Burnham Series 8H 8He Boiler Installation And Operation Manual

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81416023R5 - 4/15 Price - $5.00

Commercial Boilers

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3050579

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

SERIES 8H / 8HE

GAS - FIRED BOILER

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.

2

IMPORTANT INFORMATION -

READ AND sAvE ThEsE INsTRucTIONs FOR REFERENcE

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.

Hazard Denitions

Indicates a potentially hazardous situation which,

if not avoided, could 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 special instructions on installation,

operation, or maintenance which are important

but not related to personal injury hazards.

All boilers must be installed in accordance with National, State and Local Plumbing, Heating

and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations

may differ from this instruction manual. Authorities having jurisdiction should be consulted

before installations are made.

In all cases, reference should be made to the following Standards:

USA BOILERS

A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil

Burning Equipment”, for recommended installation practices.

B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.

C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces,

Vents, and Solid Fuel Burning Appliances”, For Venting requirements.

D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and

Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls

and safety devices.

E. All wiring on boilers installed in the USA shall be made in accordance with the National

Electrical Code and/or Local Regulations.

CANADIAN BOILERS

A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil

Burning Equipment", for recommended Installation Practices.

B. The equipment shall be installed in accordance with the current Installation Code for Gas

Burning Appliances and Equipment, CSA B149, and applicable Provincial Regulations for

the class; which should be carefully followed in all cases.

Authorities having jurisdiction should be consulted before installations are made.

C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian

Electrical Code and/or Local Regulations.

3

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

in this manual.

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

injury or loss of life. Read and understand the entire manual before attempting installation, start-up

operation, or service. Installation and service must be performed only by an knowledgeable, experienced,

and skilled installer or service agency.

This boiler must be properly vented.

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 system must be inspected and cleaned before the start of the heating season

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

unobstructed venting system is 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.

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 IV, Paragraph C.

This boiler is supplied with safety devices 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 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.

Boiler 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.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions,

including all those contained in component manufacturers manuals which are provided with the boiler

before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or

liquids.

Do not operate boiler with control which has been subject to water.

All cover plates, enclosures and guards must be in place at all times.

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.

4

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 IX, Paragraph B.

NOTICE

All Series 8HE 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 8HE

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. The MAWP for all Series 8HE

Boiler is 50 psi (Water Only).

It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler

MAWP. Therefore, in addition to Safety Relief Valves set for 50 psi, Burnham also offers Safety Relief Valves

set for 30 psi (By Special Order Only).

NOTICE

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.

USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially

oriced to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code,

NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orice sizing is indicated on the

rating label.

5

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.

6

Table of Contents

I. Pre-Installation .............................................................8

II. Boiler Assembly .........................................................10

III. Gas Control System Assembly ..................................17

(Knockdown Boilers)

IV. Water Trim and Piping ...............................................24

V. Gas Piping ..................................................................28

VI. Venting .......................................................................30

VII. Electrical ....................................................................33

VIII. System Start-up ..........................................................49

IX. Service .......................................................................57

X. Repair Parts ................................................................62

7

Figure 1: Dimensional Data

Boiler

Model

Input

(MBH)

Dimensions (Inches) Recommended

Chimney Size

(Round)

Water

Content

(Gallons)

Approx. Shipping Weight

(LB.)

A B C D E Packaged Knockdown

805H 252 20 10 7 24-13/16 16-1/8 7” dia. x 15 ft. 11.9 600 610

806H 315 23-3/4 11-7/8 8 27-13/16 18 8” dia. x 15 ft. 13.9 690 700

807HE 340 27-1/2 13-3/4 8 27-13/16 18 8” dia. x 15 ft. 15.9 785 870

808HE 410 31-1/4 15-5/8 9 30-13/16 20 8” dia. x 15 ft. 17.9 895 955

809HE 460 35 17-1/2 10 33-1/2 22 10” dia. x 15 ft. 19.9 985 1050

810HE 505 38-3/4 19-3/8 10 33-1/2 22 10” dia. x 15 ft. 21.9 1075 1150

Table 1: Dimensional Data

8

I. Pre-Installation

Carefully read all instructions before installing

boiler. Failure to follow all instructions in proper

order can cause personal injury or death.

A. 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 claim

for damage or shortage in shipment must be led

immediately against carrier by consignee. No claims

for variances or shortages will be allowed by Boiler

Manufacturer, unless presented within sixty (60) days

after receipt of equipment.

B. Installation must conform to the requirements of

the authority having jurisdiction. In the absence of

such requirements, installation must conform to the

National Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or

CAN/CSA B149.1 Installation Codes. Where required

by the authority having jurisdiction, the installation

must conform to the Standard for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME

No CSD-1.

C. Provide clearance between combustible material and

boiler jacket (following clearances are minimums):

1. USA, 805H-807HE: listed for Alcove installation

a. Front: 18”

b. Top: 36”

c. Draft hood, rear, sides and ue connector: 6”

Appliance is design certied for installation on

noncombustible ooring only. For installation

on combustible ooring only when installed on

special base listed in Table 2. Boiler must not be

installed on carpeting. When boiler is installed on

concrete which is over a material that is subject

to melting (PVC, PEX radiant tubing, etc.), the

special base must be used. A concrete pad is not

sufcient to protect combustible ooring.

