, read all instructions in this manual and all other information

shipped with the boiler. Post all instructions and manuals near the boiler for

reference by service personnel. Perform steps in the order given. Failure to comply

could result in severe personal injury, death or substantial property damage.

The following dened terms are used throughout this manual to bring attention to the presence of hazards of various

risk levels or to important information concerning the life of the product.

Indicates an imminently hazardous situation

which, if not avoided, will result in death, serious

injury or substantial property damage.

Indicates a potentially hazardous situation which,

if not avoided, may result in moderate or minor

injury or property damage.

Indicates a potentially hazardous situation which,

if not avoided, could result in death, serious injury

or substantial property damage.

Indicates special instructions on installation,

operation, or maintenance which are important

but not related to personal injury hazards.

Hazard definitions

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. The warranty for this boiler is valid only if the boiler

has been installed, maintained and operated in accordance with these instructions.

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

If you smell gas or fuel oil vapors, do not try to operate the burner/boiler system. Do not touch any

electrical switch or use any phone in the building. Immediately call the gas or oil supplier from a remotely

located phone.

Burner/boiler systems produce steam or hot water in a pressurized vessel by mixing extremely ammable

gaseous, liquid or solid fuels with air to produce combustion and very hot products of combustion.

Explosions, res severe personal injury, death and/or property damage will result from improper, careless

or inadequate installation, operation or maintenance of fuel-burning and boiler equipment.

IMPORTANT INFORMATION -

READ and save these instructions for reference

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal

injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or

death. Read and understand all instructions, including all those contained in component manufacturers

manuals which are provided with the appliance before installing, starting-up, operating, maintaining or

servicing this appliance. Keep this manual and literature in legible condition and posted near appliance

for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable

installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in

the layout and installation of hydronic heating systems should attempt installation of any boiler.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are

operating properly when the installation is completed.

Installation is not complete unless a pressure relief valve is installed into the specied tapping on the

supply manifold located on top and at rear of appliance - See Section III, Paragraph 33, ‘e’ of this manual

for details.

This boiler is NOT suitable for installation on combustible ooring.

Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to

assure that the unit is properly adjusted and maintained.

Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale.

The inside of the combustion chamber should also be cleaned and inspected at the same time.

Have Burner and Controls checked at least once a year or as may be necessitated. Do not operate

unit with jumpered or absent controls or safety devices. Do not operate unit if any control, switch,

component, or device has been subject to water.

Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy

metals, 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.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings 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.

This appliance must be properly vented and connected to an approved vent system in good condition.

Do not operate boiler with the absence of an approved vent system.

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 and air intake systems must be inspected and cleaned before the start of the

heating season and should be inspected periodically throughout the heating season for any obstructions.

Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could

cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efciency.

This boiler is supplied with controls 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 is designed to burn natural and/or LP gas only. Do not use gasoline, crankcase drainings, or

any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel

(i.e. wood, coal). All ammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler

at all times. Keep the boiler area clean and free of re hazards.

Float type low water cutoff devices require annual inspection and maintenance. Refer to instructions in

Section V, Paragraph 7 for inspection and cleaning instructions.

Series 5B cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler and

Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each Series 5B

jacket, which indicates the boiler Maximum Allowable Working Pressure (MAWP). Each cast iron section is

permanently marked with the MAWP listed on the boiler’s ASME Data Label. Those values for the Series 5B

are as follows:

MAWP, Water - 50 PSI

MAWP, Steam - 15 PSI

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

(1)

LEH 1111111111111111111

(1)

REH 1111111111111111111

(1)

C 45678891011 12 13 14 15 16 16 17 18 19 21

(2)

CX --- --- --- --- --- --- --- --- --- 1 1 1 1 1 1 2 2 3 3

(3)

CXP --- --- --- --- --- 1 1 1 1 --- --- --- --- --- 1 --- --- --- ---

(1) Section Marking Cast on Section

(2) “C” Cast on Section - When supply and return connections are tapped, section is paint stencilled “CX”

(3) “C” Cast on Section - When supply and return connections are tapped and plugged, section is paint stencilled “CXP”

CARTONS, PACKAGES, OR BUNDLES

1Base-Burner-Manifold Assembly (By Gas and By Pilot System) - One Left & One Right Req’d on 5015B and Larger Boilers

COMPLETE 1

14 --- --- --- --- --- --- --- --- ---

L. SUB-BASE --- --- --- --- --- --- --- --- ---

R. SUB-BASE --- --- --- --- --- --- --- --- ---

2Tie Rod Bundle(s) 4 Sizes - One to Five Per Boiler

22” --- --- 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

27” --- --- 1 2 1 --- --- --- 2 1 --- --- --- --- 1 --- --- --- 2

37” 1 --- --- --- 1 2 1 --- 1 2 3 2 1 --- 3 4 3 1 ---

42” --- 1 --- --- --- --- 1 2 --- --- -- 1 2 3 --- --- 1 3 3

2 A Draw-up Rod Bundle(s) 3 Sizes - One to Three Per Boiler

37¾” --- --- --- --- --- 2 2 1 1 --- --- --- --- --- --- --- --- --- ---

49¼” 1 1 --- --- --- --- --- 1 1 2 2 1 1 1 --- --- --- 3 2

67¼” --- --- 1 1 1 --- --- --- --- --- --- 1 1 1 2 2 2 --- 1

3 A Boiler Assembly Carton(s) 6 Sizes - One to Five Per Boiler

3A6 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- ---

3A7 --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- ---

3A8 --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- --- 1

3A9 --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- 1 1

3A10 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- ---

3AM --- --- --- --- --- 1 1 1 1 1 2 2 2 2 2 3 3 3 3

4Boiler Sealing Carton(s) 5 Sizes - One to Three Per Boiler

06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 --- 1 --- ---

07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 2 --- --- ---

08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 ---

09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- 2 2 2

10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 --- --- 1

5Integral Draft Hood Carton(s) 5 Sizes - One to Four Per Boiler (Natural & LP)

06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 1 --- 1 ---

07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 2 3 3

08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- --- 1

09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- --- --- ---

10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 1 --- ---

SECTION I – EQUIPMENT CHECK LIST

U.S.A. EQUIPMENT CHECK LIST

(For Canadian Equipment Check List, Turn to Pages 7 and 8)

This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered.

It covers standard equipment for both steam and water boilers without Tankless Heaters. Heaters or optional equipment ordered will be in

addition to, or in lieu of, equipment shown below.

By opening cartons in numerical sequence, boiler assembly is simplied. If there is an exception, it will be pointed out in the boiler

assembly procedure. When it does occur, you will nd that assembly of the boiler is further simplied.

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

CARTONS, PACKAGES OR BUNDLES

7 S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler

1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

2 --- --- --- 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---

3 --- --- --- --- --- --- 1 1 1 1 1 1 1 1 1 --- --- --- ---

4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1 1 1

67 BC-2 Low Water Cut-off Carton (Steam Boilers Only) One Per Boiler

1111111111111111111

7 W Water Trim Carton (Water Boilers Only - Includes L4006A Temp. Limit Control) 3 Sizes - One Per Boiler

2 1 1 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---

3 --- --- --- --- --- -- 1 1 1 1 1 1 1 1 1 1 1 --- ---

4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1

64 Low Water Cut-off Carton (Water Boilers Only) One Per Boiler

1111111111111111111

8 Complete Jacket Carton Assembly - One Per Boiler

9Gas Train Cartons (By Gas) 2 Sizes - One or Two Per Boiler

1 1* 1* 1* --- --- --- --- --- --- 2 1 --- --- --- --- --- --- --- ---

2 --- --- --- 1* 1 1 1 1 1 --- 1 2 2 2 2 2 2 2 2

3 EI 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

EI Controls Carton(s) (By Gas) (Intermittent Elec. Ign. - 100% Shutoff - 24V.) 1 Size - One or Two Per Boiler

1 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

2------------111112222222222

HCP

Plain Heater Cover Plate (Not furnished on Water Boiler Ordered With Two Tankless Heaters) One Per Boiler

1111111111111111111

HCP

Tapped (¾” NPT) Heater Cover Plate (Not Furnished on Water Boiler Ordered With Tankless Heater(s) One Per Boiler

1111111111111111111

U.S.A. EQUIPMENT CHECK LIST

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 claims for damage or shortage in

shipment must be led immediately against the carrier by the consignee. No claims for variances or shortages will be

allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment.

*Carton 91, or 92 on sizes 5006B thru 5009B is standard on all systems except EI and may be optional on 5006B thru

5009B EI.

Carton 93 is standard on sizes 5006B thru 5009B for EI systems.

This Series 5B Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters:

Approval No. G1-0202-11A.

The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.

SECTION I – EQUIPMENT CHECK LIST (continued)

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

(1)

LEH 1111111111111111111

(1)

REH 1111111111111111111

(1)

C 45678891011 12 13 14 15 16 16 17 18 19 21

(2)

CX --- --- --- --- --- --- --- --- --- 1 1 1 1 1 1 2 2 3 3

(3)

CXP --- --- --- --- --- 1 1 1 1 --- --- --- --- --- 1 --- --- --- ---

(1) Section Marking Cast on Section

(2) “C” Cast on Section - When supply and return connections are tapped, section is paint stencilled “CX”

(3) “C” Cast on Section - When supply and return connections are tapped and plugged, section is paint stencilled “CXP”

CARTONS, PACKAGES, OR BUNDLES

1Base-Burner-Manifold Assembly (By Gas and By Pilot System) - One Left & One Right Req’d on 5015B and Larger Boilers

COMPLETE 1

14 --- --- --- --- --- --- --- --- --- ---

L. SUB-BASE --- --- --- --- --- --- --- --- ---

R. SUB-BASE --- --- --- --- --- --- --- --- ---

2Tie Rod Bundle(s) 4 Sizes - One to Five Per Boiler

22” --- --- 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

27” --- --- 1 2 1 --- --- --- 2 1 --- --- --- --- 1 --- --- --- 2

37” 1 --- --- --- 1 2 1 --- 1 2 3 2 1 --- 3 4 3 1 ---

42” --- 1 --- --- --- --- 1 2 --- --- -- 1 2 3 --- --- 1 3 3

2 A Draw-up Rod Bundle(s) 3 Sizes - One to Three Per Boiler

37¾” --- --- --- --- --- 2 2 1 1 --- --- --- --- --- --- --- --- --- ---

49¼” 1 1 --- --- --- --- --- 1 1 2 2 1 1 1 --- --- --- 3 2

67¼” --- --- 1 1 1 --- --- --- --- --- --- 1 1 1 2 2 2 --- 1

3 A Boiler Assembly Carton(s) 6 Sizes - One to Five Per Boiler

3A6 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- ---

3A7 --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- ---

3A8 --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- --- 1

3A9 --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- 1 1

3A10 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- ---

3AM --- --- --- --- --- 1 1 1 1 1 2 2 2 2 2 3 3 3 3

4Boiler Sealing Carton(s) 5 Sizes - One to Three Per Boiler

06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 --- 1 --- ---

07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 2 --- --- ---

08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 2

09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- 2 2 1

10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 --- --- ---

5Integral Draft Hood Carton(s) 5 Sizes - One to Four Per Boiler

06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 1 --- 1 ---

07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 2 3 3

08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- --- ---

09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- --- --- ---

10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 1 --- ---

CANADIAN

EQUIPMENT CHECK LIST

This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler

ordered. It covers standard equipment for both steam and water boilers without Tankless Heaters. Heaters or optional equipment

ordered will be in addition to, or in lieu of, equipment shown below.

By opening cartons in numerical sequence, boiler assembly is simplied. If there is an exception, it will be pointed out in the

boiler assembly procedure. When it does occur, you will nd that assembly of the boiler is further simplied.

SECTION I – EQUIPMENT CHECK LIST (continued)

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

CARTONS, PACKAGES OR BUNDLES

7 S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler

1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

2 --- --- --- 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---

3 --- --- --- --- --- --- 1 1 1 1 1 1 1 1 1 --- --- --- ---

4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1 1 1

67 BC-2 Low Water Cut-off Carton (Steam Boilers Only) One Per Boiler

1111111111111111111

7 W Water Trim Carton (Water Boilers Only - Includes L4006A Temp. Limit Control) 3 Sizes - One Per Boiler

2 1 1 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---

3 --- --- --- --- --- -- 1 1 1 1 1 1 1 1 1 1 1 1 1

4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1

64 Low Water Cut-off Carton (Water Boilers Only) One Per Boiler

1111111111111111111

8 Complete Jacket Carton Assembly - One Per Boiler

Gas Train Cartons (By Gas) 2 Sizes - One or Two Per Boiler

1 1 1 --- --- --- --- --- --- 2 1 --- --- --- --- --- --- --- ---

--- --- --- 1 1 1 1 1 1 --- 1 2 2 2 2 2 2 2 2

THERM. Controls Carton(s) (Manual Ignition. - 100% Shutoff - 24V.) 1 Size - One or Two Per Boiler

Natural 11111111---222222222---

HCP

Plain Heater Cover Plate (Not furnished on Water Boiler Ordered With Two Tankless Heaters) One Per Boiler

1111111111111111111

HCP

Tapped (¾” NPT) Heater Cover Plate (Not Furnished on Water Boiler Ordered With Tankless Heater(s) One Per Boiler

1111111111111111111

CANADIAN

EQUIPMENT CHECK LIST

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 claims for damage or shortage in

shipment must be led immediately against the carrier by the consignee. No claims for variances or shortages will be

allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment.

SECTION I - EQUIPMENT CHECK LIST - Page 5

SECTION II - GENERAL INFORMATION - Page 10

SECTION III - INSTALLATION INSTRUCTIONS - Page 11

SECTION IV - OPERATION - Page 43

SECTION V - SERVICE - Page 64

SERVICE RECORDS - Pages 73, 110, 111

SECTION VI - REPAIR PARTS - Page 74

APPENDIX A - FIGURES - Page 105

APPENDIX B - TABLES - Page 108

SECTION I – EQUIPMENT CHECK LIST (continued)

FIG. 1

DIMENSIONAL DATA

Boiler

Size

Jacket

Overall

Length

‘A’

Draft Hood Height, Size and Location

Top Supply

and Rear Return

Location

Supply

Conn.

Qty &

Size

Return Conn.

Qty. & Size

Gas Conn.

Size Nat. &

Propane

No. & Dia. of

Flue Outlets

Approx.

Shipping

Weight

(LB.)

‘B’

Dia.

‘C’

Dia.

‘D’

Dia.

‘E’

Dia. ‘F’ ‘G’ ‘H’ ‘J’ ‘K’ ‘M’ ‘N’

5006B 34 9 --- --- --- --- --- --- 17 19-3/4 --- --- (2) 3 (2) 3 1 (1) 9 1160

5007B 39-3/8 10 --- --- --- --- --- --- 19-3/4 32-1/4 --- --- (2) 3 (2) 3 1 (1) 10 1340

5008B 44-3/4 12 --- --- --- --- --- --- 22-3/8 38-3/8 --- --- (2) 3 (2) 3 1 (1) 12 1525

5009B 50-1/4 12 --- --- --- --- --- --- 25-1/8 43-3/4 --- --- (2) 3 (2) 3 1-1/4** (1) 12 1720

5010B 55-3/4 12 --- --- --- --- --- --- 27-7/8 49-1/4 --- --- (2) 3 (2) 3 1-1/4 (1) 12 1895

5011B 61-1/8 9 9 --- --- 27-1/4 --- --- 17 54-3/4 --- --- (2) 3 (2) 3 1-1/4 (2) 9 2085

5012B 66-1/2 9 10 --- --- 29-7/8 --- --- 19-3/4 60-1/8 --- --- (2) 3 (2) 3 1-1/4 (1) 9, (1) 10 2280

5013B 72 10 10 --- --- 32-5/8 --- --- 19-3/4 65-1/2 --- --- (2) 3 (2) 3 1-1/4 (2) 10 2460

5014B 77-1/2 10 12 --- --- 35-3/8 --- --- 22-3/8 71 --- --- (2) 3 (2) 3 1-1/4 (1) 10, (1) 12 2640

5015B 82-7/8 12 12 --- --- 38 --- --- 22-3/8 38-1/4 38-1/4 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1* (2) 12 2870

5016B 88-1/4 12 12 --- --- 40-3/4 --- --- 25-1/8 38-1/4 43-5/8 --- (3) 3 (2) 3, (1) 2-1/2 (1) 1, (1) 1-1/4* (2) 12 3070

5017B 93-3/4 12 12 --- --- 43-1/2 --- --- 25-1/8 43-5/8 43-5/8 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 12 3265

5018B 99-1/4 12 12 --- --- 46-1/4 --- --- 27-7/8 43-5/8 49-1/8 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 12 3445

5019B 104-5/8 12 12 --- --- 49 --- --- 27-7/8 49-1/8 49-1/8 (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 12 3620

5020B 110 9 9 12 --- 27-1/4 38 --- 27-7/8 54-1/2 49-1/8 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 9, (1) 12 3810

5021B 115-1/2 9 10 12 --- 29-7/8 40-3/4 --- 27-7/8 27-3/8 32-5/8 49-1/8 (4) 3 (2) 3, (2) 2-1/2 (2) 1-1/4* (1) 9, (1) 10, (1) 12 4005

5022B 121 10 10 12 --- 32-5/8 40-3/4 --- 27-7/8 32-3/4 32-5/8 49-1/8 (4) 3 (2) 3, (2) 2-1/2 (2) 1-1/4* (2) 10, (1) 12 4185

5024B 131-3/4 9 10 10 10 29-7/8 32-5/8 32-5/8 19-3/4 27-3/8 65-1/4 32-3/4 (5) 3 (2) 3, (3) 2-1/2 (2) 1-1/4* (1) 9, (3) 10 4530

5026B 142-3/4 10 12 10 10 35-3/8 35-3/8 32-5/8 19-3/4 32-3/4 70-3/4 32-3/4 (5) 3 (2) 3, (3) 2-1/2 (2) 1-1/4* (3) 10, (1) 12 4895

* Dual Manifolds - 5015B thru 5026B **1” - USA - EI

NOTE

1. 5006B THRU 5014B BOILERS REQUIRE

SINGLE GAS TRAIN LOCATION ON

LEFT END OF BOILER (STANDARD)

GAS TRAIN MAY BE RELOCATED

TO RIGHT END OF BOILER (EXCEPT

5012B AND 5014B BOILERS).

2. 5015B THRU 5026B BOILERS REQUIRE

DUAL GAS TRAINS.

3. GAS SUPPLY PRESSURE, IN W.C.

NATURAL GAS

MAXIMUM: 14” W.C.

MINIMUM: 5.5” W.C.

(5009B AND 5011B THRU 5014B AND

5020B THRU 5026B)

MINIMUM: 5” W.C.

(5006B THRU 5008B AND 5010B, 5015B

THRU 5019B)

LP GAS:

MAXIMUM: 14” W.C.

MINIMUM: 11” W.C.

4. WATER BOILERS - MAXIMUM DESIGN

WORKING PRESSURE: 50 PSI.

5. STEAM BOILER - MAXIMUM DESIGN

WORKING PRESSURE: 15 PSI.

6. DIMENSIONS IN INCHES

SECTION II – GENERAL INFORMATION

1. BOILER INSTALLATION must conform to the

requirements of the authority having jurisdiction, or in

the absence of such requirements, to:

USA – “National Fuel Gas Code, ANSI Z223.1”.

When required by the authority having jurisdiction,

the installation must conform to American Society of

Mechanical Engineers Safety Code for Controls and

Safety Devices for Automatically Fired Boilers, No.

CSD-1.

CANADA – “Installation Codes for Natural and

Propane Gas Burning Appliances and Equipment,

CAN/CSA-B149 (.1 or .2)”.

DO NOT INSTALL THIS BOILER ON CARPETING.

2. BOILER LOCATION – locate on a level NON-

COMBUSTIBLE FLOOR as close as possible to

chimney so that vent connection is short and direct.

Boiler must not be installed directly on

combustible ooring. A concrete pad is not

sufcient to protect combustible ooring.

The boiler shall be installed such that the gas ignition

system components are protected from water (dripping,

spraying, rain, etc.) during boiler operation and service

(circulator replacement, control replacement, etc.).

Do not install boiler where gasoline or other ammable

vapors or liquids, or sources of hydrocarbons (i.e.

bleachers, cleaners, chemicals, sprays, paint removers,

fabric softeners, etc. ) are used or stored.

Refer to table below for minimum clearances, service

clearances, and clearances for removal of Tankless

Heaters.

3. PROVIDE COMBUSTION AND VENTILATION

AIR.

In the USA refer to National Fuel Gas Code, NFPA

54/ANSI Z223. Section 5.3, Air for Combustion and

Ventilation. In Canada refer to Natural Gas Installation

Code, CAN/CSA-B149.1 – latest edition or Propane

Installation Code, CAN/CSA-B149.2 – latest edition.

Local code provisions may apply and should be

referenced.

Adequate combustion and ventilation air must be

provided to assure proper combustion.

a. Determine volume of space (boiler room). Rooms

communicating directly with the space, in which

the appliances are installed, through openings not

furnished with doors, are considered a part of the

space.

Volume (ft³) = Length (ft) x Width (ft) x Height (ft)

b. Determine total input of all appliances in the space.

Add inputs of all appliances in the space and round

the result to the nearest 1000 Btu per hour.

c. Determine type of space.

Divide Volume by Total Input of all appliances

in space. If the result is greater than or equal to

50 ft³/1000 Btu per hour, then it is considered an

unconned space.

If the result is less than 50 ft³/1000 Btu per hour,

then the space is considered a conned space.

d. For boiler located in an unconned space of a

conventionally constructed building, the fresh

air inltration through cracks around windows

and doors normally provides adequate air for

combustion and ventilation.

e. For boiler located in a conned space or an

unconned space in a building of unusually tight

construction, provide outdoor air with the use

of two permanent openings which communicate

directly or by duct with the outdoors or spaces

(crawl or attic) freely communicating with the

outdoors. Locate one opening within 12 inches of

top of space. Locate remaining opening within 12

inches of bottom of space. Minimum dimension

of air opening is 3 inches. Size each opening per

following:

1. Direct communication with outdoors. Minimum

free area of 1 square inch per 4,000 Btu per hour

input of all equipment in space.

2. Vertical ducts. Minimum free are of 1 square

inch per 4,000 Btu per hour input of all

CLEARANCES - From Table below and from dimensional data in Fig. 1, determine BOILER ROOM space necessary for appropriate access

to and servicing of Boiler. Consideration should be given to other appliances installed in the same area. Consult with local Building and

Safety Codes for compliance.

MINIMUM CLEARANCE - JACKET TO

COMBUSTIBLE CONSTRUCTION

RECOMMENDED

SERVICE CLEARANCE TO

NON-COMBUSTIBLE CONSTRUCTION

CLEARANCES REQ’D FOR REMOVAL

OF TANKLESS HEATER

AT-2 AT-3 AT-4

Left Side 24” (61 cm) 18” (Controls) 27” 32” 42”

Right Side 24” (61 cm) 18” (Controls) 27” 32” 42”

Front 24” (61 cm) 36” (Cleaning-Burner Removal) --- --- ---

Rear 24” (61 cm) 36” (Cleaning) --- --- ---

Top 24” (61 cm) ---------------------------------------- --- --- ---

SECTION III – INSTALLATION INSTRUCTIONS

equipment in space. Duct cross-sectional area

shall be same as opening free area.

3. Horizontal ducts. Minimum free area of 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.

Alternate method for boiler located within

conned space. Use indoor air if two permanent

openings communicate directly with additional

space(s) of sufcient volume such that combined

volume of all spaces meet criteria for unconned

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.

4. LOUVERS AND GRILLES of Ventilation Ducts

All outside openings should be screened and louvered.

Screens used should not be smaller than ¼ inch mesh.

Louvers will prevent the entrance of rain and snow.

a. Free area requirements need to consider the blocking

effect of louvers, grilles, or screens protecting the

openings. If the free area of the 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.

b. Louvers and grilles must be xed in the open

position or interlocked with the equipment to open

automatically during equipment operation.

FIG. 2

SINGLE MANIFOLD BASE 5006B

THRU 5014B SECTION BOILERS

1. BASE-BURNER-MANIFOLD ASSEMBLY(S).

a. 5006B section thru 5014B section boilers require

single base assembly, see Fig. 2.

b. 5015B section thru 5026B section boilers require a

left and a right base subassembly, see Fig. 3.

Remove Base Assembly(s) From Skid(s)

c. Remove bolts securing Base Assembly(s) to

shipping skid(s) and place Base(s) in location where

Boiler is to be installed.

d. Join Base Sub-assemblies together (15 section &

larger boilers) by rst removing upper shipping

strip and lower shipping angles from subassemblies.

Use (4) ¼”-20 x ¾” MS, nuts and washers to attach

subassemblies, see Fig. 3.

e. Attach Front Intermediate Jacket Panel Support

Bracket and Lower Rear Intermediate Panel Support

Bracket to lower channel on Front Base Frame and

Rear Base Frame, respectively, using (4) ¼”-20 x

¾” MS, nuts and washers.

f. Base must be level in both directions and secure on

the oor. Shim and grout under Base if necessary.

g. Place cardboard covering over the top of the burner

assembly to protect them during the assembly of the

boiler sections.

2. CLEAN BOILER SECTIONS inside and out to remove

dirt due to shipment and handling.

Open Tie Rod Bundle(s). Open Draw-up Rod

Bundle(s).

Open Boiler Assembly Carton(s).

3. SET LEFT END SECTION ON BASE so that locating

lugs on bottom of section go inside Front and Rear Base

Frames. Slide section on base until these lugs strike

High Base End Panel at left end of Base, see Fig. 4.

(Note – if High Base End Panel is at right end of Base,

section assembly must start with Right End Section).

Left end sections are identied by “LEH” cast on

section; Right End Sections are identied by “REH”

cast on section.

4. CLEAN NIPPLES AND NIPPLE PORTS thoroughly

with a de-greasing solvent. Use the Loctite® #592

supplied to lubricate the nipples and nipple ports.

Apply the lubricant to the nipples and nipple ports, then

use a brush to disperse it evenly around the nipples and

the nipple ports. Use approximately 25 ml of Loctite®

#592 per ueway [(1) 7” and (2) 3” nipples and their

(6) corresponding nipple ports]. Use Nipple Gauge

furnished – follow instructions included with gauge to

set nipples. USE ALL PRECAUTIONS TO AVOID

COCKED NIPPLES.

5. PAINT ALL GROUND SURFACES of each section

with the Sealer Compound furnished.

6. ASSEMBLE CENTER SECTIONS. Refer to Fig. 6

for proper location of Tapped, and sometimes plugged,

SECTION II – GENERAL INFORMATION (continued)

Center Sections on 11 section and larger boilers. THIS

IS IMPORTANT.

a. Carefully join a Center Section with nipples in

adjoining section and bump lightly to secure.

b. Run nut approximately 8” on two (2) ¾” draw-up

rods of equal length. (Note – more than one set of

draw-up rods are furnished on 8 section and larger

boilers). Place draw-up channel and one at washer

against nut.

FIG. 3

DUAL MANIFOLD BASES - 5015B THRU 5026B SECTION BOILERS

FIG. 4

LEH SECTION ON BASE FIG. 5

ASSEMBLY OF CENTER SECTIONS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 6

ARRANGEMENT OF SECTIONS AND CANOPY(S)

SECTION III – INSTALLATION INSTRUCTIONS (continued)

c. Insert short end of draw-up rod through front & rear

nipple ports on both sections, see Fig. 5.

d. Place two (2) at washers, draw-up channel and a

nut on each end of draw-up rods and nger tighten.

e. DRAW UP CENTER SECTION SLOWLY AND

EVENLY, tightening each DRAW-UP ROD a little

at a time so that sections are equally spaced. KEEP

NIPPLES ALIGNED WITH NIPPLE PORTS. If

necessary, tap Nipples lightly with a blunt tool or

rod to keep Nipples from cocking while Sections are

being drawn up. DO NOT DRAW UP SECTION(S)

WHEN NIPPLES ARE COCKED. Continue

tightening Draw-Up Rods equally until Sections

meet iron-to-iron on the ground surface. BUMPING

OUTER EDGES OF SECTION WITH WOODEN

BLOCK WILL EASE DRAW-UP OPERATION.

f. KEEP DRAW-UP ROD THREADS, NUTS AND

WASHERS LUBRICATED with grease or heavy oil

to prevent damage to rods and threads and to make

assembling easier.

g. USING A PINCH BAR, insert WOOD WEDGES

under last Center Section assembled so as to raise

it just above Boiler Base. This will keep the next

section to be assembled above the base, thus making

it easier to join and draw-up. MOVE WOOD

WEDGES FORWARD EACH time a Section has

been drawn up.

7. ASSEMBLE REMAINING END SECTION WITH

DRAW-UP RODS in a manner similar to that for

assembling Center Sections. Remove wedges from

under Boiler. Be sure Boiler is aligned and seated on

Base.

a. After section assembly is completed install 5/8” tie

rods from tie rod bundle through the upper lug holes

in the front of Boiler and Lower lug holes in the rear

of Boiler sections and tighten until they are nger

tight only, to allow for expansion. This is necessary

in order to allow clearance for installation of Flue

cover plates. Finally, remove ¾” draw-up rods from

nipple ports.

FIG. 7

PURPOSE OF TAPPINGS AND THEIR LOCATIONS

PURPOSE OF TAPPINGS 1

Location Tapping Per

End Section Size Steam Boilers Water Boilers

A 1 3” Supply Supply

B 1 3” Return Return

C21 1-1/2” Pressure Operating Control

(Bushed to 1/4”)

Temperature Operating Control (less heater)

Bushed to 3/4”; Plug (with heater)

D 1 1/2” Pressure Gauge Theraltimeter

E 2 1/2” Water Gauge, LWCO & Pressure Limit Plug

F 1 3/8” Try-Cock (Special Order) ----

G31 ---- Cover Plate Cover Plate or Tankless Heater

H 1 1” See Note 4 See Note 4

J 1 1-1/2” Indirect Water Heater

Supply or Return ----

K 1 3/4” Indirect Water Heater Limit ----

1 Tappings on both end sections are identical - Recommend trim be installed in left end section or on same end as gas train.

2 This tapping is used for safety valve and surface blowoff (steam boilers) and safety relief valve (water boilers) on end not equipped with trim.

3 Temperature operating control location on tankless heater equipped boilers. Also alternate operating control location, tapped cover plate.

4 If using a oat type LWCO, feeder or pump controller on a steam boiler that does not use quick connect hook up ttings, install between

tappings H and return B. Use opposite return B for system return connection. Water boilers using a probe LWCO must mount probe in

supply pipe above boiler without any stop valves.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 8

INSTALLATION OF BUILT-IN HEATER FIG. 9

TESTING BOILER ASSEMBLY FOR LEAKS

Open Steam or Water Trim Carton

8. USE THE PLUGS IN THIS CARTON to plug tappings

in End Sections that will not be utilized on nal

installation, see Fig. 7.

Open Tankless Heater Carton(s) If Supplied.

Open Heater Opening Cover Plate Carton(s).

9. INSTALL BUILT-IN WATER HEATER(S) OR

HEATER OPENING COVER PLATE(S), See Fig.

8. Heater may be installed in either End Section or,

in some cases, in both End Sections. Heater Opening

Cover Plates are used to cover any unused heater

openings.

a. Place rubber gasket against surface of plate and

align holes.

b. Place washer on each of 3/8” Cap Screws furnished

and insert cap screws through plate and gasket.

Start all screws in taps before nal tightening.

10. HYDROSTATIC TEST, see Fig. 9: After the boiler

sections have been assembled, it is essential that the

boiler be hydrostatically tested before the canopy, ue

cover plates, jacket, or piping is installed.

a. Plug all boiler tappings and ll boiler completely

with cold water.

DO NOT install gauge until after hydrostatic

testing the boiler. Gauge failure may result.

b. All completed boilers must satisfactorily pass the

prescribed hydrostatic test.

(1) STEAM BOILERS: The assembled boiler must

be subjected to a hydrostatic test of 45 psig to 55

psig.

(2) HOT WATER BOILERS: The assembled boiler

must be subjected to a hydrostatic test of 75 psig

to 85 psig.

Failure to properly hydrotest all boilers at the

correct pressure may result in section assembly

failure in operation.

11. EXAMINE BOILER CAREFULLY, INSIDE AND

OUTSIDE, to insure against leaks from cocked nipples

or through concealed breakage caused in shipping and

handling. This precaution is for your protection and

will simplify handling of necessary replacements and

adjustment claims. After making certain that there are

no leaks, drain boiler and remove plugs for boiler trim

and other connections.

Open Boiler Sealing Carton.

12. SEAL BETWEEN BOILER SECTIONS AND BASE,

see Fig. 10.

a. Push ¾” braided ceramic bre Rope (furnished) into

gap between bottom of End Section and Low Base

End Panel until rope touches Front and Rear Base

Frames. Place the 1-1/2” x 2” x 5/8” steel spacers

between low base panel and section and in front of

rope – align holes. Secure section to low base end

panel with 3/8”-16 x 2” Cap Screws, washers and

nuts.

b. Secure opposite end section to high base end panel

with 3/8”-16 x 2” Cap Screws, washers and nuts.

c. Apply Furnace Cement to gaps between section

assembly and base to make gas tight seal.

d. Check all joints between Boiler sections and use

remaining Furnace Cement or Sealer Compound to

make joints gas tight.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

13. INSTALL FLUE COVER PLATES over cleanout

openings on Front and Rear of Boiler. Use ¼” Carriage

Bolts installed at top and bottom of ue openings and

secure with washer and jam nut to provide a xed

stud. Install ue cover plates over studs with insulation

against Boiler and secure with washers and nuts, see

Fig. 11.

14. CONNECT SUPPLY AND RETURN PIPING TO

HEATING SYSTEM.

CLEARANCES – Steam and Hot water pipes shall

have clearances of at least ½” from all combustible

construction.

Before using copper for steam piping, consider

the following characteristics of copper piping:

1) high coefcient of thermal expansion can

induce mechanical stresses and cause expansion/

contraction noises if not accounted for in the

piping system design and installation,

2) high heat transfer rate (heat loss) of uninsulated

copper piping must be included in the normal

piping and pickup factors used to size the boiler,

3) soldering or brazing pastes and uxes that end

up in the system can cause poor heat transfer,

surging, and unsteady water line and wet steam

if not thoroughly removed during the boil out

procedure and,

4) galvanic corrosion of the adjoining metal may

occur due to dissimilar metals in certain water

chemistries if dielectric unions are not used.

a. With Steam Heating System, refer to Fig. 12, 13, 14

or 15.

b. With Forced Circulation HOT WATER HEATING

SYSTEMS, see Fig. 16A and 16B. For additional

reference, consult I=B=R Installation and Piping

Guide No. 250.

NOTE: When Hot Water Heating Boilers are

connected to Heating Coils located in Air Handling

Units where they may be exposed to refrigerated

air circulation, the Boiler Piping System must

be equipped with Flow Control Valves or other

automatic means to prevent gravity circulation of

the Boiler Water during the cooling cycle.

c. With COMBINATION HEATING AND COOLING

(REFRIGERATION) SYSTEMS having the same

Distributing Units, Piping and Circulator, See Fig.

17. For additional reference, consult ASHRAE

Systems Handbook 2008 Edition.

d. NOTE: Valves must be installed in the supply and

return branches to the Heating Boiler and Water

Chiller so as to prevent circulation of Chilled Water

through the Boiler or Heated Water through the

Chiller.

OXYGEN CORROSION:

Oxygen contamination of the boiler water will cause

corrosion of the iron and steel boiler components,

which can lead to failure. As such, any system must

be designed to prevent oxygen absorption in the rst

place or prevent it from reaching the boiler. Problems

caused by oxygen contamination of boiler water are not

covered by Burnham’s standard warranty.

FIG. 10

SEALING OF BASE, INSTALLATION OF

FLUE COVERS AND CANOPIES

FIG. 11

ATTACHMENT OF FLUE COVERS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 12

RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN

I OR 2 SUPPLY CONNECTIONS - 5006B THRU 5014B

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 13

RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN

3 SUPPLY CONNECTIONS - 5015B THRU 5020B

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 14

RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN

4 OR 5 SUPPLY CONNECTIONS - 5021B THRU 5026B

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 15

TYPICAL STEAM PIPING ARRANGEMENT FOR BOILERS WITH PUMPED CONDENSATE RETURN AND BOILER FEED UNIT

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 16A

RECOMMENDED WATER BOILER PIPING

1 SUPPLY CONNECTION & 1 RETURN CONNECTION

SIZES 5006B THRU 5019B

FIG. 16B

RECOMMENDED WATER BOILER PIPING

3 SUPPLY CONNECTIONS & 2 RETURN CONNECTIONS

SIZES 5020B THRU 5026B

SECTION III – INSTALLATION INSTRUCTIONS (continued)

There are many possible causes of oxygen

contamination such as:

1. Addition of excessive make-up water as a result of

system leaks.

2. Absorption through open tanks and ttings.

3. Oxygen permeable materials in the distribution

system.

In order to insure long product life, oxygen sources

should be eliminated. This can be accomplished by

taking the following measures:

FIG. 17

RECOMMENDED BOILER PIPING FOR

COMBINATION HEATING & COOLING SYSTEMS

1. Repairing system leaks to eliminate the need for

addition of make-up water.

2. Eliminating open tanks from the system.

3. Eliminating and/or repairing ttings which allow

oxygen absorption.

4. Use of non-permeable materials in the distribution

system.

5. Isolating the boiler from the system water by

installing a heat exchanger.

Open Jacket Parts Carton

15. INSTALLATION OF JACKET PARTS COMMON TO

ALL BOILER SIZES

1. Attach Lower Jacket End Panel Support Bracket to

Base End Panel (Both ends) using ¼”-20 x ½” self-

tapping screws, see Fig. 2 and 18.

2. Attach Lower Left and Lower Right Jacket End

Panels to their respective brackets using #10-32 x

½” self-tapping screws, see Fig. 19.

3. See Fig. 7 “Purpose of Tappings and Their

Location” and remove necessary knockouts from

Upper Left and from Upper Right Jacket End

Panels.

4. Place Upper Right End Panel on top of Lower

Right End Panel with lip on bottom of Upper Panel

positioned behind Lower Panel. Secure to section

using #10-32 x ½” self-tapping screws. Attach

Upper Left End Panel in a similar manner, see Fig.

19.

NOTE: FOR INSTALLATION OF THE

FRAMEWORK FOR THE LOWER UNCOMMON

JACKET PARTS REFER TO THE FOLLOWING:

a. 5006B thru 5010B section boilers – Paragraph

16, Fig. 21

b. 5011B thru 5026B section boilers – Paragraph

30, Fig. 24, 25 or 26

COMPLETION OF JACKET INSTALLATION –

5006B THRU 5010B SECTION BOILERS

NOTE: Do not tighten any screws until Jacket

installation is complete.

INSTALLATION OF LOWER FRAMEWORK

16. With “U” channel facing down, slip upper front channel

behind joints formed by End Panels and secure to End

Panels using #8 SMS. Position Lower Front Channel

so that “U” of channel faces boiler. Slip Lower Front

Channel behind Lower End Panels and secure with

#8 SMS. Repeat similar procedure for installation of

Upper Rear and Lower Rear Channels.

17. INSTALLATION OF VESTIBULE PANEL refer to

Fig. 20.

FIG. 18

INSTALLATION OF JACKET SUPPORT

BRACKETS TO BASE END PANELS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 19

INSTALLATION OF JACKET END PANELS

FIG. 20

VESTIBULE ATTACHMENT DIAGRAM

Attach Hex Couplings to end of

Carriage Bolts which secure ue

cover plates.

NOTE: Select Carriage Bolts which

line up with holes in the Vestibule

Panel.

18. SECURE VESTIBULE PANEL TO

HEX COUPLINGS using ¼”-20 x

3/8” slotted pan head machine screws.

19. ATTACH REAR TOP JACKET

PANEL TO UPPER END PANELS

using #8 SMS. Refer to Fig. 21.

20. INSTALLATION OF CANOPY-

DRAFT HOOD 5006B thru 5010B

Section Boilers, see Fig. 22. Place

Cerafelt strips on top of section

assembly next to ledges formed by

center sections and next to ledge on

end sections. Overlap at corners.

21. SECURE CANOPY-DRAFT HOOD

with 5/16”-18 x 5/8” MS driven into

the tapped lugs provided for this

purpose on top of the sections. Two

screws are required at each end.

Refer to Fig. 23.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 21

EXPLODED VIEW OF JACKET

5006B THRU 5010B SECTION BOILERS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 22

SECURING OF CANOPY/DRAFT HOOD

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 23

CANOPY/DRAFT HOOD MOUNTING DIAGRAM

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 24

EXPLODED VIEW OF JACKET

5011B THRU 5019B SECTION BOILERS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

22. INSTALLATION OF TOP FRONT JACKET PANEL

a. Remove knockout for supply piping (right or left for

water boilers – both knockouts for steam boilers)

refer to recommended boiler piping diagrams in this

manual.

b. Attach Top Front Jacket Panel to left and right end

Jacket Panel and to Top Flange on the Vestibule

Panel using #8 SMS. See Fig. 24.

23. INSTALLATION OF LEFT AND RIGHT TOP SIDE

JACKET PANEL

a. Remove knockout, right or left, only if needed.

(See Fig. 7 for purpose of tappings), secure top side

panels to upper end panels with #8 SMS.

24. INSTALL KNOBS on the four remaining panels using

#10-32 x 3/16” MS.

25. INSTALL UPPER FRONT, LOWER FRONT, UPPER

REAR AND LOWER REAR PANELS using procedure

described in detail “A” of Fig. 25.

Panel with louvers must be at front of boiler for

ventilation of vestibule. Panel with perforations

must be at front of boiler for ventilation and

combustion air.

26. TIGHTEN ALL SHEET METAL SCREWS.

27. INSTALL THE FOLLOWING PLATES OR LABELS

which are found in the Instruction Envelope. See Fig.

21 or 24 for location.

(1) Rating Label

(2) Operating Instruction Plate (#8 SMS required to

fasten)

(3) Combustible Clearance Flooring & Adequate

Combustion Plate

(4) Minimum Service Clearance Label (self-adhesive)

(5) Burnham Logo (self-adhesive) – Apply to Top

Panel

(6) Boiler Ventilation For Your Safety Label – Apply

to Top Panel

(7) Proceed to Paragraph 33 (Steam Boilers) or

Paragraph 34 (Water Boilers).

COMPLETION OF JACKET INSTALLATION 5011B

THRU 5026B SECTION BOILERS.

28. PARAGRAPHS 1 THRU 4 HAVE ALREADY BEEN

COMPLETED. Refer to Paragraph 16 for installation

of lower framework.

a. Install Vestibule Panel(s) – refer to Fig. 21 and 24.

Attach Hex Couplings to end of Carriage Bolts

which secure Flue Cover Plates.

NOTE: Select Carriage Bolts which line up with holes

in the Vestibule Panel(s).

b. Attach Intermediate Vestibule Panel(s) to one of the

Vestibule Panel(s) using #8 SMS.

c. Secure Left and Right Vestibule Panels to Hex

Couplings using ¼”-20 x 3/8” slotted pan head

machine screws.

d. Attach the Lower Rear Intermediate Panels to the

Lower Rear Intermediate Panel Support Bracket(s)

using #10-32 x ½” self tapping screws.

e. Attach the Upper Rear Intermediate Panel(s) to the

Lower Rear Intermediate Panel(s) using #8 SMS.

f. Attach Rear Top Intermediate Jacket Panel(s) to Rear

Top Left and Right Jacket Panels using #8 SMS.

g. Place Assembled Rear Top Jacket Panel in position

and attach to Upper End Panels and Upper Rear

Intermediate Panel using #8 SMS.

i. INSTALLATION OF CANOPY-DRAFT HOOD

5011B THRU 5026B SECTION BOILERS –

these boilers require two or more Canopy-Draft

Hoods – refer to Fig. 6 for proper arrangement.

Determine where ends of Canopy-Draft Hood

rest on intermediate sections. Place 1” x 14-1/2”

Cerafelt strips on top of intermediate section at

these locations. Place Cerafelt strips on top of

section assembly next to ledges formed by center

sections and next to ledges on end sections.

Overlap at corner.

ii. SECURE CANOPY-DRAFT HOODS with

machine screws and bolts as shown in Fig.

23. Select the type of fastener indicated and

drive them into the Tapped Lugs provided for

this purpose on top of the sections. Where two

Canopy-Draft Hoods join together, the securing

tabs will overlap.

iii. Attach the Front Intermediate Panel to the Front

Intermediate Panel Support Bracket(s), using

#10-32 x ½” self tapping screws.

29. INSTALLATION OF TOP FRONT JACKET PANELS

a. Remove knockout for supply piping. Refer to

recommended boiler piping diagrams in this manual.

b. Attach Top Front Jacket Panels to left and right end

Jacket Panels and also to top ange on the Vestibule

Panel using #8 SMS. Refer to Fig. 25 or 26.

30. PLACE TOP INTERMEDIATE PANEL(S) ON TOP

OF LEFT AND RIGHT PANELS, making sure that

Front Intermediate Panel(s) is under Top Intermediate

Panel(s). Secure Top Intermediate Panel using #8 SMS.

31. INSTALL KNOBS ON THE UPPER FRONT AND

UPPER REAR PANELS using #10-32 x 3/16” MS.

Install Upper Front, Lower Front, Upper Rear and

Lower Rear Panels using procedure we described in

detail “A” of Fig. 25 or 26.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 25

EXPLODED VIEW OF JACKET

5020B THRU 5022B SECT. BOILERS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

Panel with louvers must be at front of boiler for

ventilation of vestibule. Panel with perforations

must be at front of boiler for ventilation and

combustion air.

FIG. 26

EXPLODED VIEW OF JACKET

5024B AND 5026B SECT. BOILERS

SECTION III – INSTALLATION INSTRUCTIONS (continued)

Panel with louvers must be at front of boiler for

ventilation of vestibule. Panel with perforations

must be at front of boiler for ventilation and

combustion air.

FIG. 27

STEAM TRIM AND CONTROLS

32. TIGHTEN ALL SHEET METAL SCREWS.

a. Install the following plates or labels which are found

in the Instruction Envelope. See Fig. 25 or 26 for

location.

(1) Rating Label

(2) Operating Instruction Plate (#8 SMS required to

fasten)

(3) Combustible Clearance Flooring & Adequate

Combustion Plate

(4) Minimum Service Clearance Label

(5) Burnham Logo – Apply to Top Panel

(6) Boiler Ventilation/For Your Safety Label

b. Proceed to Paragraph 33 (Steam Boilers) or

Paragraph 34 (Water Boilers).