2. USA, 808HE-810HE: for installation in room

which is large in comparison with size of boiler.

a. Front: 18”

b. Top: 51½”

c. Draft hood, rear, sides, and ue connector: 6”

3. Canada, 805H-810HE:

a. Top and front: 18” (45.7 cm)

b. Flue, rear and sides: 6” (15.2 cm)

D. Provide clearance for servicing and proper operation

(following clearances are recommended and may be

reduced to minimum clearances shown above):

1. Single boiler, 805H-807HE, Front/Top: 24” (61.0

cm)

2. Single boiler, 808HE-810HE, Front/Top: 48”

(122.0 cm)

3. Multiple/modular boiler, USA /Canada, Sides: 1”

(2.5 cm)

E. Install boiler on level oor as close to chimney as

possible. For basement installation provide a solid base

such as concrete or masonry construction if oor is not

level or if water may be encountered on oor around

boiler.

F. Protect gas ignition system components from

water (dripping, spraying, rain, etc.) during boiler

operation and service (circulator replacement, control

replacement, etc.).

G. Provide combustion and ventilation air in accordance

with applicable provisions of local building codes,

or the National Fuel Gas Code, NFPA 54/ANSI

Z223.1, Air for Combustion and Ventilation; or CAN/

CSA B149.1, Venting Systems and Air Supply for

Appliances.

Adequate combustion and ventilation air must be

provided to assure proper combustion.

The following guideline is based on the National Fuel

Gas Code, NFPA 54/ANSI Z223.1.

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

communicating directly with space (through

permanent openings not furnished with doors) are

considered part of space.

Volume [ft3] = Length [ft] x Width [ft] x Height [ft]

2. Determine Total Input of all appliances in space.

Round result to nearest 1,000 Btu per hour (Btuh).

3. Determine type of space. Divide Volume by Total

Input.

a. If result is greater than or equal to 50 ft3 per

1,000 Btuh, space is considered an unconned

space.

Boiler Model Special Base Part Number

805H 61816055

806H 61816065

807HE 61816075

808HE 61816085

809HE 61816095

810HE 61816105

Table 2: Special Base Required for Installation on

Combustible Flooring

9

b. If result is less than 50 ft3 per 1,000 Btuh, space

is considered a conned space.

4. Determine building type. A building of unusually

tight construction has the following characteristics:

a. Walls and ceiling exposed to outside atmosphere

have a continuous water vapor retarder with a

rating of 1 perm or less with openings gasketed

and sealed, and

b. Weather-stripping has been added on openable

windows and doors, and

c. Caulking or sealants applied in joints around

window and door frames, between sole

plates and oors, between wall-ceiling joints,

between wall panels, at plumbing and electrical

penetrations, and at other openings.

5. For boiler located in an unconned space in a

building of other than unusually tight construction,

adequate combustion and ventilation air is normally

provided by fresh air inltration through cracks

around windows and doors.

6. For boiler located in an unconned space in a

building of unusually tight construction or in

a conned space, provide outdoor air through

permanent opening(s) which communicate directly

or by duct with the outdoors or spaces (crawl or

attic) freely communicating with the outdoors.

Minimum dimension of air opening(s) is 3” (7.6

cm).

a. Two permanent openings: Locate one opening

within 12 inches (30.5 cm) of top of space.

Locate remaining opening within 12 inches

(30.5 cm) of bottom of space. Size each opening

per following:

i. Direct communication with outdoors.

Minimum free area of each opening must be

1 square inch per 4,000 Btu per hour input

of all equipment in space.

ii. Vertical ducts. Minimum free area of each

opening must be 1 square inch per 4,000

Btu per hour input of all equipment in space.

Duct cross-sectional area shall be same as

opening free area.

iii. Horizontal ducts. Minimum free area of each

opening must be 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.

b. One permanent opening shall be permitted where

the boiler has clearances of at least 1” (2.5 cm)

from the sides and rear and 6” (15.2 cm) from

the front. Locate the opening within 12 inches

(30.5 cm) of top of space. Size opening per

following:

i. Minimum free area of 1 square inch per

3,000 Btu per hour input of all equipment in

space.

ii. Free area shall not be less than the sum

of the areas of all vent connectors in the

conned space.

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.

7. Ventilation Duct Louvers and Grilles. Equip outside

openings with louvers to prevent entrance of rain

and snow, and screens to prevent entrance of insects

and rodents. Louvers and grilles must be xed in

open position or interlocked with equipment to open

automatically before burner operation. Screens must

not be smaller than ¼ inch mesh.

Consider the blocking effect of louvers, grilles and

screens when calculating the opening size to provide

the required free area. If free area of 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.

8. For Specially Engineered Installations. The above

requirements shall be permitted to be waived

where special engineering, consistent with good

engineering practice and approved by the authority

having jurisdiction, provides an adequate supply of

air for combustion, ventilation, and dilution of ue

gases.

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals,

sprays, paint removers, fabric softeners, etc.) are

used or stored.

Mis-sizing of the boiler with regard to the heating

system load will result in excessive boiler cycling

and accelerated component failure. Burnham

DOES NOT warrant failures caused by mis-sized

boiler applications. DO NOT oversize the boiler

to the system. Modular/multiple boilers greatly

reduce the likelihood of boiler oversizing.

10

II. Boiler Assembly

A. Remove Crate

1. Remove all fasteners at crate skid.

2. Lift outside container and remove with all other

inside protective spacers and bracing.

B. Remove boiler from skid. See Figure 2. Exercise care

to avoid dropping boiler.

1. Place boiler in approximate location. Refer to

Section I: Pre-Installation. Remove base hold down

bolts.

2. Using pry bar under rear corner of Base End Panel,

raise boiler and install 1½” wood blocks under rear

corners. Install ¾” pipe roller between Base and

skid.

3. Remove 1½” wood blocks. Place 3” pipe roller on

oor behind skid.