NOTE: IF WATER BOILER, PROCEED DIRECTLY

TO Paragraph 34.

33. INSTALL STEAM TRIM AND CONTROLS, See

Fig. 7 and 27.

a. Pressure Gauge is to be installed with ½” nipple and

½” x ¼” reducing coupling in ½” tapping provided

in upper corner of End Section using wrench applied

to square shank on back of gauge. DO NOT APPLY

FORCE ON GAUGE CASE.

b. Install 67BC-2 Low Water Cut-Off or 47-2

Combination Feeder and Low Water Cut-Off in

accordance with the Instructions packed with the

control. ½” pipe extensions are provided and must

be installed in the ½” tappings adjacent to the

Pressure Gauge before the control can be mounted.

Unions are furnished with the 67BC-2 Low Water

Cut-Off for ease of installation. 1” pipe tappings

have been provided in the End Sections for other

types of Low Water Cut-Offs and Low Water Cut-

Off & Feeder combinations. Fig. 28 illustrates the

required mounting elevations for a M&M 150 and a

67M oat LWCO. Fig. 15 illustrates a typical steam

piping arrangement for pumped return systems.

c. Install Gauge Glass Fittings into ends of tees used

to connect the 67BC-2 or 47-2 Control. If other

control is furnished, install Gauge Glass Fitting

directly into ½” pipe extensions.

d. Install Pressure Limit Controls as follows:

(1) Boiler equipped with 67BC-2 Low Water Cut-

Off – Connect Pressure Limit furnished to ¼”

street ell and ¼” pigtail siphon. For installation

of second pressure limit (not furnished), bush

1½” pipe tapping in upper corner of End

Section. Connect Pressure Limit to this bushing

with ¼” pigtail siphon.

(2) Boiler equipped with Low Water Cut-Off other

than (1) above or with Low Water Cut-Off

Feeder Combination – Bush 1½” pipe tapping

in upper corner of End Section and connect

Pressure Limit furnished to this bushing with

¼” pigtail siphon. For installation of second

pressure limit bush any available tapping on

opposite end section that is above normal water

line. Connect Pressure Limit to this bushing

with ¼” pigtail siphon.

(3) Tighten limit controls by using wrench on hex

tting at bottom of control.

(4) The L404 Pressuretrol must be accurately

leveled for proper operation. It is level when the

leveling indicator hangs freely with its pointer

directly over the index mark inside the back

of the case. Level the controller by carefully

bending the steam trap (siphon loop).

e. Install Pressure Safety Valve with ttings furnished,

into 1½” pipe tapping in upper corner of End

Section, see Fig. 12. DO NOT INSTALL A

SHUTOFF VALVE BETWEEN SAFETY VALVE

AND BOILER. If this boiler tapping is to be used

as Surface Blowoff, replace ell with tee and plug

open end of tee or valve off opening. Pressure

Safety Valve must be in leg of tee and in a vertical

position with handle up.

f. Install Boiler Drain Valve and 3” x ¾” Bushing into

one of the two return tappings. The drain valve

may also be installed in return piping, but it must

be installed in the leg of a tee so that it is directly

opposite and as close as possible to the return

tapping. The leg of the tee must be at least 1½” pipe

size.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 28

MOUNTING ELEVATIONS OF M&M 150 AND A 67M FLOAT LWCO

SECTION III – INSTALLATION INSTRUCTIONS (continued)

A Bottom Blowoff using a valve must also be

connected to one of the return tappings. The ¾”

Drain Valve may be used for Bottom Blowoff for

5009B or smaller boilers, since any Bottom Blowoff

piping or valves for 5009B or smaller boilers must

be at least ¾”. Bottom Blowoff piping and valves

for Boilers 5010B through 5021B must be at least

1”. Bottom Blowoff piping and valves for 5022B

Boilers and larger must be at least 1¼”.

g. If boiler has been ordered with 3/8” try-valve

tapping, install try-cock.

h. Install “Lowest Permissible Water Level Plate”

and “Frequent Water Addition – Caution Label” on

upper left end jacket panel.

i. Proceed directly to Paragraph 36.

34. INSTALL WATER TRIM AND CONTROLS, see

Fig. 7 and 29.

a. Temperature Gauge is to be installed with ½”

nipple and ½” x ¼” reducing coupling in ½”

tapping provided in upper corner of End Section

using wrench applied to square shank on back of

gauge. DO NOT APPLY PRESSURE ON GAUGE

GLASS.

b. Install Temperature Limit Controls as follows:

Bush 1-1/2” tapping in upper corner of End Section

to ¾” and install Temperature Limit Control

furnished following instructions supplied with

control. On boilers without Built-in Tankless

Heater, install second temperature limit control (not

furnished) in Tapped Heater Opening Cover Plate.

FIG. 29

WATER TRIM AND CONTROLS

On boilers with Built-in Tankless Heater, install

operating control in ¾” tapping in Heater Plate-plug

tapping in Second Heater when supplied.

c. On boilers equipped for forced circulation hot

water heating without domestic hot water, a reverse

acting circulator control may be needed to prevent

condensation of ue gases during periods of low

boiler water temperature. This control can be

installed in the Tapped Heater Opening Cover Plate.

d. TANKLESS HEATER PERFORMANCE

Tankless heater ratings in Series 5B boilers are

based on continuous draw, temperature rise of 100ºF

(40-140ºF) and boiler water temperature of 200ºF.

Some of the items affecting the coil performance are

as follows:

(1) FLOW REGULATION – If ow through the

heater is greater than its rating, the supply of

adequate hot water may not be able to keep

up with the demand. For this reason a FLOW

REGULATOR matching the heater rating should

be installed in the cold water line to the heater.

(2) FLUSHING OF HEATER - All water contains

some sediment which settles on the inside of

the coil. Consequently, the heater should be

periodically back-washed. This is accomplished

by installing hose bibs as illustrated in Fig. 30

and allowing water at city pressure to run into

hose bib A, through the heater, and out hose bib

B until the discharge is clear. The tees in which

the hose bibs are located should be the same size

as heater connections to minimize pressure drop.

(3) HARD WATER – This is applicable to some

city water and particularly to well water. This

should not be a deterrent but precautions are

necessary. A water analysis is necessary and an

appropriate water softener installed. This is not

only benecial to the heater but to piping and

xtures plus the many other benets derived

from soft water.

NOTE: A hot water boiler installed above radiation

level must be provided with a low water cut-off

device as part of the installation.

Install automatic mixing valve at tankless heater

outlet to avoid risk of burns or scalding due to

excessively hot water at xtures. Adjust and

maintain the mixing valve in accordance with the

manufacturers instructions.

e. Following recommendations supplied with control,

install #64 Low Water Cut-Off in 1” pipe tapping

“H” (Fig. 7) and System Return Piping. Control

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 30

RECOMMENDED PIPING TO

BUILT-IN TANKLESS HEATERS

TABLE I - NATURAL GAS

Maximum Capacity of Piping in Cubic Feet of Gas Per Hour

(Based on a Pressure Drop of 0.3” Water

and 0.6 Specic Gravity)

Pipe

Length

in Feet

NOMINAL IRON PIPE SIZE IPS INCHES

¾ 1 1¼ 1½ 2 2½ 3 4

10 278 520 1050 1600 3050 4800 8500 17500

20 190 350 730 1100 2100 3300 5900 12000

30 152 285 590 890 1650 2700 4700 9700

40 130 245 500 760 1450 2300 4100 8300

50 115 215 440 670 1270 2000 3600 7400

60 105 195 400 610 1150 1850 3250 6800

70 96 180 370 560 1050 1700 3000 6200

80 90 170 350 530 990 1600 2800 5800

90 84 160 320 490 930 1500 2600 5400

100 79 150 305 460 870 1400 2500 5100

125 72 130 275 410 78 1250 2200 4500

150 64 12 250 380 710 1130 2000 4100

175 59 110 225 350 650 1050 1850 3800

200 55 100 210 320 610 980 1700 3500

TABLE II

Multipliers to be used with Table I when Pressure Drop is not 0.3”

Pressure Drop Multiplier

0.1 .577

0.2 .815

0.5 1.29

1.0 1.83

0.3 1.00

TABLE III

Multipliers to be used with Tables I and II for

Specic Gravity Other than 0.60

Specic Gravity Correction Factors

.50 1.10

.55 1.04

.60 1.00

.65 .96

.70 .93

36. OPEN GAS TRAIN CARTON(S)

CONNECT GAS TRAIN(S) TO ELBOW ON END OF

MANIFOLD(S) according to the Gas Trains on pages

90 thru 96. On those boilers with two manifolds (15

sect. and larger), two identical sets of Gas Controls are

furnished. Hence, the procedure for installing one set is

equally applicable to the second set.

PRESSURE TESTING of gas service piping must be

done before connecting to the boiler gas train. Test for

leaks by introducing, from an isolated source, air or

inert gas to the piping. Piping shall withstand 3 PSI

gage pressure for a period of not less than 10 minutes

without showing any drop in pressure.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

must be mounted so that cut off point is above

marking on Lowest Permissible Water Line Plate.

f. Install Pressure Safety Relief Valve, using ttings

furnished, into 1-1/2” pipe tapping in upper corner

of End Section. DO NOT INSTALL A SHUTOFF

VALVE BETWEEN SAFETY RELIEF VALVE

AND BOILER. Safety Relief Valve must be

installed in a Vertical Position with handle up.

g. Install Boiler Drain Valve into one of unused return

tappings that has been bushed to ¾”. Drain Valve

can also be installed in return piping, preferably

in leg of tee that is located in line with return

connection on Boiler.

35. CONNECT PIPING TO BUILT-IN HEATER(S) IF

USED, see Fig. 30, top - left side of this page.

38. THE INSTALLATION OF THE REMAINDER OF THE GAS CONTROLS IS DEPENDENT ON THE CONTROL

SYSTEM FURNISHED. REFER TO THE TABLE BELOW FOR THE FIGURES IN THIS MANUAL APPLICABLE

TO THE VARIOUS CONTROL SYSTEMS OFFERED AS STANDARD OR AS OPTIONAL EQUIPMENT. IF THE

CONTROL SYSTEM ORDERED IS NOT LISTED, SPECIAL INSTRUCTIONS HAVE BEEN PREPARED BY THE

APPLICATION ENGINEERING DEPARTMENT AND CAN BE FOUND IN THE INSTRUCTION ENVELOPE

FURNISHED WITH THE BOILER.

BOILER SIZE CONTROL

SYSTEM

NATURAL GAS LP

REFERENCE

FIGURES

USA CANADA USA CANADA

STD OPT STD OPT STD OPT STD OPT

6 thru 9 sect. EI X --- --- X X --- --- --- 31, 32

10 thru 26 sect. EI X --- --- X --- --- --- --- 31, 33

6 thru 26 sect. EI --- X --- --- --- --- 31, 33

6 thru 14 sect. EP --- X --- X --- --- --- --- 34, 35

15 thru 26 sect. EP --- X --- X --- --- --- --- 34, 35

6 thru 13 sect. Thermocouple --- --- X --- --- --- --- --- 36, 37

15 thru 24 sect. Thermocouple --- --- X --- --- --- --- --- 36, 37

37. A DRIP LEG SHOULD BE PROVIDED IN THE

VERTICAL DROP TO EACH GAS TRAIN, see

Fig. 1. An additional Manual Shut-off valve and

ground joint union, as show in Fig. 1, should be

installed in the piping to each gas train for ease of

servicing.

CONNECT GAS SERVICE FROM METER TO GAS

TRAIN in accordance with the requirements of the

authority having jurisdiction or, in the absence of such

requirements to the –

USA – “National Fuel Gas Code, ANSI Z223.1”.

CANADA – “Installation Codes for Natural and LP Gas

Burning Appliances and Equipment, CAN/B149.1 &

.2”.

The size of the gas train(s) has no criteria as to the size

of the service from the meter to the gas train(s). Sizing

of the service is dependent on:

a. Required supply of gas in cu. ft./hr.

input of boiler in BTUH

= heat value of gas,

BTU/cu. ft.

b. Allowable loss of pressure in piping to obtain

minimum input pressure indicated on rating label of

boiler.

c. Length of piping in feet and number of elbows – for

practical purposes each 90º elbow can be considered

as the following equivalent in length of straight

pipe:

3/4” - 2.1 ft. 2” - 5.2 ft.

1” - 2.6 ft. 2-1/2” - 6.2 ft.

1-1/4” - 3.5 ft. 3” - 7.7 ft.

1-1/2” - 4.0 ft. 4” - 10.1 ft.

d. Specic gravity of gas

In the absence of requirements of the authority

having jurisdiction, the tables below may be used to

size natural gas supply piping.

A pipe thread compound resistant to the action

of liqueed petroleum gases must be used on all

threaded joints in the gas piping.

Pressure testing of the Gas Supply Piping Boiler and

its connections is required before placing the boiler

in operation.

The boiler and shutoff valve must be disconnected

from the gas supply piping system during any

pressure testing at pressures greater than ½” psig.

The boiler must be isolated from the gas supply

piping system during any pressure testing at

pressures equal to or less than ½ psig.

WITH GAS SUPPLY “OFF” and Service Piping

connected to the boiler, open Manual Valve(s) and

pilot valve(s) at end of Gas Train(s) and reduce

pressure to ½ lb. gage pressure. Using soap solution

or other approved method check gas train piping,

pilot piping, bleed piping and orices for leaks.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 31

INSTALLATION OF S8610M MODULE

EI Control System

1. INSTALLATION OF GAS VALVE TRANSFORMER

AND PILOT PIPING (for Robertshaw Pilot Piping,

see Fig. 32) – Attach the bracket for mounting of the

junction box to the lower front corner of the Jacket

Upper End Panel using two #10-32 x ½” MS and nuts.

Mount junction box to bracket using #8 SMS, see Fig.

27 or 29. Connect pilot solenoid valve to bottom center

knockout of J-box using conduit ttings furnished,

(V88 Gas Train only) see Fig. 33. Mount transformer

on J-box. If Foot Mounted Transformer, connect to

J-box with Straight Connector, BX, Straight Connector

and ½” pipe coupling. Drill holes in Jacket and fasten

Transformer using SMS. Install RV-12LT pilot line

regulator (packed in Gas Train Carton) and other 1/8”

pipe ttings as shown in Section VI, Repair Parts (V88

Gas Train only).

Using ¼” OD aluminum tubing, connect the inlet of

the pilot solenoid valve to the pilot valve installed in

the manual shut off valve in the Gas Train. Using ¼”

aluminum tubing, complete installation to Pilot Burner,

see Fig. 33 (V88 Gas Train only).

2. INSTALLATION OF BLEED PIPING (V88 Gas Train

only) – Using ¼” OD aluminum tubing, install a bleed

line on both diaphragm gas valves, connect together,

and, on USA boilers, run tubing to bleed line protruding

from inside base, see Fig. 33. On boilers installed in

Canada, run bleed line to outdoors.

3. INSTALLATION AND WIRING OF S8610M

IGNITION CONTROL MODULE – Using two #10-32

x 2” MS, and nuts, install the S8610M module bracket

on the manifold just to the right of the main burner

SECTION III – INSTALLATION INSTRUCTIONS (continued)

with pilot, see Fig. 31. Using two #6 x ¾” SMS, install

the S8610M module on the bracket. Connect the two

wires from the Q3481B pilot to the S8610M module as

shown on Fig. 40, 41 or 42.

a. Ground Wire (200ºC) to “BNR GND” terminal

b. Ignition Sensor Wire to “Spark” terminal

Secure these wires to Pilot Piping with Wire Tie to

provide strain relief.

Using wiring harness furnished, connect leads with

push-on terminals on S8610M module as shown in

Fig. 40, 41 or 42. Run harness outside of jacket on

underside of manifold and secure in this position

with Wire Ties furnished. Connect the six wires in

the harness to the specied controls as shown in Fig.

40, 41 or 42.

FIG. 32

PILOT PIPING - EI CONTROL SYSTEM

(Robertshaw7000)

U.S.A. 5006B THRU 5009B

FIG. 33

PILOT PIPING - EI CONTROL SYSTEM (V88A)

U.S.A. 5010B THRU 5026B - NAT. GAS

CANADA - 5006B THRU 5026B - NAT. GAS

4. COMPLETION OF WIRING – Connect power supply

fused disconnect switch, service switch, primary side

of transformer, gas valves and remaining controls – see

Fig. 40, 41 or 42 for wire type and connections to be

made. All wiring must be adequately supported and

strain relief provided. All wiring including ground

connections must comply with the requirements of

the authority having jurisdiction and, in the absence

of such, to the National Electrical Code, ANSI NFPA

No. 70-2005, or the Canadian Electrical Code, C22.1,

whichever is applicable.

EP Control System

1. INSTALLATION OF “EP PANEL”, - Attach the EP

Control Panel with RM7890 control, see Fig. 34, to the

front top jacket panel, preferably on the closest jacket

panel to the gas train installed. There are (3) three KO’s

and (4) four fastening holes provided for this purpose,

use (4) four #8 SMS to fasten the Control Panel to the

front top jacket panel. If Foot Mounted Transformer,

connect to J-box using straight connector, BX, straight

connector and ½” pipe nipple. Drill holes in Jacket

and fasten Transformer using SMS. Install Honeywell

SECTION III – INSTALLATION INSTRUCTIONS (continued)

RM7890 Control (located in RM7890 Control Carton)

onto prewired sub base.

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. Install Honeywell R7847 Flame Amplier.

Install heat shield (optional).

2. INSTALLATION OF PILOT PIPING – Install the

H91WA-4 pilot solenoid valve in the bottom center

knockout of the J-box using conduit ttings furnished,

see Fig. 35. Install RV-12LT regulator, (Packed in Gas

Train Carton) and 1/8” tee in the ¼” OD pilot tubing as

shown in Fig. 35.

3. INSTALLATION OF BLEED PIPING – Using ¼” OD

aluminum tubing, install a bleed line on both diaphragm

valves, connect together, see Fig. 35, and, on USA

boilers, run tubing to bleed line protruding from inside

base, see Fig. 35. On boilers installed in Canada, run

bleed line to outdoors.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

FIG. 34

INSTALLATION OF EP CONTROL PANEL

FIG. 35

PILOT PIPING - EP CONTROL SYSTEM

NOTE - PILOT PIPING DUPLICATED ON

15 SECT. AND LARGER BOILERS.

4. INSTALLATION OF IGNITION TRANSFORMER

AND WIRING OF PILOT – If space permits, mount

the ignition transformer on the Jacket above the Gas

Train using four #8 x ½” SMS. Holes will have to

be drilled for this purpose. If space does not permit

mounting the Ignition Transformer on the Jacket, install

the Ignition Transformer on a nearby wall.

Connect the two wires from the Q179C pilot to the

RM7890 sub-base as follows:

a. Ground Wire (200ºC) to the “12” terminal

b. Flame detector wire (Honeywell 1298020) to “11”

terminal

c. Ignition Cable (Honeywell 1061012) to the

Secondary (High Voltage) terminal of the Ignition

Transformer

Run these wires to outside of jacket on underside of

manifold and secure in this position with Wire Ties

furnished to provide strain relief. Provide adequate

support and strain relief for wiring outside jacket.

5. COMPLETION OF WIRING – Connect power supply

fused disconnect switch, service switch, primary and

secondary side of gas valve transformer, primary side

of ignition transformer, and remaining controls – see

Fig. 44 for wire type and connections to be made. All

wiring must be adequately supported and strain relief

provided. All wiring including ground connections

must comply with the requirements of the authority

having jurisdiction and, in the absence of such, to the

National Electrical Code, ANSI NFPA No. 70-2005,

or the Canadian Electrical Code, C22.1, whichever is

applicable.

Thermocouple Control System

1. INSTALLATION OF PILOT SAFETY SWITCH AND

PILOT PIPING - Using two #10-32 x 2” MS and nuts,

install the L62GB-3C pilot safety switch bracket on

the manifold just to the right of the main burner with

pilot. Install L62GB-3C pilot safety switch on bracket

using two #10-32 x ½” MS. “IN” on pilot safety switch

should be pointed in the direction of the Gas Train to

which the pilot safety switch is to be connected, see

Fig. 37.

Using ¼” OD aluminum tubing, connect the pilot

shutoff valve installed in the manual shutoff valve

in the gas train, to the inlet of the RV-12LT regulator

(packed in Gas Train Carton). Regulator should be

above Gas Train and near front of boiler, see Fig. 36.

Install 3/8” tee into outlet of regulator (USA boilers)

and, using ¼” OD aluminum tubing, connect outlet of

tee to “IN” connection on pilot safety switch, see Fig.

36.

Using ¼” OD aluminum tubing, connect the outlet of

the pilot safety switch to the tubing or tting connected

to the pilot burner, see Fig. 36.

Connect Q309 thermocouple to pilot safety switch.

Connect power supply fused disconnect switch,

service switch, primary and secondary of Gas Valve

Transformer, gas valves, and other controls - see Fig’s

46 and 47 for wiring type and connections to be made.

All wiring must be adequately supported and strain

relief provided.

All wiring including ground connections must

comply with the requirements of the authority having

jurisdiction and, in the absence of such to the National

Electrical Code, ANSI NFPA No. 70-2005.

2. INSTALLATION OF GAS VALVE TRANSFORMER

AND COMPLETION OF WIRING - Attach the bracket

for mounting of the junction box to the lower front

corner of the Jacket Upper End Panel using two #10-

32 x ½” MS and nuts. Mount junction box to bracket

using #8 SMS, see Fig. 36. Install Transformer on

junction box.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

“THERMOCOUPLE CONTROL SYSTEM”

CANADA ONLY

FIG. 36

PILOT PIPING

THERMOCOUPLE CONTROL SYSTEM

CANADA ONLY

FIG. 37

NOTE - TWO PILOT SAFETY SWITCHES REQUIRED ON 15 SECT. AND LARGER BOILERS.

INSTALLATION OF PILOT SAFETY SWITCH

THERMOCOUPLE CONTROL SYSTEM

SECTION III – INSTALLATION INSTRUCTIONS (continued)

Venting

1. INSTALL VENT CONNECTOR from canopy Draft

Hood or damper to chimney maintaining 6” clearances

from combustible materials.

2. INSTALL VENT SYSTEM – Typical vent systems are

shown in Fig. 38 and 39. Some of the factors affecting

vent sizing and construction accompany these gures.

Vent installation shall be in accordance with local

building codes; or the local authority having

jurisdiction; or the National Fuel Gas Code, ANSI

Z223.1/NFPA 54; or the Standard for Chimneys,

Fireplaces, Vents and Solid Fuel Burning Appliances,

ANSI/NFPA 211. Both of the aforementioned

standards, ANSI Z223.1 and ANSI/NFPA 211,

specify Type B and Type L double wall metal vents

and re clay tile lined masonry chimneys as suitable

chimney constructions for Category I, draft hood

equipped appliances, such as this Series 5B boiler.

Both standards prohibit the use of unlined masonry

construction as a chimney, with the exception in

ANSI Z223.1/NFPA 54 that “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 efciency.” ANSI/NFPA 211

prohibits the use of single wall metal vent as a chimney,

while ANSI Z223.1 allows it under very restrictive

conditions.

In Canada, refer to CAN/CSA-B149.1 or .2-M86 and

local codes for venting.

SOME ITEMS RELATIVE TO CONSTRUCTION

AND SIZING OF VENT SYSTEM

(1) Total Vent Height.

(2) Vent Connector – make Initial Rise as high as

possible.