4. Roll boiler off skid. Move skid out of way.

5. Roll boiler until 3” roller is located as shown. Use

pry bar to install wood blocks under front corners of

base. Remove 3” roller. Figure 2: Skid Removal

Tapping Size Purpose

A 2” Supply

B 2” Return

C 3/4” Relief Valve

D 3/4” Limit

E 3/4” Auxiliary Limit

F 3/4” Washout

G 3/4” Drain

Table 3: Purpose of Tappings

Figure 3: Tapping Locations

11

6. Lift boiler with pry bar. Remove wood blocks.

Lower boiler.

C. For Packaged Boiler only, proceed to Paragraph E.

D. Test Section Assembly for leaks before connecting to

system and installing controls, trim and jacket. Refer to

Figure 3 and Table 3.

1. Plug Tappings C & E (¾ NPT) and Return Tapping

B (2 NPT).

2. Insert ¾” NPT x ¼” NPT bushing in Tapping D.

Install pressure gauge capable of indicating 50 psi.

3. Insert 2” NPT x ¾” NPT bushing in Supply Tapping

A. Install purge valve with a hose that runs to a

drain.

4. Connect ll valve and piping to Drain Tapping G.

Do not use air to leak test boiler.

5. Fill boiler completely with water by venting air

through purge valve. Close purge valve and apply

water pressure of at least 10 psi but less than 50 psi

gauge pressure.

Figure 4: Installation of Special Base for Combustible Flooring

6. Examine boiler for leaks or damage due to shipment

or handling.

7. Remove plugs from Return Tapping B, Tapping C,

and Tapping E (if second limit or operating control

is used). Also remove ll valve and piping, purge

valve and piping, and pressure gauge.

E. Install special base if installation is on combustible

ooring. See Figure 4. Floor shield adds 4¾” to boiler

height.

1. Place special base on combustible oor with surface

marked “FRONT” in upward position.

2. Locate special base with spacing to combustible

materials as shown in Figure 4.

3. Place boiler on special base. Boiler must rest inside

locating brackets. Boiler jacket panels will overhang

special base.

4. Do not enclose boiler (including special base) on all

four sides. Models 807HE may be enclosed on three

sides (alcove) while maintaining clearances shown

in Figure 4.

12

F. Move boiler to permanent location by sliding or

walking. Do not drop.

For Packaged Boiler, proceed to Paragraph L.

G. Conrm that one (1) Flue Bafe is properly

positioned in each Boiler Flueway. Tabs at the top

of each Flue Bafe should be resting on top row of Flue

Pins on each adjoining section.

H. Install Canopy on section assembly. See Figure 5.

Canopy and hardware are located in Combination

Boiler Parts and Control Carton.

1. Position Canopy on top of Section Assembly. Locate

between end sections and sealing ledge on front and

back of each section.

2. Fasten each end with ¼” - 20 x 1” carriage bolts,

washers and nuts.

3. Seal between Canopy and Section Assembly with

furnace cement.

I. Inspect joints between sections. They were factory

sealed. If any openings resulted during shipment or

handling, reseal with furnace cement. Conrm tie rods

are only hand tight to allow for thermal expansion.

J. Install Base Front Panel. See Figure 5. Panel and

hardware located in Combination Boiler Parts and

Control Carton.

1. Attach Base Front Panel to Section Assembly using

¼” - 20 x 1¼” carriage bolts, washers and nuts.

2. Seal between top of Base Front Panel and Section

Assembly with furnace cement (shipped in

Combination Boiler Parts and Control Carton).

3. Seal between top of Base Rear Panel and Section

Assembly with furnace cement.

K. Install Pilot/Main Burner Assembly. See Figure 7.

Assembly is located in Combination Boiler Parts and

Control Carton. Verify assembly is properly located

on support bracket in Base Rear Panel, seated on Main

Burner Orice, and secured with hitch pin clip.

L. Adjust Burner Air Shutters on all Burners. See

Figure 7. (On Packaged Boilers, Front Door and

Burner Access Panel(s) must be removed to make

adjustments.) Distance between front edge of Burner

Air Shutter and burner mounting ring should be

approximately 11/16”. To adjust this distance, loosen

screw at top of air shutter and slide into correct

position. Then tighten screw. (Replace Burner Access

Panel(s) and Front Door on Packaged Boilers.)

For Packaged Boiler, proceed to Section IV: Water Trim

and Piping.

Figure 5: General Assembly (Knockdown Boilers)

13

Figure 6: Flame Roll-out Switch Installation

Figure 7: Burner/Burner Access Panel Installation

14

M. Attach Flame Roll-out Switch to Burner Access Panel.

See Figure 6. Flame Roll-out Switch and hardware

are located in Combination Boiler Parts and Control

Carton. Flame Roll-out Switch is a single use device

- do not test with heat - switch cannot be reset.

1. Cut insulation from semicircular notch at right

end of the burner access panel. Models 808HE -

810HE have two (2) burner access panels. Remove

insulation from notch of right side burner access

panel only.

2. Attach Flame Roll-out Switch Mounting Bracket to

burner access panel with (1) #8 x ½” lg. sheet metal

screw.

3. Attach Flame Roll-out Switch to mounting bracket

with (1) #8 x ¾” lg. sheet metal screw.

N. Install Burner Access Panel(s). Locate Burner Access

Panel(s) in Combination Boiler Parts and Control

Carton. Engage Burner Access Panel holes with

projections on Base Front Panel. See Figure 5.

O. Install Immersion Well(s).

1. Remove Immersion Well(s) from Combination

Boiler Parts and Control Carton..

2. Insert Immersion Well in Tapping D. See Figure 3.

3. If second limit or operating control is used, insert

immersion well in Tapping E. If vertical gas

piping is to be installed inside of boiler jacket, it

is recommended that second limit be installed in

system piping.