(3) Length of Lateral – hold to a minimum.

(4) Number of Elbows – hold to a minimum.

(5) UL Listed Vent Cap – assures full vent capacity

and freedom from adverse wind effects.

(6) Locate Boiler as close to Chimney as possible

consistent with necessary clearances, see page 10,

lower table.

(7) Run Breaching Horizontal and slope upward to

Chimney maximum of ¼” per ft.

(8) Use thimble where Breaching enters masonry

chimney – keep breaching ush with inside of ue

liner – do not connect into same leg of chimney

serving an open replace.

(9) Install vent above bottom of Chimney to prevent

blockage – inspect chimney for obstructions

or restrictions and remove – clean chimney if

necessary.

FIG. 38

SINGLE VENT SYSTEM

FIG. 39

MANIFOLD VENT SYSTEM

(10) Provide cleanout in chimney.

(11) Slip joint or draw band – facilitates installation and

future servicing when necessary.

(12) Venting of other appliances into same chimney

or into a common vent will affect sizing of the

chimney or common vent.

(13) Correction for altitude – design vent system for sea

level input.

(14) Provide adequate ventilation of Boiler Room, see

page 10 – this cannot be overemphasized.

(15) Never pass any portion of a vent system thru a

circulating air duct or plenum.

(16) Support of lateral runs so that vent pipe does not

sag.

(17) Support of common vent where it passes thru a

ceiling or roof.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

(18) Clearances to combustible material – use of

thimbles.

(19) Firestops.

(20) Flashing and storm collars.

(21) Guying or bracing of common vent pipe above

roof.

(22) Securing and gas tightness of joints.

(23) Lightning arrester if top of metal vent is one of

highest points on the roof.

Where choice is possible, many advantages can be

listed for the UL Listed double wall metal type B vent:

1. Warm up is faster with type B vents than vents

having greater mass.

2. Type B vents permit closer clearance to

combustible material than single wall metal

vents unless special precautions are taken with

the latter.

3. Type B vents are less prone to condensation and

corrosion than single wall metal vents.

4. Type B vents are lightweight, easy to handle and

assemble.

SECTION III – INSTALLATION INSTRUCTIONS (continued)

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. 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.

A. SEAL ANY UNUSED OPENINGS IN THE COMMON VENTING SYSTEM.

B. VISUALLY INSPECT THE VENTING SYSTEM FOR PROPER SIZE AND HORIZONTAL PITCH AND DETERMINE

THERE IS NO BLOCKAGE OR RESTRICTION, LEAKAGE, CORROSION AND OTHER DEFICIENCIES WHICH

COULD CAUSE AN UNSAFE CONDITION.

C. 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 VENTING SYSTEM

ARE LOCATED AND OTHER SPACES OF THE BUILDING. TURN ON CLOTHES DRYER 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.

D. PLACE IN OPERATION THE APPLIANCE BEING INSPECTED. FOLLOW THE LIGHTING INSTRUCTIONS.

ADJUST THERMOSTAT SO APPLIANCE WILL OPERATE CONTINUOUSLY.

E. 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.

F. 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 OTHER GAS BURNING APPLIANCE TO THEIR PREVIOUS

CONDITIONS OF USE.

G. ANY IMPROPER OPERATION OF THE COMMON VENTING SYSTEM SHOULD BE CORRECTED SO THE

INSTALLATION CONFORMS WITH THE NATIONAL FUEL GAS CODE, 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 CHAPTER

10 IN THE NATIONAL FUEL GAS CODE, ANSI Z223.1.

SECTION IV - OPERATION

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler

when the boiler underwent tests specied in ANSI Z21.13.

1. GENERAL

a. INITIAL FILL – Before putting water into a new

boiler, make certain that the ring equipment is in

operating condition to the extent that this is possible,

without actually ring into an empty boiler. This

is necessary because raw water must be boiled

[or heated to at least 180ºF] promptly after it is

introduced into the boiler in order to drive off the

dissolved gases which might otherwise corrode the

boiler.

b. PURGE GAS PIPING OF AIR – Check Manual

Shut Off Valve(s) and Pilot Shut Off Valve(s) at

boiler to see that they are closed. Turn gas on

at meter. Disconnect Pilot Tubing at Pilot Shut

Off Valve(s), open Pilot Valve(s) until gas ows

from valve(s) KEEPING A CONSTANT CHECK

DURING THE PURGING. Close pilot valve(s)

and reconnect the pilot tubing. (In Canada, refer

to applicable Installation Codes for purging

procedure.)

c. SINCE LIGHTING INSTRUCTIONS,

SHUTDOWN INSTRUCTIONS, AND CONTROL

SEQUENCE OF OPERATION VARY WITH

GAS CONTROL SYSTEM INSTALLED,

REFERENCE SHOULD NEXT BE MADE TO

THE APPLICABLE CONTROL SYSTEM:

wasted, operate boiler only for the length of time it

takes for condensate to run clear. If the latter cannot

be achieved or if the condensate is returned to the

boiler, boil out the boiler using the surface blowoff

connection. See Fig. 7.

a. Drain boiler until water is just visible in gauge

glass. Run temporary 1½” pipe line from the

surface blowoff connection to an open drain or

some other location where hot water may be

discharged safely. Do not install valve in this

line.

b. Add an appropriate amount of recommended boil

out compound.

c. Start burner and operate sufciently to boil

the water without producing steam pressure.

Boil for about 5 hours. Open boiler feed pipe

sufciently to permit a steady trickle of water

from the surface blowoff pipe. Continue this

slow boiling and trickle of overow for several

hours until the water coming from the overow

is clear.

d. Stop burner and drain boiler in a manner and to

a location that hot water can be discharged with

safety.

e. Rell boiler to normal water line. If water in

gauge glass does not appear to be clear, repeat

steps (a. through c.) and boil out the boiler for a

longer time.

2. Low pressure steam boilers such as the 5B series

should be maintained with appropriate water

treatment compounds. Add suitable water treatment

compounds as recommended by your qualied water

treatment company.

3. Remove temporary surface blowoff piping, plug

tapping and reinstall safety valve. Boil or bring

water temperature to 180ºF promptly in order to

drive off the dissolved gases in the fresh water.

4. If unsteady water line, foaming or priming persist,

install gate valve in Hartford Loop and drain valves

in return main and at boiler and proceed as follows:

a. Connect hoses from drain valves to oor drain.

Close gate valve in Hartford Loop and open

drain valve in return main. Fill boiler to normal

water level, turn on burner and operate boiler

at this water level for at least 30 minutes after

the condensate begins to run hot, then turn off

burner.

Close all radiator valves. Remove all supply

main air valves and plug the openings in supply

main.

EI Control System - Page 46

EP Control System - Page 52

THERM Control System - Page 57

Check all electrical circuits and connections. Then

follow lighting instructions up to a point where the

boiler is ready to light.

2. BOILER AND SYSTEM CLEANING

INSTRUCTIONS FOR TROUBLE FREE

OPERATION

A qualied water treatment chemical specialist

should be consulted for recommendations regarding

appropriate chemical compounds and concentrations

which are compatible with local environmental

regulations.

A. Steam Boilers

1. Oil, greases & sediments which accumulate in a

new boiler and piping must be removed in order

to prevent an unsteady water line and carry over

of the water into the supply main above boiler.

Operate the boiler with steam in the entire system

for a few days allowing the condensate to return

to the boiler. If the condensate can temporarily be

b. Draw about 5 gallons of hot water from

boiler into a container and dissolve into it the

appropriate amount of a recommended boilout

compound. Remove safety valve from boiler

and pour this solution into boiler, then reinstall

safety valve.

c. Turn on burner and keep operating while feeding

water to boiler slowly. This will raise water

level in boiler slowly into supply main and back

through return main, owing from drain hose

at about 180ºF. Continue until water runs clear

from drain hose for at least 30 minutes.

d. Stop feeding water to boiler but continue

operating burner until excess water in boiler

ows out through supply main and water lowers

(by steaming) until it reaches normal level in

boiler.

Turn off burner. Drain boiler. Open all radiator

valves. Reinstall all supply main air valves.

Open gate valve in Hartford Loop.

e. When boiler has cooled down sufciently

(crown-sheet of sections are not too hot to

touch), close the drain valves at boiler and in

return main and feed water slowly up to normal

level in boiler. Turn on burner and allow boiler

to steam for 10 minutes, then turn off burner.

Draw off one quart of water from bottom gauge

glass tting and discard. Draw off another quart

sample and if this sample is not clear, repeat the

cycle of draining the boiler and return main and

relling the boiler until sample is clear.

f. If the boiler water becomes dirty again at a later

date due to additional sediment loosened up in

the piping, close gate valve in Hartford Loop,

open drain valve in return main, turn on burner

and allow condensate to ow to drain until it has

run clear for at least 30 minutes while feeding

water to boiler so as to maintain normal water

level. Turn off burner, drain boiler, open gate

valve in Hartford Loop, then repeat step 1 above.

3. Make pH or Alkalinity Test

After boiler and system have been cleaned and

relled as previously described, test the pH of

the water in the system. This can easily be done

by drawing a small sample of boiler water and

testing with Hydrion paper which is used in the

Boiler Size Water Content (Gallons)

Water Boiler Steam Boiler

5006B 37.6 25.6

5007B 43.4 29.3

5008B 49.1 33.0

5009B 54.9 36.8

5010B 60.6 40.5

5011B 66.4 44.2

5012B 72.1 47.9

5013B 77.9 51.6

5014B 83.7 55.4

5015B 89.4 59.1

5016B 95.2 62.8

5017B 100.9 66.5

5018B 106.7 70.2

5019B 112.5 73.9

5020B 118.2 77.7

5021B 124.0 81.4

5022B 129.7 85.1

5024B 141.2 92.5

5026B 152.8 100.0

TABLE IV: WATER CONTENT

SECTION IV - OPERATION (continued)

Recommended Water Quality Requirements

pH: 8.3 - 10.5

TDS: < 3500 ppm

Total alkalinity ppm as CaCO3 : < 1200

Total copper ppm: < .05

Oily matter ppm: < -1

Total harness ppm: < -3

Chlorides: < 50 ppm

same manner as litmus paper, except that it gives

specic readings. A color chart on the side of

the small hydrion dispenser gives the reading in

pH. Hydrion paper is inexpensive and obtainable

from any chemical supply house or through your

local druggist. The pH should be in accordance

to “Minimum Water Quality Requirements” chart

below. Add some washout chemicals (caustic soda),

if necessary, to bring the pH within the specied

range. With this lower level of protection, care must

be exercised to eliminate all of the free oxygen in

the system.

4. Boiler is now ready to be put into service.

3. CONDENSATION

Following a cold start, condensation (sweating) may

occur in a gas red boiler to such an extent that it

CONTROL VARIATIONS

NATURAL GAS

MODEL NO. CONTROL

SYSTEM

TYPE OF

PILOT

GAS VALVES OPTIONAL MAIN

VALVES

REFERENCE

PAGE

PILOT MAIN

5006B-5009B (USA) EI Elec. Ign. (1) 7000DERHC-S7C (B) 47

5010B-5026B (USA)

5006B-5026B (CANADA) EI Elec. Ign. (1) H91WG-6 (2) V88A (B)** 48-50

5008B-5026B

(USA & CANADA) EP Elec. Ign. Q179C (1) H91WA-4 (2) V88A (A), (B)* 54 & 55

5006B-5013B (CANADA) 24V Standing (1) L62GB-3C (2) V88A (A), (B) 58

5015B-5024B (CANADA) 24V Standing (1) L62GB-3C (2) V88A (A), (B) 59

LP GAS

MODEL NO. CONTROL

SYSTEM

TYPE OF

PILOT

GAS VALVES OPTIONAL MAIN

VALVES

REFERENCE

PAGE

PILOT MAIN

5006B-5009B (USA) EI Elec. Ign. (1) 7000DERHC-S7C 47

(A) -- (1) Honeywell V5055B Motorized Gas Valve with V4055A/V4062A/V9055A Actuator and (1) ITT K3A

Solenoid Valve (120V)

(B) -- (1) Honeywell V8944B Combination Gas Valve and (1) ITT K3A Solenoid Valve (24V)

* -- To be used with (1) H91WA-4 Pilot Valve (120V)

** -- To be used with (1) H91WG-6 Pilot Valve (24V)

NOTE:

1. For Steam or Water

2. For 24V Thermostat Application - Wire S861OM Relay in Place of Operating Control Set Thermostat Heat

Anticipator at 0.4 Amp. See Pages 47, 48 and 49.

3. All Battery Operated Thermostats must be Electrically Isolated From the Primary Circuit by an Isolating Relay.

appears that the boiler is leaking. This condensation

can be expected to stop after the boiler is hot.

SECTION IV - OPERATION (continued)

4. EI CONTROL SYSTEM – The EI control system

utilizes a solid state ignition control which lights the

pilot burner by spark. Pilot gas is ignited and burns

during each running cycle (intermittent electric pilot).

Main burner and pilot gas are extinguished during the

“off” cycle.

This system permits the main gas valves

[Robertshaw7000 for 5006B thru 5009B, (2) V88A’s

for 5010B thru 5014B] to open, and the pilot line gas

valve to remain open, only when the Pilot Burner is

proven to be lit.

Should a loss of ame occur, the main valve closes

and the spark reoccurs within 0.8 second. The ignition

module has an internal 100% lockout function to

completely shutdown the system should the pilot gas

fail to ignite within approximately 90 seconds. 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.

a. OPERATING INSTRUCTIONS

(1) Make sure all Manual Main Shut-off Valves and

all Pilot Valves have been off for at least ve

minutes.

(2) Set Operating and Limit Controls to desired

settings.

(3) Turn all Manual Main Shut-Off Valves and Pilot

Valves to Open Position.

(4) Turn on Main Electric Switch and Service

Switch – Pilot(s) will automatically light main

burners.

b. NORMAL OPERATION SEQUENCE

5006B thru 5009B, see Fig. 40

5010B thru 5014B, see Fig. 41

5015B thru 5026B, see Fig. 42

c. SHUT DOWN INSTRUCTIONS

(1) Close manual shut-off valves and pilot valves.

(2) Turn off main electric switch.

d. SAFETY SHUTDOWN

(1) Safety Switch Circuit

If limit control, low water cut-off or any other

electrical safety switch opens, power to the 24V

terminal of all S8610M Ignition Controls is

interrupted thus de-energizing terminals PV and

MV. Loss of power to these terminals means

loss of power to all pilot gas valves and to main

gas valves, respectively. Thus, pilot burner and

main burner ames are extinguished.

Normal operation can be resumed when the

cause of safety switch malfunction is corrected.

Any controls with Manual Reset must be

reactivated.

(2) Pilot Failure

Pilot failure can occur during the start-up or

during the operating cycle of the boiler. Any

failure of a Q3481B pilot will close the main

gas valves controlled by this pilot within 0.8

second. For 90 seconds after pilot failure, the

Ignition Control will try to reestablish pilot

ame. If the pilot ame cannot be sensed by

the sensing probe, 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.

On 15 section and larger boilers, where two

manifolds, gas trains and pilot systems are

employed, failure of one pilot will not affect

operation of the other system. Thus, it is

possible to re the boiler at a reduced rate thru

one manifold while the other is inoperative.

Pilot failure is caused by one of the following:

(a) Pilot burns yellow resulting in weak signal

from sensor to Ignition Control – may be

due to dirt or lint that has covered the lower

portion of the pilot burner – remove with a

soft brush or by vacuuming.

(b) Loss of pilot gas – may be due to faulty

pilot solenoid valve, improper wiring, loose

connections, or low voltage.

faulty probe, improper or loose electrical

connection, or faulty Ignition Control.

Be sure power is off when checking high voltage

connections.

For S8610M Trouble Shooting Guide, see Page 51.

SECTION IV - OPERATION (continued)

FIG. 40

SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (ROBERTSHAW7000 GAS VALVE)

U.S.A. 5006B THRU 5009B

SECTION IV - OPERATION (continued)

FIG. 41

SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (V88 GAS TRAIN)

U.S.A. 5010B THRU 5014B

CANADA 5006B THRU 5014B

EI SEQUENCE OF OPERATION - 5006B THRU 5009B

WHEN OPERATING CONTROL CLOSES, THE ELECTRIC SPARK AND PILOT VALVE ARE AUTOMATICALLY

ENERGIZED. THE SENSING PROBE PROVES THE PRESENCE OF THE PILOT FLAME. INTERNAL SWITCH

ACTION DE-ENERGIZES THE SPARK AND ENERGIZES THE MAIN GAS VALVES STARTING MAIN BURNER

OPERATION. WHEN THE OPERATING CONTROL IS SATISFIED THE PILOT GAS VALVE AND THE MAIN GAS

VALVES ARE DE-ENERGIZED STOPPING THE BURNER OPERATION.

IN THE EVENT OF EXCESSIVE STEAM PRESSURE (STEAM BOILER) OR EXCESSIVE BOILER WATER

TEMPERATURE (WATER BOILER), THE HIGH LIMIT CONTROL WILL DE-ENERGIZE THE PILOT GAS VALVE

AND THE MAIN GAS VALVES STOPPING BURNER OPERATION.

THE LOW WATER CUT-OFF WILL ALSO STOP BURNER OPERATION IF THE WATER LEVEL IN THE BOILER

SHOULD DROP BELOW THE LOWEST SAFE LEVEL.

SECTION IV - OPERATION (continued)

FIG. 42

SCHEMATIC WIRING DIAGRAM - 5015B THRU 5026B SECTION BOILERS

EI CONTROL SYSTEM

SECTION IV - OPERATION (continued)

EI SEQUENCE OF OPERATION - 5010B THRU 5014B

WHEN OPERATING CONTROL CLOSES, THE ELECTRIC SPARK AND PILOT VALVE ON EACH SIDE ARE

AUTOMATICALLY ENERGIZED. THE SENSING PROBE ON EACH OF THE PILOTS PROVES THE PRESENCE

OF THE PILOT FLAME. INTERNAL SWITCH ACTION IN EACH IGNITION MODULE DE-ENERGIZES THE SPARK

AND ENERGIZES THE MAIN GAS VALVES FOR ITS RESPECTIVE GAS TRAIN, STARTING MAIN BURNER

OPERATION. WHEN THE OPERATING CONTROL IS SATISFIED THE PILOT GAS VALVE AND MAIN GAS

VALVES FOR EACH GAS TRAIN ARE DE-ENERGIZED STOPPING BURNER OPERATION.

IN THE EVENT OF EXCESSIVE STEAM PRESSURE (STEAM BOILER) OR EXCESSIVE WATER TEMPERATURE

(WATER BOILER) THE HIGH LIMIT CONTROL WILL DE-ENERGIZE THE PILOT VALVES AND MAIN GAS VALVES

ON BOTH SIDES STOPPING BURNER OPERATION.

THE LOW WATER CUT-OFF WILL ALSO STOP BURNER OPERATION IF THE WATER LEVEL IN THE BOILER

SHOULD DROP BELOW THE LOWEST SAFE LEVEL.

SHOULD ONE OF THE PILOT FLAMES FAIL TO IGNITE OR BECOME EXTINGUISHED, THE MAIN GAS VALVES

CONTROLLED BY THAT PARTICULAR PILOT WOULD CLOSE STOPPING BURNER OPERATION ON THE

BURNERS SUPPLIED BY THAT GAS TRAIN. OPERATION OF THE BURNERS SUPPLIED BY THE SECOND GAS

TRAIN WOULD BE UNAFFECTED.

FIG. 43

LADDER WIRING DIAGRAM - 5015B THRU 5026B SECTION BOILERS

EI CONTROL SYSTEM

SECTION IV - OPERATION (continued)

TROUBLE SHOOTING GUIDE

BOILERS EQUIPPED WITH S8610M INTERMITTENT ELECTRIC IGNITION

SECTION IV - OPERATION (continued)

7. EP CONTROL SYSTEM – 5006B thru 5014B

The EP Control System utilizes an RM7890A Relay

Module and a Q179C Rectication Pilot, which in

addition to a pilot burner and rectifying ame rod ame

detector to prove pilot, includes an ignition electrode

for spark ignition of the pilot. A Webster 612-6A7

Transformer supplies the high voltage spark potential.

Once pilot ame continues as long as there is a “call for

heat” (intermittent electrically ignited pilot).

The RM7890A Relay Module Primary Control is a

non-programming amplifying relay which when used

with the Q179C Pilot provides solid state electronic

Flame Safeguard Protection that will not allow the main

gas valves to open on “call for heat” for that will shut

down main burners within 0.8 second if pilot ame is

not “proved”. Relay Module will lockout on safety

shutdown within 15 seconds if there is a pilot ame

failure on start or, if during the “run” cycle, pilot ame

is not re-established. Since #8 terminal in the Relay

Module is de-energized at end of safety switch timing, a

solenoid valve in the pilot line will close and thus 100%

shut-off is achieved.

a. OPERATING INSTRUCTIONS

(1) Make sure Manual Main Shut-off Valve and

all Pilot Valves have been off for at least ve

minutes.

(2) Set Operating and Limit Controls to desired

settings.

(3) Turn Manual Main Shut-off Valve and Pilot

Valve to Open Position.

(4) Turn on Main Electric Switch and Service

Switch – Pilot will automatically light main

burners.

SEQUENCE OF OPERATION EP - See Fig. 44

b. NORMAL OPERATION - 5006B thru 5014B

(1) When the operating control calls for heat,

terminal #6 of RM7890A Relay is energized.

(2) A component check circuit in the RM7890A

Relay is activated which, checks the electronic

network in the relay.

(3) Terminals #8 and #10 of the relay are energized.

Terminal #8 opens pilot line solenoid valve

supplying gas to pilot. Terminal #10 energizes

ignition transformer creating electric spark

ignition at pilot.

(4) Flame rod circuit between Q179C pilot and

RM7890A proves presence of pilot ame

electronically.

(5) Terminal #10 to ignition transformer is de-

energized.

(6) Terminal #9 is energized and supplies power to

the main gas valves.

(7) Main gas valves open and main burners are

lighted by pilot.

(8) When operating control is satised, terminals

#6 and #9 are de-energized. Main Gas Valves

and pilot line solenoid valve are all de-energized

and main burner and pilot burner ames are

extinguished.

c. SAFETY SHUTDOWN

(1) SAFETY SWITCH CIRCUIT

If limit control, low water cut-off or any other

electrical safety switch opens, power to terminal

#6 in relay is interrupted thus de-energized

terminal #9 and #8 in relay which de-energizes

main gas valves and pilot valves. Main gas

burners and pilot burners are immediately

extinguished. Normal operation can be resumed

when the cause of safety switch malfunction

is corrected. Make sure all manual resets are

activated where involved.

(2) PILOT FAILURE

(a) Pilot failure can occur during the start of

operating cycle of the boiler. Any pilot

failure, on the Q179C electronic pilot, after

ignition of pilot ame will close the main

gas valves in 0.8 second.

(b) For 15 seconds after failure of the Q179C

pilot, the relay through terminals #8 and #10

will try to establish pilot ame. If not pilot

ame can be sensed by the ame rod circuit,

terminal #8 and #10 are de-energized, and

the relay will lock out on safety.

(1) Complete loss of gas supply.

(2) Poor ignition spark caused by low

voltage, poor ground connection, faulty

wiring, and possibly a defective ignition

transformer.

(3) Low gas pressure will prevent ame rod

circuit from sensing pilot ame properly.

(4) Unusually strong secondary air drafts

can blow the pilot ame away from the

ame rod momentarily causing nuisance

shutdown.

(5) A pilot line solenoid valve will not open

because of faulty wiring, low voltage, or

possibly the valve is defective.

(6) A defective RM7890A may be the cause

but items (1) thru (5) should be followed

rst. Refer also to RM7890A relay

literature furnished with the control.

(d) By referring to the Sequence of Operations

step-by-step operation of the system can

be controlled and the cause of pilot failure

can be readily found. After the cause of

the pilot failure has been corrected, resume

normal operation by following the Lighting

Instructions.

(3) SHUTDOWN INSTRUCTIONS

(a) Close manual shut-off valves and pilot

valves.

(b) Turn off main electric switch.

8. EP CONTROL SYSTEM – 5015B thru 5026B (see Fig.

45)

The 5015B thru 5026B boilers utilize two EP control

systems that are interconnected electrically thru all

operating and safety controls. Should any of the

aforementioned controls break the power supply circuit,

both EP control systems would be de-energized. The

succeeding paragraphs describe the function and

operation of each EP Control System. Should a pilot

failure on one EP Control System occur, the other EP

Control System would not be affected. Thus main

burners on the unaffected side would ignite on a “call

for heat” and would continue to operate until the

SECTION IV - OPERATION (continued)

operating control was satised.

The EP Control System utilizes and RM7890A Relay

Module and a Q179C Rectication Pilot, which in

addition to a pilot burner and rectifying ame rod ame

detector to prove pilot, includes an ignition electrode

for spark ignition of the pilot. A Webster 612-6A7

Transformer supplies the high voltage spark potential.

Once pilot ame is proven, ignition stops but pilot

ame continues as long as there is a “call for heat”

(intermittent electrically ignited pilot).

The RM7890A Primary Control is a non-programming

amplifying relay which when used with the Q179C

Pilot provides solid state electronic Flame Safeguard

Protection that will not allow the main gas valve to

open on “call for heat” or that will shut down main

burners within 0.8 second if pilot ame is not “proved”.

Relay Module will lock out on safety shutdown within

15 seconds if there is a pilot ame failure on start or, if

during the “run” cycle, pilot ame is not re-established.

Since #8 terminal in the Relay Module is de-energized

at end of safety switch timing, a solenoid valve in the

pilot line will close and thus 100% shut-off is achieved.

FIG. 44

WIRING DIAGRAM - 5006B THRU 5014B SECTION BOILERS

EP CONTROL SYSTEM

SECTION IV - OPERATION (continued)

FIG. 45

WIRING DIAGRAM - 5015B THRU 5026B SECTION BOILERS

EP CONTROL SYSTEM

SECTION IV - OPERATION (continued)

a. OPERATING INSTRUCTIONS

(1) Make sure all Manual Main Shut-off Valves and

all Pilot Valves have been off for at least ve

minutes.

(2) Set Operating and Limit Controls to desired

setting.

(3) Turn all Manual Main Shut-off Valves and Pilot

Valves to Open Position.

(4) Turn on Main Electric Switch and Service

Switch. Pilots will automatically light main

burners.

SEQUENCE OF OPERATION EP – See Fig. 45

b. NORMAL OPERATION – 5015B thru 5026B

1. When the operating control calls for heat,

terminal #6 of each RM7890A is energized.

2. A component check circuit in each RM7890A is

activated which checks the electronic network of

the relay.

3. Terminals #8 and #10 of each RM7890A relay

are energized. Terminal #8 opens the pilot line

solenoid valve supplying gas to the Q179C pilot.

Terminal #10 energizes ignition transformer

creating electric spark ignition at the Q179C

pilot.

4. Flame rod circuit between each Q179C pilot and

terminal “11” on its respective RM7890A proves

presence of ame electronically at its Q179C

pilot.

5. Terminal #10 of each RM7890A and the ignition

transformer connected to it is de-energized.

6. Terminal #9 on each RM7890A is energized

supplying power to its respective main gas

valves.

7. Main gas valves open and main burners are

ignited by the pilot ames.

8. When the operating control is satised, terminals

6 and all other terminals on both RM7890A

relays are de-energized. The main gas valves

and pilot valve for each gas train are closed

and main burners and pilot burner ames are

extinguished.

c. SAFETY SHUTDOWN

(1) SAFETY SWITCH CIRCUIT

If limit control, low water cut-off or any other

electrical safety switch opens, power to terminal

6 and all other terminals on both RM7890A

relays are interrupted de-energizing the main

gas valves and pilot valves and the main gas

burners and pilot burners are immediately

extinguished. Normal operation can be resumed

when the cause of the safety switch malfunction

is corrected. Make sure all manual resets are

activated where applicable.

(2) PILOT FAILURE

(a) Pilot failure can occur during the start and

operating cycle of the boiler. Any pilot

failure on either of the Q179C Electronic

Pilots, after ignition of pilot ame will close

the pilot valve and the main gas valves

controlled by that particular RM7890A relay

in 0.8 second. The burners controlled by the

other RM7890A will continue to burn.

(b) For 15 seconds after failure of a Q179C

pilot, the relay through terminals #8 and #10

will attempt to re-establish pilot ame. If no

pilot ame can be sensed by the ame rod

circuit in 15 seconds, terminals #8 and #10

are de-energized, and the relay will lock out

on safety.

(1) Complete loss of gas supply.

(2) Poor ignition spark caused by low

voltage, poor ground connection, faulty

wiring, and possibly a defective ignition

transformer.

(3) Low gas pressure will prevent ame rod

circuit from sensing pilot ame properly.

(4) Unusually strong secondary air drafts

can blow the pilot ame away from the

ame rod momentarily causing nuisance

shutdown.

(5) A pilot line solenoid valve will not open

because of faulty wiring, low voltage, or

possibly the valve is defective.

(6) A defective RM7890A may be the cause

but items (1) thru (5) should be followed

rst. Refer also to RM7890A relay

literature furnished with the control.

(d) By referring to the Sequence of Operations

step by step operation of the system can

be controlled and the cause of pilot failure

can be readily found. After the cause of

pilot failure has been corrected, resume

normal operation by following the Lighting

Instructions.

(3) SHUTDOWN INSTRUCTIONS

(a) Close manual shut-off valves and pilot

valves.

(b) Turn off main electric switch.

SECTION IV - OPERATION (continued)

9. THERMOCOUPLE CONTROL SYSTEM (Canada

Only)

The 5006B thru 5014B boilers are equipped with

a Thermocouple Control System that utilizes a

constant-burning Q327A pilot, a Q309 thermocouple,

and a L62GB-3C Pilot Safety Switch. The Q309

thermocouple proves pilot ame and, in the absence

of such, will cool and, within 45 to 90 seconds, will

cause the L62GB-3C Pilot Safety Switch to which it is

connected, to break the electrical circuit to the main gas

valves as well as shut off the ow of gas to the pilot.

Thus, 100% shut-off is achieved.

The 5015B thru 5024B boilers utilize two

Thermocouple Control Systems that are interconnected

electrically thru all operating and safety controls.

Should any of the aforementioned controls break the

power supply circuit, both Thermocouple Control

Systems would be de-energized. The proceeding

paragraph describes the function and operation of each

Thermocouple Control System. Should a pilot failure

on one Thermocouple Control System occur, the other

Thermocouple Control System would not be affected.

Thus main burners on the unaffected side would ignite

on a “call for heat” and would continue to operate until

the operating control was satised.

SECTION IV - OPERATION (continued)

a. LIGHTING INSTRUCTIONS

(1) Make sure that all main manual and pilot valves

have been off for at least ve (5) minutes.

(2) Set operating and limit controls to desired

setting.

(3) Open pilot valve.

(4) Depress button on pilot safety switch to which

it is connected and hold lighted match on pilot.

Hold button in for at least one minute, or until

the pilot burner remains lit after the button is

released. Repeat for second pilot when boiler is

so equipped.

(5) Open manual main shut-off valve(s).

(6) Turn on main electric switch.

NORMAL OPERATION SEQUENCE

5006B thru 5014B, see Fig. 46

5015B thru 5024B, see Fig. 47

When operating control (A) calls for heat, it energizes main gas valves (B), starting burner operation.

The burners will operate until operating control (A) is satised. The high limit control (C), will stop burner

operation in case of excessive steam pressure (steam boiler) or excessive boiler water temperature (water boiler).

Low water cut-off (D) will stop burner operation if the water level in boiler drops below the lowest safe level.

The pilot safety switch (E), connected to main gas valve (B), prevents operation of the main burners in case the

pilot ame becomes extinguished. Pilot safety switch (E) provide for 100% shut-off of gas supply.

FIG. 46

WIRING DIAGRAM - 5006B THRU 5014B SECT. BOILERS

THERMOCOUPLE CONTROL SYSTEM

CANADA ONLY

SECTION IV - OPERATION (continued)

When the operating control (A) calls for heat, it energizes the main gas valves (B) in both gas trains

starting burner operation. The burners will operate until the operating control is satised. The high limit

control (C) will stop burner operation in case of excessive steam pressure (steam boiler) or excessive

boiler water temperature (water boiler).

The low water cut-off (D) will stop burner operation if the water level in the boiler drops below the low-

est safe level.

Should one of the pilot ames become extinguished the pilot safety switch (E) to which it is connected

would shut off the gas supply to that pilot and to the main gas valves and burners it is serving (100%

shut-off). Operation of the burners supplied by the second gas train will be unaffected.

FIG. 47

WIRING DIAGRAM - 5015B THRU 5024B SECTION BOILERS

THERMOCOUPLE CONTROL SYSTEM

CANADA ONLY

SECTION IV - OPERATION (continued)

10. CHECK GAS INPUT RATE TO BOILER

(1) Input Rate and Maximum Inlet Pressure shown on

Rating Plate must not be exceeded. Inlet pressure

must not be lower than minimum inlet pressure

shown on Rating Plate.

(2) All Rate checks and all adjustments are to be

made while boiler is ring – all other appliances

connected to the same meter as the boiler must be

off.

(3) Water Manometer or water column gauge should

be connected to a shut-off valve installed in the

1/8” pipe tapping in each manifold – boiler off. By

installing gas valve upstream of manometer, gas

pressure can be introduced gradually – without

shut-off valve, surge of pressure when boiler is

turned on, could blow liquid out of manometer.

(4) LP Gas Input

(a) Adjust Gas Train Regulator(s) so that manifold

pressure is ten (10) inches water column.

Turning Regulator Adjusting Screw Clockwise

increases pressure, Counterclockwise rotation

decreases pressure. If boiler is equipped with

two manifolds (5015B thru 5026B), pressure

in each must be equal.

(5) Natural Gas Input

(a) Approximate Input – Adjust Gas Train

Regulator(s) so that manifold pressure is three

and a half (3½) inches from water column.

Turning Regulator Adjusting Screw Clockwise

increases pressure, Counterclockwise rotation

decreases pressure. If boiler is equipped with

two manifolds, pressure in each must be equal.

If more accurate check on input is necessary,

see (b) below.

For minor input changes readjust Gas Train

Regulator(s) to increase or decrease manifold

pressure to obtain corresponding increase or

decrease in gas input. If it is necessary to

increase manifold pressure more than 0.3” of

water to obtain rated input, remove orices

and drill one size larger. Reinstall and recheck

input rate.

(b) Additional Check on Input – Since input is

a function of heating value, specic gravity

and volume of gas ow contact your utility

for the rst two items in order to utilize the

formula below. The gas meter should then be

clocked for three (3) minutes with stop watch

and substituting the appropriate values in the

formula below, determine what the gas ow

should be in this 3 minute period to give the

input shown on the Rating Plate:

Burners are normally shipped with the air

shutters in the wide open position. Loosen air

shutter securing screws and close air shutters

until yellow tips appear on ames, then open

shutters slowly until dened inner cones may

be seen. Lock shutters in this position.

(d) ADJUST BLEED LINE REGULATOR

(V88A’s)

All gas boilers for the USA and Canada are

normally equipped with two diaphragm gas

valves per manifold. The gas valve(s) nearest

the manifold on all boilers, is equipped with an

adjustable bleed. This bleed regulator should

be adjusted so that the burners reach full re

in approximately 10-12 seconds after the main

gas valves have been energized.

(e) ADJUST PILOT LINE PRESSURE – See

Section V - Service; 6. Pilot Flame

Shut down boiler and remove gas valve and

manometer from 1/8” pipe tapping in each

manifold. Plug tappings with square head pipe

plugs. Install gas valve in tee in each pilot line.

Connect manometer to each gas valve and, with

boiler in operation, set pilot line pressure at

5.5” water – natural gas boilers and 6.5” water

– propane gas boilers.

Shut boiler down, remove gas valves and

manometers and plug tees with square head

pipe plugs. Restart boiler.

cu. ft. per =

3 min.

Btuh Input

Heating x 20 x multiplier

Value

of gas

(from

table

below)

(Btu/cu.ft.)

spec. gravity multiplier

.50 1.10

.55 1.04

.60 1.00

.65 0.96

.70 0.93

SECTION IV - OPERATION (continued)

The following procedures should only be

performed by a qualied service technician.

11. MINIMUM INPUT ADJUSTMENTS

This section covers Minimum Input Adjustments on

Honeywell V8944B Diaphragm Type “Lo-Hi-Lo” Gas

Valves, Honeywell V5055B Fluid Power Gas Valves

equipped with either a V4062A “Lo-Hi-Lo” Actuator or

a V9055A “Modulating” Actuator.

a. Minimum Input Adjustments – “Lo-Hi-Lo”

Combination Valve, V8944B (Natural Gas Only)

On boilers equipped with the V8944B combination

diaphragm valve/regulator, Low Fire Adjustment

should not be less than Minimum Input shown on

Rating Plate (1/3 of full rated input). Fig. 48 shows

the outlet pressure adjustment screws for low and

high re. The V8944B low and high re pressure

settings are factory set at 0.8” and 3.5” W.C.

respectively. If further adjustments are necessary,

remove pressure regulator adjustment caps and

insert a screwdriver to raise or lower the regulator

pressure.

c. MINIMUM INPUT ADJUSTMENTS –

MOTORIZED “MODULATING” ACTUATOR,

V9055A

On boilers equipped with Fluid Power Valves that

have “Modulating” Actuators, Low Fire Adjustment

should not be less than Minimum Input shown on

Rating Plate (1/3 of full rated input).

Fig. 50 shows the Low Fire Adjusting Screw for

increasing or decreasing low re input on the

Honeywell V9055A “Modulating” Actuator. To

adjust the low re setting after the burners are “on”,

the following procedure should be used.

(1) With power to actuator “off”, remove the wiring

compartment cover.

(2) Check to make sure the low re adjustment is

set at MAX (full clockwise) to insure a safe

light-off. (Low re adjustment is preset at the

factory in the MAX position.)

Fig. 49 shows the Limit Switch Cam and Scales to

indicate direction to rotate cam for increasing or

decreasing low re input on the Honeywell V4062A

“Lo-Hi-Lo” Actuator. To adjust the low re setting

after the burners are “on”, the following procedure

should be used.

(1) With power to actuator “off”, remove the

wiring compartment cover.

(2) Check to be sure the low re adjustment is set

at MAX to insure a safe light-off. (Low re

adjustment is preset at factory in the MAX

position.)

(3) Disconnect the controller lead from terminal #4

on the actuator to keep the valve in the low re

position.

(4) Start the system and establish the main burner

ame.

(5) Loosen the setscrew in the cam (Fig. 49) with

the special wrench taped to inside of actuator

cover. Keep the wrench seated in the setscrew.

Rotate the cam slightly downward (by moving

the wrench toward the base of actuator) to open

bleed valve. Actuator will start to close.

(6) When valve reaches desired low re position,

quickly tighten setscrew and remove wrench. If

the desire low re setting is “missed”, merely

loosen the setscrew and rotate cam in the

opposite direction to the desired set point.

(7) Shut down burner, and then restart. Repeat

several times to be sure the low re setting

is that desired and suitable for correct burner

lightoff. Readjust if necessary.

(8) Disconnect power and reconnect controller lead

removed in step (3) above.

(9) Replace the wiring compartment cover.

b. MINIMUM INPUT ADJUSTMENTS –

“Lo-Hi-Lo” MOTORIZED ACTUATOR, V4062A

On boilers equipped with Fluid Power Valves that

have “Lo-Hi-Lo” Actuator, Low Fire Adjustment

should not be less than Minimum Input shown on

Rating Plate (1/3 of full rated input).

SECTION IV - OPERATION (continued)

FIG. 48

V8944B COMBINATION VALVE

FIG. 49

LOW FIRE ADJUSTMENT - V4062 ACTUATOR

(3) Remove the lead to V9055A terminal R.

Jumper terminal R to W. This will prevent the

actuator from going to the high re position.

(4) Energize the system and light the main burner.

(5) Use a Phillips screwdriver, or standard type with

a blade no more than 3/16 inch wide, to turn

the low re adjusting screw for the desired low

re position. DO NOT PUSH INWARD ON

SCREW.

(6) Shut down the burner, and then restart. Repeat

several times to be sure the low re setting is

that desired and suitable for correct burner light

off.

(7) Turn off power supply. Remove R-W jumper,

and reconnect the lead to terminal R on the

V9055A.

(8) Replace the wiring compartment cover.

FIG. 50

LOW FIRE ADJUSTMENT - V9055A ACTUATOR

12. MAIN BURNER FLAMES should have a clearly

dened inner cone, see Fig. 55 with no yellow tipping.

Orange-yellow streak caused by dust should not be

confused with true yellow tipping.

13. CHECK PILOT FLAME. Flame should be a blue

medium hard ame enveloping approximately 3/8” of

the end of the thermocouple, ame sensor, or sensing

probe, see Fig. 56 thru 59.

SECTION IV - OPERATION (continued)

14. CHECK THERMOSTAT OPERATION. Raise and

lower thermostat setting as required to start and stop

burners.

15. CHECK HIGH LIMIT CONTROL. Jumper

Thermostat terminals or thermostat connections in

Limit Control. Allow burners to operate until shutdown

by limit. REMOVE JUMPER.

16. TEST IGNITION SYSTEM SAFETY SHUT-OFF

DEVICE AS FOLLOWS:

Place the boiler into operation by following the

appropriate lighting instructions in this manual.

Proceed with test as follows:

a. Thermocouple Pilot System

Using a 3/8” wrench loosen the thermocouple lead

at the gas valve. Main gas and pilot gas must shut

off. If not, replace gas valve.

b. EI Pilot System

Carefully remove ignitor sensor wire from ignition

module Main gas and pilot gas must shut off

immediately. If not, replace the module.

c. EP Pilot Systems

Carefully remove the ame rod wire from terminal

“11” on the RM7890 Control. Main gas and pilot

gas must shut off. If not, replace the RM7890

Control.

17. COMBUSTION CHAMBER BURN-OFF

a. 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.

b. Ventilate the boiler room, set the high limit to its

maximum setting, set the thermostat to call for heat.

Allow the boiler to re for at least an hour or until

the odor from the cornstarch has dissipated.

c. Return the high limit and thermostat to their desired

settings.

Avoid operating this boiler in an environment

where saw dust, loose insulation bers, 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.

SECTION IV - OPERATION (continued)

1. GENERAL – “Inspection should be conducted

annually. Service as frequently as specied in

paragraphs below.” While service or maintenance is

being done, Electrical Power and all Gas Supply to the

Boiler must be “off”.

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation. Verify proper

operation after servicing.

2. VENT SYSTEM – Vent system should be checked

annually for:

a. obstructions

b. accumulations of soot

c. deterioration of vent pipe or vent accessories due to

condensation or other reasons

d. proper support – no sags, particularly in horizontal

runs

e. tightness of joints

Remove all accumulations of soot with wire brush

and vacuum. Remove all obstructions. Replace

all deteriorated parts and support properly. Seal all

joints. See Fig. 53.

SECTION V – SERVICE

3. CLEANING OF FLUES AND BURNERS – Flue

passageways in the boiler sections should be checked

annually for any blockage or accumulation of soot.

To obtain access to the ue cleanout panels, which

are installed on both the front and rear of the boiler,

the upper front and upper rear jacket panels must be

removed, see Fig. 51. Also remove front vestibule

panel. See Fig. 20.

FIG. 51

REMOVAL OF JACKET FRONT PANEL

This boiler used ammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool

before attempting any disassembly or service.

More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that

all gas valves and electrical disconnect switches are off before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler.

Never modify, remove or tamper with any control device.

This boiler must only be serviced and repaired by skilled and experienced service technicians.

If any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this manual.

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires

are reconnected properly.

NEVER operate boiler without all sight glasses and brackets in place and securely fastened and sealed.

Very HOT combustion gas may cause burn injury.

Read, understand and follow all the instructions and warnings contained in ALL of the component

instruction manuals.

Assure that all safety and operating controls and components are operating properly before placing the

boiler back in service.

Important Product Safety Information

Refractory Ceramic Fiber Product

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 above 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.

Remove the Front Cleanout Panels rst by removing

the upper and lower nuts and washers securing these

panels to the boiler sections, see Fig. 52.

CARE SHOULD BE EXERCISED IN REMOVING

THE CLEANOUT PLATES FROM THE BOLTS SO

THAT THE INSULATION IS NOT DAMAGED. IF

DAMAGED, ALL EDGES OF THE CLEANOUT

PLATES SHOULD BE SEALED WITH BOILER

PUTTY WHEN REINSTALLED UNTIL

INSULATION CAN BE REPLACED.

Using a ashlight, examine all ue passageways. If

passageways are free of soot and obstructions, it is not

necessary to remove the rear cleanout panels. Remove

the Burner Access Panels at front of base and place

paper or cardboard over burners. With long handle

wire ue brush and vacuum, brush ueways thoroughly

through front and rear cleanout openings – see Fig. 53.

Remove material placed over burners and vacuum the

following with care so as not to disturb base insulation:

oor, top of burners, primary air opening in burners,

and primary air openings in pilot. This will remove any

dust or lint that may have accumulated as well as any

foreign matter that may have been dislodged during the

cleaning of the ues.

FIG. 53

CLEANING OF FLUEWAYS

SECTION V – SERVICE (continued)

FIG. 52

ATTACHMENT OF FLUE COVERS

THIS PAGE LEFT BLANK INTENTIONALLY

SECTION V – SERVICE (continued)

FIG. 54-1

PILOT LOCATIONS

SECTION V – SERVICE (continued)

FIG. 54-2

PILOT LOCATIONS

If Burners must be removed, use the following

procedure:

a. Mark location on manifold of all burners with pilots.

b. Using a pair of pliers, remove hitch pin clips

(shaped like a hairpin) from groove in main burner

orices. SAVE ALL CLIPS.

c. Remove all burners without pilots by lifting front

of burner slightly, then pushing burner toward rear

of boiler until front of burner clears orice, then

lift rear of burner until head of weld pin on bottom

rear of burner clears keyhole slot in base rear

panel. Burner is now free and can be lifted out thru

opening in base front frame.

d. Remove all burners with pilots by rst tracing all

electrical leads coming from pilot to their points of

connection, remove leads from terminals to which

they are connected, and then tag each lead with

respective terminal designation. Disconnect Pilot

Tubing at nearest connection to pilot and remove

burner as outlined in paragraph c. above.

e. When replacing burners, reverse procedure used in

removal of burners. Make sure burners are secure in

keyhole slots in base rear panel and hitch pin clips

are installed in grooves in all main burner orices.

Burners with pilots must be in same locations as

original installation. If markings placed on manifold

(when burners were removed) are obliterated, see

Fig. 54. Reconnect electrical leads and reconnect

pilot tubing.