P. Install Jacket. See Figure 8.

1. Locate four (4) Jacket Attachment Brackets in

Combination Boiler Parts and Control Carton.

Attach to Front Base Panel and Rear Base Panels

with #8 sheet metal screws. See Figure 5.

2. Hang Left Side Panel and Right Side Panel onto

Jacket Attachment Brackets.

3. Attach Lower Rear Panel to Left and Right Side

Panels. Do not tighten sheet metal screws.

4. Attach Upper Rear Panel to Lower Rear Panel. Do

not install three (3) upper screws.

5. Remove Rating Label from envelope marked

“RATING LABEL ENCLOSED”. Remove

Combustible Clearance Label from Combination

Boiler Parts and Controls Carton. Attach to

Vestibule Panel in locations shown.

6. Attach Vestibule Panel to Left Side and Right Side

Panels.

7. Attach Lower Front Tie Bar to Left Side and Right

Side Panels.

8. Engage Upper Front Panel in slots on Left Side

and Right Side Panels. Place Top Panel in position.

Attach Top Panel to Left Side, Right Side and Upper

Rear Panels.

9. Tighten all jacket screws.

10. Afx Lighting/Operating Instructions Label and

Wiring Diagram Label to inside of Front

Removable Door. Labels are located in

Combination Boiler Parts and Control Carton.

Q. Install Junction Box. See Figure 8. Attach junction

box to inside of Left Side Panel with ¼” - 20 x ¼” lg.

machine screw (located in Combination Boiler Parts

and Control Carton).

R. Install Limit Control. Locate limit in Combination

Boiler Parts and Control Carton. Insert limit probe into

left immersion well as far as possible. Tighten set screw

(Model 805 uses Hydrostat 3200 - see Installation and

Operating Manual packed in envelope taped to top of

boiler for packaged boilers and in parts and control

carton for KD boilers for set up).

S. Install Auxiliary Limit or operating control (if used).

Insert control probe into right immersion well as far as

possible. Tighten set screw.

T. Install Gas Control Assembly. Refer to Section III,

Gas Control System Assembly (Knockdown Boilers).

U. EP System: See Figure 9.

1. Install pre-wired EP Control Cabinet Assembly to

right front corner of jacket top panel.

2. Install Honeywell RM7890 Control (located in

RM7890 Control Carton).

3. 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.

4. Install Honeywell R7847 Flame Amplier.

5. Install heat shield.

15

Figure 8: Jacket Assembly

16

Figure 9: EP Control Installation

17

III. Gas Control System Assembly (Knockdown Boilers)

A. 24V Standing Pilot Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control

Carton.

1. Install Gas Control Assembly on Manifold. See

Figure 10. Use thread (joint) compound (pipe dope)

resistant to action of liqueed petroleum gas.

2. Install pilot burner piping and controls. See Figure

10.

3. Connect Thermocouple Lead to Gas Valve.

4. Mount Transformer (continuous circulation) or

Control Center (intermittent circulation) to Junction

Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

B. EI (Intermittent Ignition)

Install Gas Control System. All components are

located in Combination Boiler Parts and Control

Carton.

1. Install Gas Control Assembly on Manifold. See

Figure 11. Use thread (joint) compound (pipe dope)

resistant to action of liqueed petroleum gas.

2. Install pilot burner piping and controls.

a. Honeywell EI

i. USA - See Figure 12.

ii. Canada - See Figure 13.

3. Install Ignition Module.

a. Attach Ignition Control Mounting Bracket to

Jacket Vestibule Panel using two (2) #8 x ½”

sheet metal screws.

b. Attach Honeywell Ignition Module to Mounting

Bracket using two (2) #8 x ½” sheet metal

screws.

c. Connect pilot ground wire and ignitor/sensor

lead(s) to ignition module. Refer to “Section VII:

Electrical” for connection details.

4. Mount Transformer (continuous circulation) or

Control Center (intermittent circulation) to Junction

Box. See Figure 8.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

C. EP Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control

Carton.

1. Install Gas Control Assembly on Manifold. See

Figure 14.

2. Install pilot burner piping and controls. See Figure

14.

3. Install Ignition Transformer.

a. Attach Ignition Transformer to Jacket Vestibule

Panel using four (4) #8 x ½” lg. sheet metal

screws.

b. Connect Ignition Lead from Pilot to Ignition

Transformer.

4. Mount Transformer (continuous circulation) or

Control Center (intermittent circulation) to Junction

Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

D. EP-CSD-1 Control System

Install Gas Control System. All components are

located in Combination Boiler Parts and Control

Carton.

1. Install Gas Control Assembly on Manifold. See

Figure 15.

2. Install pilot burner piping and controls. See Figure

15.

3. Install Ignition Transformer.

a. Attach Ignition Transformer to Jacket Vestibule

Panel using four (4) #8 x ½” lg. sheet metal

screws.

b. Connect Ignition Lead from Pilot to Ignition

Transformer.

4. Mount Transformer (continuous circulation) or

Control Center (intermittent circulation) to Junction

Box.

a. Canada only - loop 4” nylon cable tie between

junction box and transformer/control center.

b. Attach transformer/control center to junction

box.

18

Figure 10: Schematic Gas Piping, 24V Standing Pilot, 806H - 807HE

19

Figure 11: Main Gas Piping, Intermittent Ignition (EI)

20

Figure 12: Schematic Pilot Piping (Honeywell EI), USA

21

Figure 13: Schematic Pilot Piping (Honeywell EI)

Canada: Natural Gas, 805H - 810HE; LP Gas, 806H - 807HE

22

Figure 14: Schematic Gas Piping, EP Control System (Natural Gas Only), 806H - 810HE

23

Figure 15: Schematic Gas Piping, EP-CSD-1 Control System, 808HE - 810HE

24

IV. Water Trim and Piping

A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water and

frequent water additions.