Reinstall Flue Cleanout Plates so that they are gas

tight. Reinstall Burner Access Panels and Jacket

Panels.

4. LUBRICATION

Manufacturers Instruction should be followed on all

parts installed on the boiler that require lubrication.

Generally this involves only the circulator in a hot

water system. This includes:

(a) Type of lubricant to be used

(b) Frequency of lubrication

5. MAIN BURNER FLAMES –

Main Burner Flames should be checked at initial

start-up, annually thereafter, or after ueway cleaning,

or after an extended shutdown period. Main Burner

Flame should have a clearly dened inner cone, see

Fig. 55, with no yellow tipping. Orange-yellow streaks

caused by dust should not be confused with true yellow

tipping.

Yellow-tipping indicates a lack of primary air and

normally can be corrected by opening the air shutter.

Improper alignment of burner on orice will also affect

primary air injection.

SECTION V – SERVICE (continued)

FIG. 55

MAIN BURNER FLAME ADJUSTMENT

FIG. 56

PILOT FLAME - HONEYWELL Q3481B

6. PILOT FLAME –

Pilot Flame should be checked at initial start-up,

annually thereafter, or after ueway cleaning, or after

an extended shutdown period.

The EI Control System utilizes a Honeywell Q3481B

pilot. Flame should be adjusted by means of the pilot

line regulator 5.5” WC pilot line press so that a medium

hard center ame envelopes approximately 3/8” of

the end of the sensing probe, see Fig. 56. If ame

is yellow, primary air slot may be covered with dirt

or lint. This can be removed with a soft brush or by

vacuuming.

a. To adjust or check spark gap between electrode and

hood on Honeywell Q3481B intermittent pilot. (See

Fig. 56)

1. Use a round wire gauge to check spark gap.

2. Spark gap should be 0.1” for optimum

performance.

SECTION V – SERVICE (continued)

FIG. 57

PILOT FLAME

HONEYWELL Q179C PILOT

FIG. 58

PILOT FLAME

HONEYWELL Q327A PILOT W/THERMOCOUPLE

7. LOW WATER CUT-OFF –

a. Float Type Low Water Cut-off

During the heating season, if an external low water

cut-off is on the boiler, the blow off valve should

be opened once a month (use greater frequency

where conditions warrant), to ush out the sediment

chamber so the device will be free to function

properly.

Low-water fuel cut-offs and water feeders should

be dismantled annually by qualied personnel,

to the extent necessary to insure freedom from

obstructions and proper functioning of the

working parts. Inspect connecting lines to boiler

The EP Control Systems utilize a Honeywell Q179C

Flame Rectication Pilot. Adjust pilot line regulator

(5.5” WC in pilot line) so that a medium hard center

ame envelops ame rod, see Fig. 57. If ame is

yellow, primary air opening may be covered with dirt

or lint. This can be removed with a soft brush or by

vacuuming.

The Thermocouple Control System utilizes a

Honeywell Q327A non-primary aerated pilot with a

Q309A thermocouple. Adjust pilot line regulator to

give a steady ame enveloping 3/8” to 1/2” of the tip of

the thermocouple, see Fig. 58.

for accumulation of mud, scale, etc. and clean as

required. Examine all visible wiring for brittle or

warn insulation and make sure electrical contacts

are clean and that they function properly. Give

special attention to solder joints on bellows and oat

when this type of control is used. Check oat for

evidence of collapse and check mercury bulb (where

applicable) for mercury separation or discoloration.

Do not attempt to repair mechanisms in the eld.

Complete replacement mechanisms, including

necessary gaskets and installation instructions, are

available from the manufacturer.

Before returning boiler to service:

Follow this low water cut-off check out procedure:

- Set thermostat to the highest setting.

- While boiler is operating, open drain valve

and slowly drain down boiler water.

SECTION V – SERVICE (continued)

Do not drain water below gauge glass.

- Main burners should turn off when water

level drops below low water cut-off. At this

point the water level in gauge glass will just

be visible.

- Be sure that it is the low water cut-off

control and not the room thermostat,

pressure cut-out or other control that has

shut off the burners.

- Rell the boiler to the normal water level.

- Main burners should reignite.

- Clean out the boiler according to the

instructions for steam boilers on page 43.

- Reset controls for normal operation.

8. FREQUENT WATER ADDITION

A leaky system will increase the volume of make-up

water supplied to the boiler which can signicantly

shorten the life of the boiler. Entrained in make-up

water are dissolved minerals and oxygen. When the

fresh, cool make-up water is heated in the boiler the

minerals fall out as sediment and the oxygen escapes

as a gas. Both can result in reduced boiler life. The

accumulation of sediment can eventually isolate

the water from contacting the cast iron. When this

happens the cast iron in that area gets extremely hot

and eventually cracks. The presence of free oxygen

in the boiler creates a corrosive atmosphere which, if

the concentration becomes high enough, can corrode

the cast iron through from the inside. Since neither of

these failure types are the result of a casting defect the

warranty does not apply. Clearly it is in everyone’s best

interest to prevent this type of failure. The maintenance

of system integrity is the best method to achieve this.

Refer to Recommended Water Quality Requirements

chart on Page 44.

9. OXYGEN CORROSION:

Oxygen contamination of the boiler water will cause

corrosion of iron and steel boiler components, and

can lead to boiler failure. Burnham Commercial’s

standard warranty does not cover problems caused

by oxygen contamination of boiler water or scale

(lime) build-up caused by frequent addition of

water.

There are many possible causes of oxygen

contamination such as:

a. Addition of excessive make-up water as a result

of system leaks.

b. Absorption through open tanks and ttings.

c. Oxygen permeable materials in the distribution

system.

In order to ensure long product life, oxygen

sources should be eliminated. This can be

accomplished by taking the following measures:

a. Repairing system leaks to eliminate the need for

addition of make-up water.

b. Eliminating open tanks from the system.

c. Eliminating and/or repairing ttings which allow

oxygen absorption.

d. Use of non-permeable materials in the

distribution system.

e. Isolating the boiler from the system water by

installing a heat exchanger.

If, during normal operation, it is necessary to add water to this boiler more frequently than once a month,

consult a qualied service technician to check your system for leaks. A leaky system will increase the

volume of make-up water supplied to the boiler which can signicantly shorten a life of the boiler. Entrained

in make-up water are dissolved minerals and oxygen. When the fresh, cool make-up water is heated in the

boiler the minerals fall out as sediment and the oxygen escapes as a gas. Both can result in reduced boiler

life. The accumulation of sediment can eventually isolate the water from contacting the cast iron. When this

happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen

in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode

the cast iron through from the inside. Since neither of these failure types are the result of a casting defect

the warranty does not apply. Clearly it is in everyone’s best interest to prevent this type of failure. The

maintenance of system integrity is the best method to achieve this.

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REPAIR PARTS INDEX

ITEM PAGE NOS.

Base Parts ...................................................................................................................... 75 thru 78

Integral Draft Hoods & Sections ..................................................................................... 79 thru 80

Sections ...................................................................................................................................... 81

Base/Pilot Assemblies ................................................................................................................ 82

Jackets ........................................................................................................................... 83 thru 87

Water / Steam Trim ......................................................................................................... 88 and 89

Gas Trains ...................................................................................................................... 90 thru 96

Support Brackets, Ignition Modules .............................................................................. 97 thru 101

Pilotstats, Transformers, Pilot

Solenoid Valves & Pilot Line

Regulators

EP Control Panel ...................................................................................................................... 102

Pilot Assemblies ......................................................................................................... 103 and 104

All Series 5B 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: 888-791-3790 or Fax (717) 293-5803.

SECTION VI - REPAIR PARTS

FIG. 59

BASE PARTS (5006B THRU 5014B)

SECTION VI - REPAIR PARTS (continued)

TABLE 2A

SERIES 5B BASE PARTS - 5006B thru 5014B

Number in ( ) in Table Relates to Corresponding Number in in Figure 60

PART

NUMBER ITEM PART SIZE

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B

7181301 High Base End Panel 12-1/2 x 25-3/4 (1) (1) (1) (1) (1) (1) (1) (1) (1)

7201319 High Base End Panel Insul. - 1” Supertemp 12 x 21-1/2 (2) (2) (2) (2) (2) (2) (2) (2) (2)

80861551 Cup Head Pin CL #10 x 1-5/8” (3) (3) (3) (3) (3) (3) (3) (3) (3)

80861503 Speed Clip 1-1/4” x 1-1/8” SS Type 304 (4) (4) (4) (4) (4) (4) (4) (4) (4)

61813061 5006B Base Front and Rear Frame Assembly 12-1/2 x 27-3/16 (5) (5) & (6) (5)

61813071 5007B Base Front and Rear Frame Assembly 12-1/2 x 32-5/8 (5) (6) (5) & (6) (5)

61813081 5008B Base Front and Rear Frame Assembly 12-1/2 x 38-1/16 (5)

61813091 5009B Base Front and Rear Frame Assembly 12-1/2 x 43-1/2 (5)

61813101 5010B Base Front and Rear Frame Assembly 12-1/2 x 48-15/16 (5)

80861601 Burner Access Panel Attaching Screw (7) (7) (7) (7) (7) (7) (7) (7) (7)

6181301 Base Spacer Assembly 11 x 22-3/4 (8) (8) (8) (8)

71813062 5006B Base Rear Panel 9-5/8 x 26-15/16 (9)

71813072 5007B Base Rear Panel 9-5/8 x 32-3/8 (9)

71813082 5008B Base Rear Panel 9-5/8 x 37-13/16 (9)

71813092 5009B Base Rear Panel 9-5/8 x 43-1/4 (9)

71813102 5010B Base Rear Panel 9-5/8 x 48-11/16 (9)

71813112 5011B Base Rear Panel 9-5/8 x 54-1/8 (9)

71813122 5012B Base Rear Panel 9-5/8 x 59-9/16 (9)

71813132 5013B Base Rear Panel 9-5/8 x 65 (9)

71813142 5014B Base Rear Panel 9-5/8 x 70-7/16 (9)

72013065 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 26-15/16 (11) 1 pc

72013075 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 32-3/8 (11) 1 pc

72013085 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 18-7/8 (11) 2 pcs

72013095 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 21-5/8 (11) 2 pcs

72013105 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 24-5/16 (11) 2 pcs

72013115 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 29-3/4 (11) 2 pcs

72013125 Base Rear Panel Insulation - 1” Supertemp 8-3/4 x 35-3/16

7181312 Front Int. Panel Support Bracket (13) (13) (13) (13)

7181313 Lower Rear Int. Panel Support Bracket (14) (14) (14) (14)

7181302 Low Base End Panel 11-7/8 x 25-3/4 (15) (15) (15) (15) (15) (15) (15) (15) V

7201320 Low Base End Panel Insul. - 1” Supertemp 11-3/8 x 21-1/2 (16) (16) (16) (16) (16) (16) (16) (16) (16)

8221306 5006B Manifold 1-1/2 Pipe x

34-5/16 (17)

8221307 5007B Manifold (17)

8221308 5008B Manifold (17)

8221309 5009B Manifold (17)

8221310 5010B Manifold (17)

8221311 5011B Manifold (17)

8221312 5012B Manifold (17)

8821313 5013B Manifold (17)

8221314 5014B Manifold (17)

8231301 Main Burners without Pilot Bracket (18) (18) (18) (18) (18) (18) (18) (18) (18)

8231302 Or Main Burners w/J991 Pilot Bracket (EI Controls) (19) (19) (19) (19) (19) (19) (19) (19) (19)

8231303 Or Main Burners w/Q179 Pilot Bkt (EP Controls) (20) (20) (20) (20) (20) (20) (20) (20) (20)

8231304 Or Main Burners w/Q327 Pilot Bkt (Thermocouple Controls) (21) (21) (21) (21) (21) (21) (21) (21) (21)

822628 Main Gas Orices (Nat. Gas) - #40 Drill (22) (22) (22) (22) (22) (22) (22) (22) (22)

822629 Or Main Gas Orices (LP) - #55 Drill (23) (23) (23) (23) (23) (23) (23) (23) (23)

822604 Hitch Pin Clip (24) (24) (24) (24) (24) (24) (24) (24) (24)

61813062 5006B Burner Access Panel Assembly 7-1/4 x 26-15/16 (25) (25) & (26) (25)

61813072 5007B Burner Access Panel Assembly 7-1/4 x 32-3/8 (25) (26) (25) & (26) (25)

61813082 5008B Burner Access Panel Assembly 7-1/4 x 37-13/16 (25) (26)

61813092 5009B Burner Access Panel Assembly 7-1/4 x 43-1/4 (25)

61813102 5010B Burner Access Panel Assembly 7-1/4 x 48-11/16 (25)

7186001 Observation Hole Cover (12) (12) (12) (12) (12) (12) (12) (12) (12)

80860900 1/4 - 20 Wing Nut (10) (10) (10) (10) (10) (10) (10) (10) (10)

8201303 Low Base End to Right Section Fiberglass Rope 3/4 X 25-3/4

FIG. 60

BASE PARTS (5015B THRU 5026B)

SECTION VI - REPAIR PARTS (continued)

TABLE 2B

SERIES 5B BASE PARTS - 5015B Thru 5026B

Number in ( ) in Table Relates to Corresponding Number in in Figure 61

PART

NUMBER ITEM PART SIZE

BOILER SIZE

5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

7181301 High Base End Panel 12-1/2 x 25-3/4 (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

7201319 High Base End Panel Insul. - 1” Thick 12 x 21-1/2 (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)

80861551 Cup Head Pin CL #10 x 1-5/8” (3) (3) (3) (3) (3) (3) (3) (3) (3) (3)

80861503 Speed Clip 1-1/4” x 1-1/8” SS Type 304 (4) (4) (4) (4) (4) (4) (4) (4) (4) (4)

61813061 5006B Base Front and Rear Frame Assembly 12-1/2 x 27-3/16 (5) & (6) (5) (5)

61813071 5007B Base Front and Rear Frame Assembly 12-1/2 x 32-5/8 (6) (5) & (6) (6), (30) & (31) (5), (30) & (31)

61813081 5008B Base Front and Rear Frame Assembly 12-1/2 x 38-1/16 (5) & (6) (5) (6)

61813091 5009B Base Front and Rear Frame Assembly 12-1/2 x 43-1/2 (6) (5) & (6) (5)

61813101 5010B Base Front and Rear Frame Assembly 12-1/2 x 48-15/16 (6) (5) & (6) (30) (30) (30)

80861601 Burner Access Panel Attaching Screw (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)

6181301 Base Spacer Assembly 11 x 22-3/4 (8) (8) (8) (8) (8) (8) (8) (8) (8) (8)

71813082 5008B Base Rear Panel 9-5/8 x 37-13/16 (9) & (32) (9)

71813092 5009B Base Rear Panel 9-5/8 x 43-1/4 (32) (9) & (32) (9)

71813102 5010B Base Rear Panel 9-5/8 x 48-11/16 (32) (9) & (32) (32) (32) (32)

71813112 5011B Base Rear Panel 9-5/8 x 54-1/8 (9)

71813122 5012B Base Rear Panel 9-5/8 x 59-9/16 (9)

71813132 5013B Base Rear Panel 9-5/8 x 65 (9) (32) (32)

71813142 5014B Base Rear Panel 9-5/8 x 70-7/16 (9)

72013065 Base Rear Panel Insulation - 1” Thick 8-3/4 x 26-15/16 (11) 2 pcs

72013075 Base Rear Panel Insulation - 1” Thick 8-3/4 x 32-3/8 (11) 2 pcs (11) 2 pcs (11) 2 pcs

72013085 Base Rear Panel Insulation - 1” Thick 8-3/4 x 18-7/8 (11) 4 pcs (11) 2 pcs

72013095 Base Rear Panel Insulation - 1” Thick 8-3/4 x 21-5/8 (11) 2 pcs (11) 4 pcs (11) 2 pcs

72013105 Base Rear Panel Insulation - 1” Thick 8-3/4 x 24-5/16 (11) 2 pcs (11) 2 pcs (11) 2 pcs (11) 2 pcs (11) 2 pcs

72013115 Base Rear Panel Insulation - 1” Thick 8-3/4 x 29-3/4 (11) 2 pcs (11) 2 pcs

72013125 Base Rear Panel Insulation - 1” Thick 8-3/4 x 35-3/16 (11) 2 pcs

7181312 Front Int. Panel Support Bracket (13) (13) (13) (13) (13) (13) (13) (13) (13) (13)

7181313 Lower Rear Int. Panel Support Bracket (14) (14) (14) (14) (14) (14) (14) (14) (14) (14)

7181302 Low Base End Panel 11-7/8 x 25-3/4 (15) (15) (15) (15) (15) (15) (15) (15) (15) (15)

7201320 Low Base End Panel Insul. - 1” Thick 11-3/8 x 21-1/2 (16) (16) (16) (16) (16) (16) (16) (16) (16) (16)

8221308 5008B Manifold 1-1/2 Pipe x 45-3/16 (17) & (29) (17)

8221309 5009B Manifold 1-1/2 Pipe x 50-5/8 (29) (17 & 29) (17)

8221310 5010B Manifold 1-1/2 Pipe x 56-1/6 (29) (17) & (29) (29) (29) (29)

8221311 5011B Manifold 1-1/2 Pipe x 61-1/2 (17)

8221312 5012B Manifold 1-1/2 Pipe x 66-15/16 (17)

8821313 5013B Manifold 1-1/2 Pipe x 72-3/8 (17) (29) (29)

8221314 5014B Manifold 1-1/2 Pipe x 77-13/16 (17)

8231301 Main Burners without Pilot Bracket (18) (18) (18) (18) (18) (18) (18) (18) (18) (18)

8231302 Or Main Burners w/Q3481B Pilot Bracket (EI Controls) (19) (19) (19) (19) (19) (19) (19) (19) (19) (19)

8231303 Or Main Burners w/Q179 Pilot Bkt (EP Controls) (20) (20) (20) (20) (20) (20) (20) (20) (20) (20)

8231304 Or Main Burners w/Q327 Pilot Bkt (Thermocouple Controls) (21) (21) (21) (21) (21) (21) (21) (21) (21) (21)

822628 Main Gas Orices (Nat. Gas) - #40 Drill (22) (22) (22) (22) (22) (22) (22) (22) (22) (22)

822629 Or Main Gas Orices (LP) - #55 Drill (23) (23) (23) (23) (23) (23) (23) (23) (23) (23)

822604 Hitch Pin Clip (24) (24) (24) (24) (24) (24) (24) (24) (24) (24)

61813062 5006B Burner Access Panel Assembly 7-1/4 x 26-15/16 (25) (25) & (26) (25)

61813072 5007B Burner Access Panel Assembly 7-1/4 x 32-3/8 (25) (26) (25) & (26) (26), (27) &

(28) (25), (27) & (28)

61813082 5008B Burner Access Panel Assembly 7-1/4 x 37-13/16 (25) & (26) (25) (25) (26)

61813092 5009B Burner Access Panel Assembly 7-1/4 x 43-1/4 (26) (25) & (26) (25)

61813102 5010B Burner Access Panel Assembly 7-1/4 x 48-11/16 (26) (25) & (26) (27) (27) (27)

7186001 Observation Hole Cover (12) (12) (12) (12) (12) (12) (12) (12) (12) (12)

80860900 1/4 - 20 Wing Nut (10) (10) (10) (10) (10) (10) (10) (10) (10) (10)

SECTION VI - REPAIR PARTS (continued)

FIG. 61

INTEGRAL CANOPY DRAFT HOODS & SECTIONS

SECTION VI - REPAIR PARTS (continued)

TABLE 3A

SERIES 5B INTEGRAL CANOPY DRAFT HOODS - BOILER SIZES

PART SIZE PART NO. Canopy -

Draft Hood No.

BOILER SIZE (QUANTITY)

5006B 5007B 5008B 5009B 5010B

36-1/2 X 25-3/4 61113063 5006B (1) 1

36-1/2 X 31-3/16 61113073 5007B (2) 1

36-1/2 X 36-5/8 61113083 5008B (3) 1

36-1/2 X 41-1/16 61113093 5009B (4) 1

36-1/2 X 47-1/2 61113103 5010B (5) 1

5011B 5012B 5013B 5014B 5015B

36-1/2 X 25-3/4 61113063 5006B (1) 2 1

36-1/2 X 31-3/16 61113073 5007B (2) 1 2 1

36-1/2 X 36-5/8 61113083 5008B (3) 1 2

36-1/2 X 41-1/16 61113093 5009B (4)

36-1/2 X 47-1/2 61113103 5010B (5)

5016B 5017B 5018B 5019B 5020B

36-1/2 X 25-3/4 61113063 5006B (1) 3

36-1/2 X 31-3/16 61113073 5007B (2)

36-1/2 X 36-5/8 61113083 5008B (3) 1

36-1/2 X 41-1/16 61113093 5009B (4) 1 2 1

36-1/2 X 47-1/2 61113103 5010B (5) 1 2 1

5021B 5022B 5024B 5026B

36-1/2 X 25-3/4 61113063 5006B (1) 1 1

36-1/2 X 31-3/16 61113073 5007B (2) 1 2 3 3

36-1/2 X 36-5/8 61113083 5008B (3) 1

36-1/2 X 41-1/16 61113093 5009B (4)

36-1/2 X 47-1/2 61113103 5010B (5) 1 1

SECTION VI - REPAIR PARTS (continued)

TABLE 3B

SERIES 5B SECTION REPLACEMENT CHART

Refer to Fig. 61

PART NO. ITEM

BOILER SIZE (QUANTITY)

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

7171301 LEH Section (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

7171303 C Center Section Plain (4) (5) (6) (7) (8) (8) (9) (10) (11) (12) (13) (14) (15) (16) (16) (17) (18) (19) (21)

7171302 REH Section (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

7171304 CX Center Section Tapped

- Not Plugged (1) (1) (1) (1) (1) (1) (2) (2) (3) (3)

6171301 CXP Center Section Tapped

- Plugged (1) (1) (1) (1) (1)

806600023 Nipple Gauge, 3” & 7” (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)

8056254 Nipple Lubricant, Loctite®

#592, 50 ml (3) (3) (1) (1) (2) (2) (3) (3) (1) (2) (3)

8056255 Nipple Lubricant, Loctite®

#592, 250 ml (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (2) (2) (2) (2) (2) (2)

SECTION VI - REPAIR PARTS (continued)

TABLE 3C

SERIES 5B BASE / PILOT ASSEMBLIES

5006B THRU 5014B BOILERS - SINGLE BASE REQUIRED

(NATURAL GAS) 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B

Complete Base Ass’y w/EI Pilot Ass’y 618130642 618130742 618130842 618130942 618131042 618131142 618131242 618131342 618131442

Complete Base Ass’y w/Thermocouple Pilot Ass’y 618130651 618130751 618130851 618130951 618131051 618131151 618131251 618131351 618131451

Complete Base Ass’y w/EP Pilot Ass’y 618130611 618130711 618130811 618130911 618131011 618131111 618131211 618131311 618131411

(LP GAS)

Complete Base Ass’y w/Thermocouple Pilot Ass’y 618130661 618130761 618130861 618130961 618131061 618131161 618131261 618131361 618131461

(NATURAL GAS) 5015B 5016B 5017B 5108B 5109B 5020B 5021B 5022B 5024B 5026B

Right Base Subass’y w/EI Pilot Ass’y 618130852 618130952 618131052 618131052 618130952 618131052 618131052 618131052 618131352 618131352