1. 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.

2. In order to insure long product life, oxygen sources

must 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.

f. Use properly designed and operating air

elimination devices in water piping.

B. Design boiler piping and ow rate to obtain proper

temperature rise though the boiler. (See Table 4)

Pressure relief valve discharge piping must be

piped such that the potential of severe burns

is eliminated. DO NOT pipe in any area where

freezing could occur. DO NOT install any shut off

valves, plugs or caps. Consult Local Codes for

proper discharge piping arrangement.

C. Install Safety Relief Valve. See Figure 16.

Components are located in Water Trim Carton. Safety

Relief Valve must be installed with spindle in vertical

position.

1. Install ¾” NPT x 3½” lg. nipple in tapping “C”. See

Figure 3.

2. Install safety relief valve on ¾” NPT nipple.

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can

lead to boiler failure. Burnham’s Warranty does not cover problems caused by oxygen contamination of

boiler water or scale (lime) build-up caused by frequent addition of water.

Table 4: Flow Rate, Temperature Rise, and

Pressure Drop

Boiler

Model

Flow Rate

(GPM)

Temp. Rise

Thru Boiler

Min. Boiler

Piping NPT

Boiler

Pressure

Drop

805H

21

14

10

20° F

30° F

40° F

1½”

1¼”

1¼”

3’

2’

1’

806H

26

17

13

20° F

30° F

40° F

1½”

1½”

1¼”

3’

2’

1’

807HE

28

19

14

20° F

30° F

40° F

2”

1½”

1¼”

3’

2’

1’

808HE

34

22

17

20° F

30° F

40° F

2”

1½”

1½”

3’

2’

1’

809HE

38

25

19

20° F

30° F

40° F

2”

2”

1½”

3’

2’

1’

810HE

42

28

21

20° F

30° F

40° F

2”

2”

1½”

3’

2’

1’

Figure 16: Safety Relief Valve Installation

25

D. Install Drain Valve in rear of Left End Section,

Tapping “G”. See Figure 17. Components are located

in Water Trim Carton.

E. Install Temperature-Pressure Gauge. Components

are located in Water Trim Carton.

1. Standard Temperature - Pressure Gauge Piping. See

Figure 18.

Figure 17: Drain Piping Installation

Figure 20: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

a. Install 2” NPT x 10” lg. nipple with gauge

tapping into Supply Tapping “A”. See Figure 3.

Gauge tapping should face forward.

b. Insert Temperature-Pressure Gauge. Tighten

by applying pressure to square shank on back

of gauge. DO NOT APPLY PRESSURE ON

GAUGE CASE since this may ruin gauge

calibration.

2. Alternate Temperature-Pressure Gauge Piping. See

Figure 19.

a. Install 2 NPT x 10” Nipple into Supply Tapping

“A”. See Figure 3.

Figure 18: Temperature-Pressure Gauge

Installation

Figure 19: Alternate Temperature-Pressure Gauge

Installation

b. Install 2 NPT x ¾ NPT x 2 NPT Tee (provided)

or 2 NPT x 2 NPT x ¾ NPT Tee (installer

furnished). ¾ NPT leg should face forward.

c. Install ¾ NPT x ¼ NPT Bushing.

d. Insert Temperature-Pressure Gauge. Tighten

by applying pressure to square shank on back

of gauge. DO NOT APPLY PRESSURE ON

GAUGE CASE since this may ruin gauge

calibration.

F. Connect system supply and return piping to boiler.

See Figure 21. Also, consult I=B=R Installation

and Piping Guide No. 250. Maintain minimum ½

inch clearance from hot water piping to combustible

materials.

1. If boiler is used in connection with refrigeration

systems, boiler must be installed with chilled

medium piped in parallel with heating boiler using

appropriate valves to prevent chilled medium from

26

entering boiler. See Figure 20. Also, consult I=B=R

Installation and Piping Guide No. 250.

2. If boiler is connected to heating coils located in

air handling units where they may be exposed to

refrigerated air, boiler piping must be equipped with

ow control valves to prevent gravity circulation of

boiler water during cooling system operation.

3. The piping diagrams shown (Figure 21, Detail “A”

and Detail “B”) are recommended for optimum

operation and long term reliability.

Burnham Commercial recommends maintaining

temperature differential (drop) across the system

at 40°F or less, and return water temperature at

minimum of 135°F.

Continued boiler operation for prolonged periods of

time under conditions when temperature differential

across the system exceeds 40°F and/or return water

temperature stays below 135°F, may result in

premature boiler failure due to ue gas condensation

and/or thermal shock.

Pump ow rates and minimum boiler supply and

return pipe sizes are shown in Table 4.

Figure 21: Recommended Boiler Piping for Circulator Zoned Heating Systems

Detail “A”: Blend Pump Piping Detail “B”: Primary/Secondary Piping

with By-Pass

27

a. A boiler by-pass is recommended for any

installation for improved system temperature

balance, while serving to protect the boiler from

sustained condensing operation. The by-pass

also provides some measure of low return water

temperature protection by reducing ow through

the boiler. See Figure 21.

b. A blend pump is recommended to divert hot

supply water into the return when system return

temperatures can periodically dip below 135°F

or when delta T’s rise beyond 40°F because of

control schemes that shut off zone pumps for

extended periods. See Figure 21, Detail “A”.

c. Primary/secondary piping with a by-pass is

recommended to provide two points of mixing

when dual temperature systems are used (i.e.

baseboard and radiant heat, outdoor reset

and domestic hot water production, systems

incorporating night setback or multiple zone

pumps on clock schedules). See Figure 21,

Detail “B”.

d. If system three-way valves are used for

temperature modulation, or if the system will

continuously run below 135°F for extended

periods (due to low temperature applications

like snow melt, heat pump systems or others),

primary/secondary boiler piping with a three-

way valve and return temperature sensor is

recommended. Refer to Burnham RTC Return

Temperature Control Manual and Tekmar Essay

#021 “Mixing Methods and Sizing of Variable

Speed Injection Pumps” for more information on

mixing devices and boiler protection from low

return water temperature.

4. A hot water boiler installed above radiation level

must be provided with a low water cutoff device as

part of installation.

5. A start-up strainer is recommended for all

installations (new and replacement alike) to prevent

system debris and sediment from ending up in the

boilers where it will inhibit heat transfer and may

eventually cause a cast iron section to crack from

overheating.

G. Alliance SL™ Water Heater (if used). Refer to

Alliance SL™ Installation, Operating and Service

Instructions for additional information. Install in same

manner as space heating zone.

Burnham Commercial recommends maintaining temperature differential (drop) across the system at

40°F or less and return water temperature at minimum of 135°F.

Continued boiler operation for prolonged periods of time under conditions when temperature differential

across the system exceeds 40°F and/or return water temperature stays below 135°F, may result in premature

boiler failure due to ue gas condensation and/or thermal shock.

If the above conditions exist, to protect a boiler from sustained ue gas condensation and/or thermal

shock, the above-recommended temperatures may be maintained by employing common industry-accepted

mixing methods to provide boiler protection.

Some common methods are boiler by-pass piping, blend pumps, primary secondary piping with a by-

pass, mixing valves and/or variable speed injection pumps.

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

28

V. Gas Piping

Failure to properly pipe gas supply to boiler may

result in improper operation and damage to the

boiler or structure. Always assure gas piping is

absolutely leak free and of the proper size and

type for the connected load.

An additional gas pressure regulator may be

needed. Consult gas supplier.

A. Size gas Piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to

boiler. Maximum allowable system pressure is ½

psig. Actual point of delivery pressure may be less;

contact gas supplier for additional information.

Minimum allowable gas valve inlet pressure is

indicated on rating label.

2. Maximum gas demand. Table 5 lists boiler input

rate. Also consider existing and expected future gas

utilization equipment (i.e. water heater, cooking

equipment).

3. Length of piping and number of ttings. Refer to

Table 6 for maximum capacity of Schedule 40 pipe.

Table 7 lists equivalent length for standard ttings.

Boiler

Model

Rated Capacity

(cubic feet per hour) Gas

Connection

Size

Natural LP / Propane

805H 252 100.8 1

806H 315 126.0 1

807HE 340 136.0 1

808HE 410 164.0 1

809HE 460 184.0 1

810HE 505 202.0 1

Table 5: Rated Input

4. Specic gravity of gas. Gas piping systems for

gas with a specic gravity of 0.70 or less can be

sized directly from Table 6, unless authority having

jurisdiction species a gravity factor be applied.

For specic gravity greater than 0.70, apply gravity

factor from Table 8. If exact specic gravity is not

shown choose next higher value.

For materials or conditions other than those listed

above, refer to the National Fuel Gas Code,

NFPA 54/ANSI Z223.1 and/or CAN/CSA B149.1

Installation Codes, or size system using standard

engineering methods acceptable to authority having

jurisdiction.

Failure to use proper thread compounds on all

gas connectors may result in leaks of ammable

gas.

Gas supply to boiler and system must be

absolutely shut off prior to installing or servicing

boiler gas piping.

B. Connect boiler gas valve to gas supply system.

1. Use methods and materials in accordance with local

plumbing codes and requirements of gas supplier. In

absence of such requirements, follow the National

Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or

CAN/CSA B149.1 Installation Codes.

2. Use thread (joint) compound (pipe dope) resistant to

action of liqueed petroleum gas.

3. Install sediment trap, ground-joint union and manual

shut-off valve upstream of boiler gas valve and

outside jacket. See Figure 22.

4. All above ground gas piping upstream from

manual gas valve must be electrically continuous

and bonded to a grounding electrode. Do not use

gas piping as a grounding electrode. Refer to the

National Electrical Code, ANSI/NFPA 70 and/or

CSA C22.1 Electrical Code.

USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially

oriced to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code,

NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orice sizing is indicated on the

rating label. High altitude boiler models are identiable by the model number’s tenth digit on the rating label.

(4=2000’ - 4500’, 5= 2000’ - 5000’)

29

Length

(Feet)

0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop

½ ¾ 1 1¼ ½ ¾ 1 1¼

10 132 278 520 1,050 175 360 680 1,400

20 92 190 350 730 120 250 465 950

30 73 152 285 590 97 200 375 770

40 63 130 245 500 82 170 320 660

50 56 115 215 440 73 151 285 580

60 50 105 195 400 66 138 260 530

70 46 96 180 370 61 125 240 490

80 43 90 170 350 57 118 220 460

90 40 84 160 320 53 110 205 430

100 38 79 150 305 50 103 195 400

Table 6: Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0.5 psig or Less

Table 7: Equivalent Lengths of Standard Pipe Fittings & Valves

Pipe

Size

I.D.