Right Base Subass’y w/Thermocouple Pilot Ass’y 618130871 618130971 618130971 618131071 618131071 618131071 618131071 618131071 618131371 618131371

Right Base Subass’y w/EP Pilot Ass’y 618130821 618130921 618130921 618131021 618131021 618131021 618131021 618131021 618131321 618131321

Left Base Subass’y w/EI Pilot Ass’y 618131541 618131641 618131741 618131841 618131941 618132041 618132141 618131052 618131352 618131352

Left Base Subass’y w/Thermocouple Pilot Ass’y 61813159 61813169 61813179 61813189 61813199 61813209 61813219 61813229 61813249 61813269

Left Base Subass’y w/EP Pilot Ass’y 61813157 61813167 61813177 61813187 61813197 61813207 61813217 61813227 61813247 61813267

(LP GAS)

Right Base Subass’y w/Thermocouple Pilot Ass’y 618130881 618130971 618130971 618131071 618131071 618131071 618131071 618131071 618131371 618131371

Left Base Subass’y w/Thermocouple Pilot Ass’y 618131511 618131611 618131711 618131811 618131911 618132011 618132111 618132211 618132411 618132611

SECTION VI - REPAIR PARTS (continued)

FIG. 62

JACKETS

SECTION VI - REPAIR PARTS (continued)

TABLE 4A

SERIES 5B JACKETS

Number in ( ) in Table Relates to Corresponding Number in in Figure 63

PART

NUMBER ITEM PART SIZE

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B

60413059 *5005B Front Top Panel 17-1/2 x 28-5/8 (1) & (2) (1)

60413069 5006B Front Top Panel 17-1/2 x 34-1/16 (1) (2) (1) & (2) (1)

60413079 5007B Front Top Panel 17-1/2 x 39-1/2 (1)

60413089 5008B Front Top Panel 17-1/2 x 44-15/16 (1)

60413099 5009B Front Top Panel 17-1/2 x 50-3/8 (1)

60413109 5010B Front Top Panel 17-1/2 x 55-13/16 (1)

7041316 Front Top Int. Panel 6-1/16 x 12 (9) (9) (9) (9) (9)

6041327 Center Top Int. Panel 6-1/16 x 6-7/8 (47) (47) (47) (27) (47)

6041328 Rear Top Int. Panel 3-25/32 x 6-1/16 (10) (10) (10) (10) (10)

60413052 *5005B Upper Rear Panel 24-1/2 x 26-5/16 (23) & (24) (24)

60413062 5006B Upper Rear Panel 24-1/2 x 31-3/4 (23) (23) (23) & (24) (23)

60413072 5007B Upper Rear Panel 24-1/2 x 37-3/16 (23) (24) (23) &

(24)

60413082 5008B Upper Rear Panel 24-1/2 x 42-5/8 (23)

60413092 5009B Upper Rear Panel 24-1/2 x 48-1/16 (23)

60413102 5010B Upper Rear Panel 24-1/2 x 53-1/2 (23)

60413053 *5005B Lower Rear Panel 9-1/2 x 26-5/16 (27) & (28) (27)

60413063 5006B Lower Rear Panel 9-1/2 x 31-3/4 (27) (28) (27) & (28) (27)

60413073 5007B Lower Rear Panel 9-1/2 x 37-3/16 (27)

60413083 5008B Lower Rear Panel 9-1/2 x 42-5/8 (27)

60413093 5009B Lower Rear Panel 9-1/2 x 48-1/6 (27)

60413103 5010B Lower Rear Panel 9-1/2 x 53-1/2 (27)

60413021 Upper Rear Int. Panel 7-5/16 x 25-1/2 (31) (31) (31) (31) (31)

60413031 Lower Rear Int. Panel 7-5/16 x 10-1/2 (32) (32) (32) (32) (32)

6041329 Upper Left End Panel 36 x 26 (13) (13) (13) (13) (13) (13) (13) (13) (13) (13)

60413071 Lower Left End Panel 36 x 10-1/2 (14) (14) (14) (14) (14) (14) (14) (14) (14) (14)

70413054 *5005B Upper Front Panel 24-1/2 x 26-5/16 (33) & (34) (33)

70413064 5006B Upper Front Panel 24-1/2 x 31-3/4 (33) (34) (33) & (34) (33)

70413074 5007B Upper Front Panel 24-1/2 x 37-6/16 (33) (34) (33) &

(34)

70413084 5008B Upper Front Panel 24-1/2 x 42-5/8 (33)

70413094 5009B Upper Front Panel 24-1/2 x 48-1/16 (33)

70413104 5010B Upper Front Panel 24-1/2 x 53-1/2 (33)

* For Multiple Usage Only

SECTION VI - REPAIR PARTS (continued)

TABLE 4B

SERIES 5B JACKETS

Number in ( ) in Table Relates to Corresponding Number in in Figure 63

PART

NUMBER ITEM PART SIZE

BOILER SIZE

5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B

60413055 *5005B Lower Top Panel 9-1/2 x 26-5/16 (37) & (37) (37)

60413065 5006B Lower Top Panel 9-1/2 x 31-3/4 (37) (38) (37) & (38) (37)

60413075 5007B Lower Top Panel 9-1/2 x 37-3/16 (37) (38) (37) & (38)

60413085 5008B Lower Top Panel 9-1/2 x 42-5/8 (37)

60413095 5009B Lower Top Panel 9-1/2 x 48-1/16 (37)

60413105 5010B Lower Top Panel 9-1/2 x 53-1/2 (37)

6041330 Upper Right End Panel 36 x 26 (15) (15) (15) (15) (15) (15) (15) (15) (15) (15)

60413051 Lower Right End Panel 36 x 10-1/2 (16) (16) (16) (16) (16) (16) (16) (16) (16) (16)

7041301 Lower End Panel Support Bkt. 1 x 21 (17) (17) (17) (17) (17) (17) (17) (17) (17) (17)

60413081 Front Int. Panel 36 x 7-5/16 (41) (41) (41) (41) (41)

604130510 *5005B Vestibule Panel 25 x 28-1/2 (18) & (19) (18)

604130610 5006B Vestibule Panel 25 x 33-15/16 (18) (19) (18) & (19) (18)

604130710 5007B Vestibule Panel 25 x 39-3/8 (18)

604130810 5008B Vestibule Panel 25 x 44-13/16 (18)

604130910 5009B Vestibule Panel 25 x 50-1/4 (18)

604131010 5010B Vestibule Panel 25 x 55-11/16 (18)

604130511 *5005B Rear Top Panel 3-3/4 x 28-5/8 (5) & (6) (5)

604130611 5006B Rear Top Panel 3-3/4 x 34-1/16 (5) (6) (5) & (6) (5)

604130711 5007B Rear Top Panel 3-3/4 x 39-1/2 (5)

604130811 5008B Rear Top Panel 3-3/4 x 44-15/16 (5)

604130911 5009B Rear Top Panel 3-3/4 x 50-3/8 (5)

604131011 5010B Rear Top Panel 3-3/4 x 55-13/16 (5)

6041331 Intermediate Vestibule Panel 24 x 6-1/8 (22) (22) (22) (22) (22)

6041332 Left Side Top Panel 3-7/8 x 14-13/16 (11) (11) (11) (11) (11) (11) (11) (11) (11) (11)

6041333 Right Side Top Panel 3-7/8 x 14-13/16 (12) (12) (12) (12) (12) (12) (12) (12) (12) (12)

7041302 #6 Left to Right Channel 1 x 33-15/16 (42)

7041303 #7 Left to Right Channel 1 x 39-3/8 (42)

7041304 #8 Left to Right Channel 1 x 44-13/16 (42)

7041305 #9 Left to Right Channel 1 x 50-1/4 (42)

7041306 #10 Left to Right Channel 1 x 55-11/16 (42)

7041307 #16 Left to Right Channel 1 x 30-9/16 (42) & (43) (42)

7041308 #17 Left to Right Channel 1 x 36 (43) (42) & (43) (42)

7041309 #18 Left to Right Channel 1 x 41-7/16 (43) (42) & (43)

80860926 Knobs Dimco - Black #516 (46) (46) (46) (46) (46) (46) (46) (46) (46) (46)

80860800 Machine Screw #10-32 x 3/16” Lg. Slotted Rd. Head (47) (47) (47) (47) (47) (47) (47) (47) (47) (47)

SECTION VI - REPAIR PARTS (continued)

TABLE 4C

SERIES 5B JACKETS

Number in ( ) in Table Relates to Corresponding Number in in Figure 63

PART

NUMBER ITEM PART SIZE

BOILER SIZE

5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

60413049 *5004B Front Top Panel 17-1/2 x 23-3/16 (2)

60413059 *5005B Front Top Panel 17-1/2 x 28-5/8 (1) (1) & (2) (2) (1), (2) & (3) (3)

60413069 5006B Front Top Panel 17-1/2 x 34-1/16 (1) (4) (1), (2) & (4)

60413079 5007B Front Top Panel 17-1/2 x 39-1/2 (1)

60413089 5008B Front Top Panel 17-1/2 x 44-15/16 (2) (1) & (2) (1)

60413099 5009B Front Top Panel 17-1/2 x 50-3/8 (2) (1) & (2) (3) (3) (3)

60413109 5010B Front Top Panel 17-1/2 x 55-13/16

7041316 Front Top Int. Panel 6-1/16 x 12 (9) (9) (9) (9) (9) (9) (9) (9) (9)

6041327 Center Top Int. Panel 6-1/6 x 6-7/8 (47) (47) (47) (47) (47) (47) (47) (47) (47)

6041328 Rear Top Int. Panel 3-25/32 x 6-1/16 (10) (10) (10) (10) (10) (10) (10) (10) (10)

60413042 *5004B Upper Rear Panel 24-1/2 x 20-7/8 (24)

60413052 *5005B Upper Rear Panel 24-1/2 x 26-5/16 (23) (23) & (24) (24) (23), (24) & (25) (25)

60413062 5006B Upper Rear Panel 24-1/2 x 31-3/4 (23) (26) (23), (24) & (26)

60413072 5007B Upper Rear Panel 24-1/2 x 37-3/16 (23)

60413082 5008B Upper Rear Panel 24-1/2 x 42-5/8 (24) (23) & (24) (23) (23)

60413092 5009B Upper Rear Panel 24-1/2 x 48-1/16 (24) (23) & (24) (25) (25) (25)

60413043 *5004B Lower Rear Panel 9-1/2 x 20-7/8 (5) (28)

60413053 *5005B Lower Rear Panel 9-1/2 x 26-5/16 (5) (27) (27) & (28) (28) (27), (28) & (29) (29)

60413063 5006B Lower Rear Panel 9-1/2 x 31-3/4 (5) (27) (30) (27), (28) & (30)

60413073 5007B Lower Rear Panel 9-1/2 x 37-3/16 (27)

60413083 5008B Lower Rear Panel 9-1/2 x 48-1/16 (28) (27) & (28) (27)

60413093 5009B Lower Rear Panel 9-1/2 x 48-1/16 (28) (27) & (28) (29) (29) (29)

6041333 Right Side Top Panel 3-7/8 x 14-13/16 (12) (12) (12) (12) (12) (12) (12) (12) (12)

60413021 Upper Rear Int. Panel 7-5/16 x 25-1/2 (31) (31) (31) (31) (31) (31) (31) (31) (31)

60413031 Lower Rear Int. Panel 7-5/16 x 10-1/2 (32) (32) (32) (32) (32) (32) (32) (32) (32)

6041329 Upper Left End Panel 36 x 26 (13) (13) (13) (13) (13) (13) (13) (13) (13)

60413071 Lower Left End Panel 36 x 10-1/2 (14) (14) (14) (14) (14) (14) (14) (14) (14)

70413044 *5004B Upper Front Panel 24-1/2 x 20-7/8 (34)

70413054 *5005B Upper Front Panel 24-1/2 x 26-5/16 (33) (33) & (34) (34) (33), (34) & (35) (35)

70413064 5006B Upper Front Panel 24-1/2 x 31-3/4 (33) (37) (33), (34) & (36)

70413074 5007B Upper Front Panel 24-1/2 x 37-6/16 (33)

70413084 5008B Upper Front Panel 24-1/2 x 48-1/16 (34) (33) & (34) (35) (35) (35)

* For Multiple Usage Only

SECTION VI - REPAIR PARTS (continued)

TABLE 4D

SERIES 5B JACKETS

Number in ( ) in Table Relates to Corresponding Number in in Figure 63

PART

NUMBER ITEM PART SIZE

BOILER SIZE

5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B

60413045 *5004B Lower Front Panel 9-1/2 x 20-7/8 (38)

60413055 *5005B Lower Front Panel 9-1/2 x 26-5/16 (37) (37) & (38) (38) (40)

60413065 5006B Lower Front Panel 9-1/2 x 31-3/4 (37) (40) (37)

60413075 5007B Lower Front Panel 9-1/2 x 37-3/16 (37) (38)

60413085 5008B Lower Front Panel 9-1/2 x 42-5/8 (38) (37) & (38) (37)

60413095 5009B Lower Front Panel 9-1/2 x 48-1/16 (38) (37) & (38) (39) (39) (39)

6041330 Upper Right End Panel 36 x 26 (15) (15) (15) (15) (15) (15) (15) (15) (15)

60413051 Lower Right End Panel 36 x 10-1/2 (16) (16() (16) (16) (16) (16) (16) (16) (16)

604130410 *5004B Vestibule Panel 25 x 23-1/4 (19)

604130510 *5005B Vestibule Panel 25 x 28-1/2 (18) (18) & (19) (19) (18), (19) & (20) (20)

604130610 5006B Vestibule Panel 25 x 33-15/16 (23) (18) (21) (18), (19) & (21)

604130710 5007B Vestibule Panel 25 x 39-3/8 (18)

604130810 5008B Vestibule Panel 25 x 44-13/16 (19) (18) & (19) (18)

604130910 5009B Vestibule Panel 25 x 50-1/4 (19) (18) & (19) (20) (20) (20)

604131010 5010B Vestibule Panel 25 x 55-11/16

604130411 *5004B Rear Top Panel 3-3/4 x 23-3-16 (6)

604130511 *5005B Rear Top Panel 3-3/4 x 28-5/8 (5) (5) & (6) (6) (5), (6) & (7) (7)

604130611 5006B Rear Top Panel 3-3/4 x 34-1/16 (5) (8) (5), (6) & (8)

604130711 5007B Rear Top Panel 3-3/4 x 39-1/2 (5)

604130811 5008B Rear Top Panel 3-3/4 x 44-15/16 (6) (5) & (6) (5)

604130911 5009B Rear Top Panel 3-3/4 x 50-3/8 (6) (5) & (6) (7) (7) (7)

604131011 5010B Rear Top Panel 3-3/4 x 55-13/16

6041331 Intermediate Vestibule Panel 6-1/8 x 24 (22) (22) (22) (22) (22) (22) (22) (22) (22)

6041332 Left Side Top Panel 3-7/8 x 14-13/16 (11) (11) (11) (11) (11) (11) (11) (11) (11)

6041333 Right Side Top Panel 3-7/8 x 14-13/16 (12) (12) (12) (12) (12) (12) (12) (12) (12)

7041301 Lower End Panel Support Bkt. 1 x 21 (17) (17) (17) (17) (17) (17) (17) (17) (17)

60413081 Front Int. Panel 36 x 7-5/16 (41) (41) (41) (41) (41) (41) (41) (41) (41)

7041307 #16 Left to Right Channel 1 x 30-9/16 (42) (42) (42)

7041308 #17 Left to Right Channel 1 x 36 (42) (45) (42) & (45)

7041309 #18 Left to Right Channel 1 x 41-7/16 (42)

7041310 #19 Left to Right Channel 1 x 46-7/8 (43) (42) & (43) (42)

7041311 #20 Left to Right Channel 1 x 52-5/16 (43) (42) & (43) (44) (44) (44)

7041312 #26 Left to Right Channel 1 x 27-3/16 (43)

7041313 #27 Left to Right Channel 1 x 32-5/8 (43) (43) (43) & (44) (44)

7041314 #28 Left to Right Channel 1 x 38-1/16 (43)

80860926 Knobs Dimco - Black #516 (46) (46) (46) (46) (46) (46) (46) (46) (46)

80860800 Machine Screw #10 -32 x 3/16” Lg. Slotted Rd. Head (47) (47) (47) (47) (47) (47) (47) (47) (47)

TABLE 4E COMPLETE JACKETS

BOILER

SIZE

PART

NO.

BOILER

SIZE

PART

NO.

BOILER

SIZE PART NO. BOILER

SIZE PART NO.

5006B 60413068 5009B 60413098 5012B 60413128 5015B 60413158 5018B 60413188 5021B 60413218

5007B 60413078 5010B 60413108 5013B 60413138 5016B 60413168 5019B 60413198 5022B 60413228

5008B 60413088 5011B 60413118 5014B 60413148 5017B 61413178 5020B 60413208 5024B 60413248

SECTION VI - REPAIR PARTS (continued)

TABLE 4F

Water Trim

Water Trim Carton Number: 7W2 7W3 7W4

Description 5006B-5011B 5012B-5022B 5024B-5026B PART NO.

Temperature Control, Honeywell L4006A2015 1 1 1 80160400

Immersion Well, Honeywell #123871A, 3/4” 1 1 1 80160452

Temperature Pressure Gauge, 100 PSI, 80-320°F, 1/2” NPT 1 1 1 8056028

Relief Valve Piping:

Nipple, 3/4” x 2” 1 1 806600003

Nipple, 1” x 2” 1 806600004

Nipple, 1-1/2” x 3” 1 1 1 806600006

Bushing, Hex, 1-1/2” x 3/4” 1 1 1 806600507

Elbow, Reducing, 1-1/2” x 3/4” x 90° 1 1 806601506

Elbow, Reducing, 1-1/2” x 1” x 90° 1 806601507

Relief Valve, ConBraCo #10-303-10, 3/4” x 3/4”, 50 psi 1 81660302

Relief Valve, ConBraCo #10-614-10, 3/4” x 1”, 50 psi 1 81660359

Relief Valve, ConBraCo #10-615-10, 1” x 1-1/4”, 50 psi 1 81660362

Plug extra tappings:

Plug, Pipe, 3/4” Countersunk 3 3 3 806603504

Plug, Pipe, 1-1/2” Countersunk 2 2 2 806603506

Plug, Pipe, 1/2” Countersunk 5 5 5 806603510

Plug, Pipe, 1” Countersunk 2 2 2 806603517

Steam Trim

Steam Trim Carton Number: 7S1 7S2 7S3 7S4

Description 5006B-5008B 5009B-5011B 5012B-5020B 5021B-5026B PART NO.

Pressuretrol, Honeywell L404F1060 1 1 1 1 80160942

Steam Gauge, 4" Dia., 30" -0-30 PSI, 1/4" 1 1 1 1 8056022

Gauge Glass Set, Conbraco #20-104-10 (6¾") 1 1 1 1 8056019

Safety Valve Piping:

Nipple, 1½" x 3”, Black 1 1 1 1 806600006

Elbow, Reducing, 1½” x ¾” x 90° 1 806601506

Elbow, Reducing, 1½” x 1” x 90° 1 806601507

Elbow, Reducing, 1½” x 1¼” x 90° 1 806601508

Elbow, 1½” x 90° 1 806601547

Safety Valve, ConBraCo #13-211-08, ¾”,

15 psi 1 81660500

Safety Valve, ConBraCo #13-202-08, 1” x 1”,

15 psi 1 81660501

Safety Valve, ConBraCo #13-213-08, 1¼” x

1½”, 15 psi 1 81660505

Safety Valve, Conbraco #13-214-08, 1½" x 2",

15 psi 1 81660503

Miscellaneous Fittings:

Coupling, Reducing, ½” x ¼” (Mount Syphon) 1 1 1 1 806602503

Extension Adapter, ½” FPT x ½” MPT

(Mount Gauge Glass) 2 2 2 2 806604501

Syphon, ¼” x 90° (Mount Pressuretrol) 1 1 1 1 8066030006

Elbow, street, ¼” x 90° (Mount Syphon) 1 1 1 1 806601509

Nipple, ½” x Close (Mount Syphon) 1 1 1 1 806600040

Plug Extra Tappings:

Plug, Pipe, ¾" Countersunk 2 2 2 2 806603504

Plug, Pipe, 1½" Countersunk 3 3 3 3 806603506

Plug, Pipe, ½" Countersunk 3 3 3 3 806603510

Plug, Pipe, 1" Countersunk 4 4 4 4 806603517

Lowest Permissible Water Level Plate 1 1 1 1 8141307

SECTION VI - REPAIR PARTS (continued)

TABLE 4G

7000DERHC GAS TRAIN - EI - 5006B THRU 5009B - USA

PART NO. ITEM BOILER SIZE

5006B 5007B 5008B 5009B

81660151 Robertshaw 7000DERHC-S7C 1” x 1” Gas Valve (Nat.) (1) (1) (1) (1)

-- OR --

81660158 Robertshaw 7000DERHC-LP-S7C 1” x 1” Gas Valve (LP) (1) (1) (1) (1)

806604002 1” Ground Joint Union (2) (2) (2) (2)

806600027 1” x 3” Lg. -- Nipple (3) (3) (3) (3)

SECTION VI - REPAIR PARTS (continued)

V88A GAS TRAINS - USA

PART NO. ITEM BOILER SIZE

5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B

Diaphragm Gas Valve

81660008 1” Honeywell V88A1618 1 --- 1 1 ---

81660009 1¼” Honeywell V88A1626 --- 1 --- 1 1

822605 Bleed Valve Assembly - Honeywell #126590 2 2 2 2 2

Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC

8226006 Maxitrol RV-61 1” x 1” 3A --- 3A 3A ---

822607 Maxitrol RV-81 1¼” x 1¼” --- 3A --- 3A 3A

LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC

8226011 Maxitrol RV-61 1” x 1” 3B --- 3B 3B ---

8226012 Maxitrol RV-81 1¼” x 1¼” --- 3B --- 3B 3B

822614 Leak Limiter - Maxitrol #12A04 (incl. w / RV-61) 4 --- 4 4 ---

8226010 Leak Limiter - Maxitrol #12A34 (incl. w / RV-81) --- 4 --- 4 4

Manual Shutoff Valve

822615 ConBraCo 50-GB5-01A 1” x 1” 5 --- 5 5 ---

8226161 ConBraCo 50-GB6-01A 1¼” x 1¼” --- 5 --- 5 5

822645 Pilot Valve 6 6 6 6 6

SECTION VI - REPAIR PARTS (continued)

V88A GAS TRAINS - CANADA

NATURAL GAS ONLY

PART NO. ITEM BOILER SIZE

5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B

Diaphragm Gas Valve

81660008 1” Honeywell V88A1618 1 --- 1 1 ---

81660009 1¼” Honeywell V88A1626 --- 1 --- 1 1

822605 Bleed Valve Assembly - Honeywell #126590 2 2 2 2 2

Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC

8226006 Maxitrol RV-61 1” x 1” 3 --- 3 3 ---

822607 Maxitrol RV-81 1¼” x 1¼” --- 3 --- 3 3

822614 Leak Limiter - Maxitrol #12A04 (incl. w / RV-61) 4 --- 4 4 ---

8226010 Leak Limiter - Maxitrol #12A34 (incl. w / RV-81) --- 4 --- 4 4

Manual Shutoff Valve

822615 ConBraCo 50-GB5-01A 1” x 1” 5 --- 5 5 ---

8226161 ConBraCo 50-GB6-01A 1¼” x 1¼” --- 5 --- 5 5

822645 Pilot Valve 6 6 6 6 6

Lubricated Plug Valve

822619 Newman-Milliken 200M - 1” 7 --- 7 7 ---

822620 Newman-Milliken 200M - 1¼” --- 7 --- 7 7

SECTION VI - REPAIR PARTS (continued)