(Inches)

Valves (Fully Open) Threaded Fittings

Gate Globe Angle Swing

Check

90°

Elbow

45°

Elbow

90° Tee, Flow

Through Run

90° Tee, Flow

Through Branch

½” 0.622 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.1

¾” 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 4.1

1” 1.049 0.56 29.4 14.7 6.8 2.6 1.23 1.8 5.3

1¼” 1.380 0.74 38.6 19.3 8.9 3.5 1.6 2.3 6.9

Specic

Gravity

Correction

Factor

Specic

Gravity

Correction

Factor

0.50 1.10 1.30 1.07

0.55 1.04 1.40 1.04

0.60 1.00 1.50 1.00

0.65 0.96 1.60 0.97

0.70 0.93 1.70 0.94

0.75 0.90 --- ---

0.80 0.87 --- ---

Table 8: Specic Gravity Correction Factors

Do not use matches, candles, open ames, or

other ignition source.

Figure 22: Recommended Gas Piping

C. Pressure Test. The boiler and its gas connection must

be leak tested before placing boiler in operation.

1. Protect boiler gas valve. For all testing over ½ psig,

boiler and its individual shut-off valve must be

disconnected from gas supply piping. For testing at

½ psig or less, isolate boiler from gas supply piping

by closing boiler’s individual manual shut-off valve.

2. Locate leaks using approved combustible gas

detector, soap and water, or similar nonammable

solution.

30

A. Install vent system in accordance with local building

codes; or local authority having jurisdiction; or

National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part

7, Venting of Equipment and/or CAN/CSA B149.1,

Venting Systems and Air Supply for Appliances. Install

any of the following for this Series 8HE Category I,

draft hood equipped appliance:

1. Type B or Type L gas vent. Install in accordance

with listing and manufacturer’s instructions.

2. Masonry or metal chimney. Build and install in

accordance with local building codes; or local

authority having jurisdiction; or Standard for

Chimneys, Fireplaces, Vents, and Solid Fuel

Burning Appliances, ANSI/NFPA 211 and/or

National Building Code of Canada.

Masonry chimney must be lined with approved

clay ue lining or listed chimney lining system

except as provided in ANSI Z223.1/NFPA 54,

Paragraph 7.5.4(a): Exception: 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.

3. Single wall metal vent. Allowed by ANSI Z223.1/

NFPA 54 under very restrictive conditions.

B. Inspect chimney and remove any obstructions or

restrictions. Clean chimney if previously used for solid

or liquid fuel-burning appliances or replaces.

Inspect existing chimney before installing boiler.

Failure to clean or replace perforated pipe or tile

lining will cause severe injury or death.

C. Install Draft Hood on canopy outlet. Maintain height

from Jacket Top Panel to Draft Hood skirt as shown

in Figure 1. DO NOT ALTER, CUT, OR MODIFY

DRAFT HOOD.

Do not alter boiler draft hood or place any

obstruction or non-approved damper in the

breeching or vent system. Flue gas spillage can

occur. Unsafe boiler operation will occur.

D. Install Blocked Vent Switch. The Blocked Vent

Switch Assembly consists of a strain relief bushing,

power cord, and switch attached to mounting bracket.

On Packaged boilers, the assembly is shipped attached

to top of boiler. On Knocked Down boilers, the

assembly is located in Combination Boiler Parts and

Control Carton.

1. Uncoil power cord.

2. Position mounting bracket onto lower edge of Draft

Hood skirt. Locate center tooth (with #10 sheet

metal screw) on outside and other two teeth inside

Draft Hood skirt. See Figure 23.

3. Slide mounting bracket tight against lower edge of

Draft Hood skirt. Position #10 sheet metal screw

above skirt’s stiffening rib.

4. Secure bracket in position by tightening #10 sheet

metal screw against outer surface of Draft Hood

skirt.

5. Insert excess power cord through Jacket Right Side

Panel hole. Remove slack.

6. Position strain relief bushing around power cord.

Pinch bushing’s two halves together and snap back

into hole in Jacket Right Side Panel.

7. Verify power cord, mounting bracket, and Blocked

Vent Switch are secure and located as shown in

Figure 23.

Do not operate boiler without Blocked Vent Switch

Properly installed.

VI. Venting

Figure 23: Blocked Vent Switch Installation

31

E. Boiler Equipped With Vent Damper. See Figure 24.

1. Open Vent Damper Carton and remove Installation

Instructions. Read Installation Instructions

thoroughly before proceeding.

Do not use one vent damper to control two or

more heating appliances.

2. Vent damper must be same size as draft hood

outlet. See Figure 1. Unpack vent damper carefully.

Forcing vent damper open or closed may damage

gear train and void warranty. Vent damper assembly

includes pre-wired connection harness with

polarized plug.

3. Mount vent damper assembly on draft hood without

modication to either (Refer to instructions packed

with vent damper for specic instructions). Vent

damper position indicator to be visible to users.

Provide adequate clearance for servicing -

provide 6” minimum clearance between damper

and combustible construction.

F. Install Vent Connector from draft hood or vent

damper to chimney. See Figure 25.

1. Do not connect into same leg of chimney serving an

open replace.

Figure 24: Vent Damper Installation

2. Where two or more appliances vent into a common

vent, the area of the common vent should at least

equal the area of the largest vent plus 50 % of the

area of the additional vents. Do not connect the

vent of this appliance into any portion of mechanical

draft system operating under positive pressure.

3. Vent connector should have the greatest possible

initial rise above the draft hood consistent with the

head room available and the required clearance from

adjacent combustible building structure.

4. Install vent connector above bottom of chimney to

prevent blockage - inspect chimney for obstructions

or restrictions and remove - clean chimney if

necessary.

5. Vent connector should slope upward from draft hood

to chimney not less than one inch in four feet. No

portion of vent connector should run downward or

have dips or sags. Vent connector must be securely

supported.

6. Use thimble where vent connector enters masonry

chimney - keep vent connector ush with inside of

ue liner.

7. Do not install Non-listed (AGA, CGA, CSA, ETL,

or UL) vent damper or other obstruction in vent

pipe.