FLUID POWER GAS TRAINS - USA

(See Page 94 for “LO-HI-LO” Natural Gas Diaphragm Type Valves)

PART NO. ITEM BOILER SIZE

5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B

Fluid Power Gas Valve

81660010 1” - Honeywell V5055B1002 1 --- 1 1 ---

81660011 1¼” - Honeywell V5055B1010 --- 1 --- 1 1

Actuators for Fluid Power Valves

81660012 “Lo-Hi-Off” Honeywell V4055A1007 - 5026B Sec. Opening Time - 120V 60HZ

81660013 “Lo-Hi-Lo” Honeywell V4062A1008 - 5026B Sec. Opening Time - 120V 60HZ

81660014 “Modulating” Honeywell V9055A1055 - 5026B Sec. Opening Time - 120V 60HZ

Solenoid Gas Valve

81660088 1” - ITT Gen. K3A562 3 --- 3 3 ---

81660086 1¼” - ITT Gen. K3A772 --- 3 --- 3 3

Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC

8226006 Maxitrol RV-61 1” x 1” 4A --- 4A 4A ---

8226012 Maxitrol RV-81 1¼” x 1¼” --- 4A --- 4A 4A

LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC

8226011 Maxitrol RV-61 1” x 1” 4B --- 3B 3B ---

8226012 Maxitrol RV-81 1¼” x 1¼” --- 4B --- 4B 4B

822614 Leak Limiter - Maxitrol #12A04 (included w/ RV-61) 5 --- 5 5 ---

8226010 Leak Limiter - Maxitrol #12A34 (included w/ RV-81) --- 5 --- 5 5

Manual Shutoff Valve

822615 ConBraCo 50-GB5-01A 1” x 1” 6 --- 6 --- ---

8226161 ConBraCo 50-GB6-01A 1¼” x 1¼” --- 6 --- 6 6

822645 Pilot Valve 7 7 7 7 7

SECTION VI - REPAIR PARTS (continued)

DIAPHRAGM VALVE “LO-HI-LO” GAS TRAIN

USA - NATURAL GAS ONLY

PART NO. ITEM BOILER SIZE

5006B 5009B 5015B 5016B 5017B

“Lo-Hi-Lo” Gas Valve

81660149 1” Honeywell V8944B1019 1 --- 1 1 ---

81660150 1¼” Honeywell V8944B1027 --- 1 --- 1 1

Solenoid Gas Valve

81660081 1” - ITT Gen. K8A461 3 --- 3 3 ---

81660094 1¼” - ITT Gen. K8A771 --- 3 --- 3 3

Manual Shutoff Valve

822615 ConBraCo 50-GB5-01A 1” x 1” 6 --- 6 6 ---

8226161 ConBraCo 50-GB6-01A 1¼” x 1¼” --- 6 --- 6 6

822645 Pilot Valve 7 7 7 7 7

SECTION VI - REPAIR PARTS (continued)

DIAPHRAGM VALVE “LO-HI-LO” GAS TRAIN

CANADA - NATURAL GAS ONLY

PART NO. ITEM BOILER SIZE

5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B

“Lo-Hi-Lo” Gas Valve

81660149 1” Honeywell V8944B1019 1 --- 1 1 ---

81660150 1¼” Honeywell V8944B1027 --- 1 --- 1 1

Solenoid Gas Valve

81660081 1” - ITT Gen. K8A461 3 --- 3 3 ---

81660094 1¼” - ITT Gen. K8A771 --- 3 --- 3 3

Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC

8226006 Maxitrol RV-61 1” x 1” 3 --- 3 3 ---

8226012 Maxitrol RV-81 1¼” x 1¼” --- 3 --- 3 3

LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC

8226011 Maxitrol RV-61 1” x 1” 3 --- 3 3 ---

8226012 Maxitrol RV-81 1¼” x 1¼” --- 3 --- 3 3

Leak Limiter

822614 Maxitrol #12A04 (included w/ RV-61) 4 --- 4 4 ---

8226010 Maxitrol #12A34 (included w/ RV-81) --- 4 --- 4 ---

Manual Valve

822615 ConBraCo 50-GB5-01A 1” x 1” 5 --- 5 5 ---

8226161 ConBraCo 50-GB6-01A 1¼” x 1¼” --- 5 --- 5 5

Pilot Valve

822645 1/8”MPT x ¼” OD Tube 6 6 6 6 6

Manual Valve

822619 Newman-Milliken 200M - 1” 7 --- 7 7 ---

822620 Newman-Milliken 200M - 1¼” --- 7 --- 7 7

SECTION VI - REPAIR PARTS (continued)

FLUID POWER GAS TRAINS - CANADA

PART NO. ITEM BOILER SIZE

5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B

Fluid Power Gas Valve

81660010 1” - Honeywell V5055B1002 1 --- 1 1 ---

81660011 1¼” - Honeywell V5055B1010 --- 1 --- 1 1

Actuators for Fluid Power Valves

81660012 “Lo-Hi-Off” Honeywell V4055A1007 - 5026B Sec. Opening Time - 120V 60HZ

81660013 “Lo-Hi-Lo” Honeywell V4062A1008 - 5026B Sec. Opening Time - 120V 60HZ - LP Only

81660014 “Modulating” Honeywell V9055A1055 - 5026B Sec. Opening Time - 120V 60HZ

Solenoid Gas Valve

81660088 1” - ITT Gen. K3A562 3 --- 3 3 ---

81660094 1¼” - ITT Gen. K3A772 --- 3 --- 3 3

Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC

8226006 Maxitrol RV-61 1” x 1” 4A --- 4A 4A ---

822607 Maxitrol RV-81 1¼” x 1¼” --- 4A --- 4A 4A

LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC

8226011 Maxitrol RV-61 1” x 1” 4B --- 3B 3B ---

8226012 Maxitrol RV-81 1¼” x 1¼” --- 4B --- 4B 4B

822614 Leak Limiter - Maxitrol #12A04 (included w/ RV-61) 5 --- 5 5 ---

8226010 Leak Limiter - Maxitrol #12A34 (included w/ RV-81) --- 5 --- 5 5

Manual Shutoff Valve

822615 ConBraCo 50-GB5-01A 1” x 1” 6 --- 6 6 ---

8226161 ConBraCo 50-GB6-01A 1¼” x 1¼” --- 6 --- 6 6

822645 Pilot Shutoff Valve 7 7 7 7 7

822619 Newman-Milliken 200M - 1” 8 --- 8 8 ---

822620 Newman-Milliken 200M - 1¼” --- 8 --- 8 8

SECTION VI - REPAIR PARTS (continued)

PART NO. 6011301 100958-01

Description Manifold Module Support Bracket Assembly Honeywell S8610M3009 Ignition Module

IGNITION MODULE #S8610M & SUPPORT BRACKET

EI CONTROL SYSTEM

SECTION VI - REPAIR PARTS (continued)

PILOTSTAT #L62GB & SUPPORT BRACKET

THERMOCOUPLE CONTROL SYSTEM

SECTION VI - REPAIR PARTS (continued)

ITEM (1) (2)

PART NO. 6011301 80160138

Description Manifold Module Support

Bracket Assembly

L62GB-3C

Pilot Safety Switch

TRANSFORMER, PENN #H91WG PILOT SOLENOID VALVE & PILOT LINE REGULATOR

EI CONTROL SYSTEM

U.S.A. - 5010B-5026B NAT. GAS

CANADA - 5006B-5026B NAT. GAS

PART NO. ITEM

7136001 (1) “J” Box Mounting Bracket 24V 100 VA Transformer - 120 60HZ Primary

80160016 (2) Penn Y64T22-0 Plate Mounted

822666 (3) Penn Pilot Solenoid Valve H91WG-6

8226005 Pilot Line Regulator

Nat. Gas - Maxitrol RV-12-LT w/orange spring 4” to 8” WC

8136037 Heyco A25F Strain Relief Adaptor

8136038 Heyco Strain Relief Bushing SR-6P-4

SECTION VI - REPAIR PARTS (continued)

100

TRANSFORMER & PILOT LINE REGULATOR

THERMOCOUPLE CONTROL SYSTEM - CANADA

PART NO. ITEM

7016001 (1) “J” Box Mounting Bracket

24V - 40 VA Transformer - 120 60HZ Primary

80160039 (2A) USA - Honeywell Plate Mounted AT140D1012

80160014 (2B) Canada - Honeywell Foot Mounted AT72D1089

8226005 (3) Pilot Line Regulator

Nat. Gas - Maxitrol RV-12-LT w/orange spring 4” to 8” WC

SECTION VI - REPAIR PARTS (continued)

101

TRANSFORMER, PENN #H91WA-4 PILOT SOLENOID VALVE & PILOT LINE REGULATOR

EP CONTROL SYSTEM

PART NO. ITEM

7016003 (1) EP Control Mounting Bracket

24V - 40 VA Transformer - 120V 60HZ Primary

80160039 (2A) USA - Honeywell Plate Mounted AT140D1012

80160014 (2B) Canada - Honeywell Foot Mounted AT72D1089

822662 (3) Penn Pilot Solenoid Valve H91WA-4, 120V

8226005 (4) Nat. Gas - Maxitrol RV-12-LT w/orange spring 4” to 8” WC

80160018 Webster 612-6A7 Ignition Transformer (not shown)

SECTION VI - REPAIR PARTS (continued)

102

CONTROL ASSEMBLY AND MOUNTING BRACKET

EP CONTROL SYSTEMS

SECTION VI - REPAIR PARTS (continued)

103

EI CONTROL SYSTEM - HONEYWELL Q3481 PILOT ASSEMBLY

EI CONTROL SYSTEM - PILOT ASSEMBLY

6236072 EI - 1, NAT., 5006B - 5009B Sections

6236075 EI - 1, LP., 5006B - 5009B Sections

6236076 EI - 2, NAT., 5010B - 5026B Sections

Not Available ........LP, 5010B - 5026B Sections

PART NO. ITEM

103704-01 (1) Pilot Burner/Igniter/Sensor Honeywell Q3481B1206, Nat. Gas with NE24 orice

100332-01 (1) Pilot Burner/Igniter/Sensor Honeywell Q3481B1180, LP Gas with KR14 orice

6136054 (2) Pilot Ground Wire Assembly, 36” (5006B - 5009B)

6137375 (2) Pilot Ground Wire Assembly, 72” (5010B - 5026B)

8236015 (3) Vent Tube Tip (USA Only) (5010B - 5026B Sections Only)

8236016 (4) Vent Tube Clip - Tinnerman C4886A4-27 (USA Only) (5010B - 5026B Sections Only)

8236048 (5) Vent Tube - ¼” x 18” Long Aluminum Tubing

For Canada, Omit Vent Tube, Vent Tube Tip and Vent Tube Clips. These items are not

used on 5006B - 5009B Sections, Robertshaw Gas Valves - USA.

SECTION VI - REPAIR PARTS (continued)

104

EP CONTROL SYSTEM - PILOT ASSEMBLY

6236003 NAT. GAS

Not Available for LP

PART NO. ITEM

8236017 (1) Flame Rectication Pilot Ass’y

Natural Gas - Honeywell Q179C1009 w/388146 AG Orice

7136255 (2) Ignition Lead - Honeywell R1061012 - 6’ Long

7136256 (3) Flame Rod Lead - Honeywell R1298020 - 6’ Long

8236021 (4) Female Rajah Connector - Honeywell 37356

6236020 (5) Ground Wire - Continental SRGX-600 200°C - Green - 72” Long

8236015 (6) Vent Tube Tip - (USA Only)

8236016 (7) Vent Tube Clip - Tinnerman C4886A4-27 (USA Only)

SECTION VI - REPAIR PARTS (continued)

105

APPENDIX A - FIGURES

Figure

Number

Page

Number Description

Section I - Equipment Check List

USA

KD Boilers 5 & 6 U.S.A. Equipment Check List

Canada

KD Boilers 7 & 8 Canadian Equipment Check List

Fig. 1 9 Dimensional Data

Section II - General Information

Section III - Installation Instructions

Fig. 2 11 Single Manifold Base 5006B Thru 5014B Section Boilers

Fig. 3 12 Dual Manifold Bases - 5015B Thru 5026B Section Boilers

Fig. 4 12 LEH Section on Base

Fig. 5 12 Assembly of Center Sections

Fig. 6 13 Arrangement of Sections and Canopy(s)

Fig. 7 14 Purpose of Tappings and Their Locations

Fig. 8 15 Installation of Built-in Heater

Fig. 9 15 Testing Boiler Assembly for Leaks

Fig. 10 16 Sealing of Base, Installation of Flue Covers and Canopies

Fig. 11 16 Attachment of Flue Covers

Fig. 12 17 Recommended Steam Boiler Piping, Gravity Return, 1 or 2 Supply Connections - 5006B Thru 5014B Section Boilers

Fig. 13 18 Recommended Steam Boiler Piping, Gravity Return, 3 Supply Connections - 5015B Thru 5020B Section Boilers

Fig. 14 19 Recommended Steam Boiler Piping, Gravity Return, 4 or 5 Supply Connections - 5021B Thru 5026B Section Boilers

Fig. 15 20 Typical Steam Piping Arrangement for Boilers with Pumped Condensate Return and Boiler Feed Unit

Fig. 16A 21 Recommended Water Boiler Piping 1 Supply Connection and 1 Return Connection, Sizes 5006B Thru 5019B Section

Boilers

Fig. 16B 21 Recommended Water Boiler Piping, 3 Supply Connections and Two Return Connections, Sizes 5020B Thru 5026B

Section Boilers

Fig. 17 22 Recommended Boiler Piping for Combination Heating and Cooling Systems

Fig. 18 22 Installation of Jacket Support Brackets to Base End Panels

Fig. 19 23 Installation of Jacket End Panels

Fig. 20 23 Vestibule Attachment Diagram

Fig. 21 24 Exploded View of Jacket, 5006B Thru 5010B Section Boilers

Fig. 22 25 Securing of Canopy/Draft Hood

Fig. 23 26 Canopy/Draft Hood Mounting Diagram

Fig. 24 27 Exploded View of Jacket, 5011B Thru 5019B Section Boilers

Fig. 25 29 Exploded View of Jacket, 5020B Thru 5022B Section Boilers

Fig. 26 30 Exploded View of Jacket, 5024B and 5026B Section Boilers

Fig. 27 31 Steam Trim and Controls

Fig. 28 32 Mounting Elevations of M&M 150 and a 67M Float LWCO

Fig. 29 33 Water Trim and Controls

Fig. 30 34 Recommended Piping to Built-in Tankless Heaters

Fig. 31 36 Installation of S8610M Module

Fig. 32 36 Pilot Piping - EI Control System (Robertshaw7000) USA 5006B Thru 5009B

Fig. 33 37 Pilot Piping - EI Control System (V88A) USA 5010B Thru 5026B - Nat. Gas; Canada - 5006B Thru 5026B - Nat. Gas

Fig. 34 38 Installation of EP Mounting Bracket and Controls

Fig. 35 38 Pilot Piping, EP Control System

106

Figure

Number

Page

Number Description

Section III - Installation Instructions (continued)

Fig. 36 40 Pilot Piping, Thermocouple Control System - Canada Only

Fig. 37 40 Installation of Pilot Safety Switch, Thermocouple Control System

Fig. 38 41 Single Vent System

Fig. 39 41 Manifold Vent System

Section IV - Operation

Fig. 40 47 Schematic Wiring Diagram - EI Control System (Robertshaw7000 Gas Valve) USA 5006B Thru 5009B

Fig. 41 48 Schematic Wiring Diagram - EI Control System (V88 Gas Train) USA 5010B Thru 5014B; Canada 5006B Thru 5014B

Fig. 42 49 Schematic Wiring Diagram - 5015B Thru 5026B Section Boilers, EI Control System

Fig. 43 50 Ladder Wiring Diagram - 5015B Thru 5026B Section Boilers, EI Control System

Fig. 44 54 Wiring Diagram - 5006B Thru 5014B Section Boilers, EP Control System

Fig. 45 55 Wiring Diagram - 5015B Thru 5026B Section Boilers, EP Control System

Fig. 46 58 Wiring Diagram - 5006B Thru 5014B Section Boilers, Thermocouple Control System (Canada Only)

Fig. 47 59 Wiring Diagram - 5015B Thru 5024B Section Boilers, Thermocouple Control System (Canada Only)

Fig. 48 61 V8944B Combination Valve

Fig. 49 62 Low Fire Adjustment - V4062 Actuator

Fig. 50 62 Low Fire Adjustment - V9055A Actuator

Section V - Service

Fig. 51 64 Removal of Jacket Front Panel

Fig. 52 66 Attachment of Flue Covers

Fig. 53 66 Cleaning of Flueways

Fig. 54-1 68 Pilot Locations

Fig. 54-2 69 Pilot Locations

Fig. 55 70 Main Burner Flame Adjustment

Fig. 56 70 Pilot Flame - Honeywell Q3481B

Fig. 57 71 Pilot Flame Honeywell Q179C Pilot

Fig. 58 71 Pilot Flame Honeywell Q327A Pilot w/Thermocouple

Section VI - Repair Parts

Fig. 59 75 Base Parts (5006B Thru 5014B)

Fig. 60 77 Base Parts (5015B Thru 5026B)

Fig. 61 79 Integral Canopy Draft Hoods and Sections

Fig. 62 83 Jackets

Robertshaw

Gas Train 90 7000DERHC Gas Train - EI - 5006B Thru 5009B - USA

Honeywell

Gas Train 91 V88A Gas Train - USA

Honeywell

Gas Train 92 V88A Gas Train - Canada (Natural Gas Only)

Honeywell

Gas Train 93 Fluid Power Gas Train - USA

Honeywell

Gas Train 94 Diaphragm Valve LO-HI-LO Gas Train, USA (Natural Gas Only)

Honeywell

Gas Train 95 Diaphragm Valve LO-HI-LO Gas Train, Canada (Natural Gas Only)

Honeywell

Gas Train 96 Fluid Power Gas Train - Canada

APPENDIX A - FIGURES (continued)

107

Figure

Number

Page

Number Description

Section VI - Repair Parts (continued)

Honeywell Ignition

Module 97 Ignition Module #S8610M and Support Bracket, EI Control System

Penn Johnson

Control System 98 Pilotstat #L62GB & Support Bracket, Thermocouple Control System

Penn Pilot Solenoid

Valve Ass’y 99

Transformer, Penn #H91WG-5 Pilot Solenoid Valve and Pilot Line Regulator EI Control System,

USA (5010B - 5026B) Natural Gas;

Canada (5006B - 5026B) Natural Gas

Maxitrol Pilot Reg

Ass’y 100 Transformer and Pilot Line Regulator, Thermocouple Control System (Canada)

Penn Pilot Solenoid

Valve Ass’y 101 Transformer, Penn #H91WA-4 Pilot Solenoid Valve and Pilot Line Regulator, EP Control System

EP Control Ass’y 102 Control Assembly and Mounting Bracket, EP Control Systems

Honeywell Q3481

Pilot Ass’y 103 EI Control System - Honeywell Q3481 Pilot Assembly

Honeywell Q179C

Pilot Ass’y 104 EP Control System - Pilot Assembly

Miscellaneous

Figures 105 - 107 Appendix A - Figures

APPENDIX A - FIGURES (continued)

108

APPENDIX B - TABLES

Table

Number

Page

Number Description

Section I - Equipment Check List

Section II - General Information

Reference 10 Clearances for Boiler Room Space

Section III - Installation Instructions

Table I 34 Natural Gas (Maximum Capacity of Piping in Cubic Feet of Gas Per Hour)

Table II 34 Multipliers to be Used with Table I when Pressure Drop is Not 0.3” WC

Table III 34 Multipliers to be Used with Table I when Specic Gravity Other than 0.60

Par: 38 35 Installation of The Remainder of The Gas Controls

Section IV - Operation

Par: 1c 43 Reference Should Next be Made to The Applicable Control System

Table IV 44 Water Content (Gallons) 5006B Thru 5026B Models

Par: 3 45 Control Variations

Flow Chart 51 Trouble Shooting Guide Boilers Equipped With S8610M Intermittent Electronic Ignition

Par: 5b 60 Additional Check on Input

Section V - Service

RCF 65 Important Product Safety Information, Refractory Ceramic Fiber Product

Form 73 Service Record, Service Performed

Section VI - Repair Parts

Index 74 Repair Parts Index

Table 2A 76 Series 5B Base Parts - 5006B Thru 5014B

Table 2B 77 Series 5B Base Parts - 5015B Thru 5026B

Table 3A 80 Series 5B Integral Canopy Draft Hoods - Boiler Sizes 5006B Thru 5010B

Table 3B 81 Series 5B Section Replacement Chart

Table 3C 82 Series 5B Base / Pilot Assemblies

Table 4A 84 Series 5B Jackets - 5006B Thru 5015B

Table 4B 85 Series 5B Jackets - 5006B Thru 5015B

Table 4C 86 Series 5B Jackets - 5016B Thru 5026B

Table 4D 87 Series 5B Jackets - 5016B Thru 5026B

Table 4E 87 Complete Jackets

Table 4F 88 Water Trim

Table 4G 89 Steam Trim

Robertshaw

Gas Train 90 7000DERHC Gas Train - EI - 5006B thru 5009B - USA

Honeywell

Gas Train 91 V88A Gas Train - USA

Honeywell

Gas Train 92 V88A Gas Train - Canada (Natural Gas Only)

Honeywell

Gas Train 93 Fluid Power Gas Train - USA

Honeywell

Gas Train 94 Diaphragm Valve LO-HI-LO Gas Train, USA (Natural Gas Only)

Honeywell

Gas Train 95 Diaphragm Valve LO-HI-LO Gas Train, Canada (Natural Gas Only)

Honeywell

Gas Train 96 Fluid Power Gas Train - Canada

Honeywell

Ignition Module 97 Ignition Module #S8610M and Support Bracket, EI Control System

109

APPENDIX B - TABLES (continued)

Table

Number

Page

Number Description

Section VI - Repair Parts (continued)

Penn Johnson

Control System 98 Pilotstat #L62GB & Support Bracket, Thermocouple Control System

Penn Pilot Solenoid

Valve Ass’y 99

Transformer, Penn #H91WG-5 Pilot Solenoid Valve and Pilot Line Regulator EI Control System,

USA (5010B - 5026B) Natural Gas;

Canada (5006B - 5026B) Natural Gas

Maxitrol Pilot Reg

Ass’y 100 Transformer and Pilot Line Regulator, Thermocouple Control System (Canada)

Penn Pilot Solenoid

Valve Ass’y 101 Transformer, Penn #H91WA-4 Pilot Solenoid Valve and Pilot Line Regulator, EP Control System

Control Assembly 102 Control Assembly & Mounting Bracket, EP Control Systems

Honeywell Q3481

Pilot Ass’y 103 EI Control System - Honeywell Q3481 Pilot Assembly

Honeywell Q179C

Pilot Ass’y 104 EP Control System - Pilot Assembly

Miscellaneous

Tables 108 - 109 Appendix B - Tables

Rear Cover Limited Warranty for Commercial Grade Boilers and Parts/Accessories

110

111

112

Burnham Series 5B Boiler Installation Operating Instructions

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