8. Locate Boiler as close to Chimney as possible

consistent with necessary clearances. See Section I:

Pre-Installation.

32

Figure 25: Typical Vent System

9. Design vent system for sea level input.

10. Provide adequate ventilation of Boiler Room. See

Section I: Pre-Installation.

11. Never pass any portion of vent system through a

circulating air duct or plenum.

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.

G. If an Existing Boiler is Removed:

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:

1. Seal any unused openings in the common venting

system.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion, or other

deciencies which could cause an unsafe condition.

3. 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 dryers 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

replace dampers.

4. Place in operation the appliance being inspected.

Follow the Lighting (or Operating) Instructions.

Adjust thermostat so appliance will operate

continuously.

5. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the ame

of a match or candle, or smoke from a cigarette,

cigar or pipe.

6. 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, replace dampers and

any other gas-burning appliance to their previous

condition of use.

7. Any improper operation of the common venting

system should be corrected so the installation

conforms with the National Fuel Gas Code, NFPA

54/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

Part 7 and Part 11 in the National Fuel Gas Code,

NFPA 54/ANSI Z223.1.

33

VII. Electrical

A. Install Boiler Wiring

1. Knockdown boilers only. Locate wiring harnesses

in Combination Boiler Parts and Control Carton.

Refer to Table 10 and connect wiring as shown on

the appropriate wiring diagram.

2. Connect supply wiring and electrically ground boiler

in accordance with requirements of authority having

jurisdiction, or in absence of such requirements the

National Electrical Code, ANSI/NFPA 70 and/or

CSA C22.1 Electrical Code.

B. Wire Vent Damper (if used; optional on 806H -

810HE). See Figure 24. Vent damper harness for 805

plugs directly into Hydrostat 3200.

NOTE: Once vent damper is connected to Hydrostat

3200, control will not operate without it plugged in.

1. Attach Vent Damper Harness to mounting hole in

Jacket Left Side Panel. Install Cable Clamp around

exible conduit and attach to Jacket Top Panel.

2. Remove factory installed Jumper Plug from Vent

Damper Receptacle on Vestibule Wiring Harness

and discard.

3. Plug Vent Damper Harness Plug into Vent Damper

Receptacle. See Figure 24.

C. Install thermostat. Locate on inside wall

approximately 4 feet above oor. Do not install on

outside wall, near replace, or where inuenced

by drafts or restricted air ow, hot or cold pipes,

lighting xtures, television, or sunlight. Allow free air

movement by avoiding placement of furniture near

thermostat.

Set heat anticipator to match control system

requirements. Refer to Table 9.

D. Wire thermostat. Provide Class II circuit between

thermostat and boiler. Refer to appropriate wiring

diagram for control system being used.

Figure 26: Vent Damper Schematic Wiring Diagram (806H - 810HE)

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any

electrical work.

Each boiler must be protected with a properly sized fused disconnect.

Never jump out or make inoperative any safety or operating controls.

The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with

a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls

used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

Positively assure all electrical connections are unpowered before attempting installation or service of

electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock

once power is turned off.

34

E. Alliance SL™ Water Heater (if used). May be used

with Intermittent Circulation only.

Refer to Alliance SL™ Installation, Operating

and Service Instructions for wiring, piping and

additional information.

F. Vent Damper Sequence of Operation. See Figure 26

for schematic wiring diagram (806H - 810HE).

1. The Vent Damper is continuously powered at

Terminal 1.

2. When there is a call for heat, the damper relay coil

is energized through Terminal 5 if all limits ahead of

the damper are satised.

3. The relay coil closes contacts which energize the

damper motor, causing the damper to open.

4. When the damper blade reaches the fully open

position, power is sent back to the ignition circuit

through Terminal 2 and the damper motor is de-

energized.

5. When the call for heat is satised, the damper

relay coil is de-energized - closing contacts which

energize the damper motor. This causes the damper

to close. When the damper blade reaches the fully

closed position, the damper motor is de-energized.

POWER FAILURE - The damper blade will stop in the

position it was in when power failed. (Combustion

can never take place unless the damper blade is in

the fully open position).

6. For Model 805, vent damper is connected directly

to Hydrostat 3200. Once vent damper is plugged in,

Hydrostat 3200 will not run without it.

G. Sequence of Operation and Wiring. Refer to Table

10 for the appropriate control system.

H. Optional Low-Water Cut-Off Wiring. See Figures 42

through 44. For Model 805, use special Hydrostat Well,

part number 105203-01.

Table 9: Heat Anticipator Settings

Control System Heat Anticipator Setting *

Continuous Circulation Intermittent Circulation

24V Standing Pilot 1.1 0.3

24V Electronic Ignition USA: 0.9 0.3

Canada: 1.2

* If room is heated above thermostat temperature setting, reduce heat anticipator setting by 0.1 or

0.2 amps. If boiler short cycles without room reaching desired temperature, increase heat anticipator

by 0.1 or 0.2 amps.

35

1. Standing Pilot (24) Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat. Vent Damper (if used) opens.

ii. Gas valves are energized allowing main gas

ow and ignition of main burners.

iii. Call or heat ends. Gas valves are de-

energized, extinguishing main ame. Vent

Damper (if used) closes.

b. Safety Shutdown

i. Limit: Automatically interrupts main burner

operation when water temperature exceeds

set point. Maximum allowable temperature

is 250°F. Circulator continues to operate

with call for heat, Vent Damper (if used)

closes. Normal operation resumes when

water temperature falls below set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate and Vent

Damper (if used) remains open with call

for heat. If blocked vent switch is activated

do not attempt to place boiler in operation.

Correct cause of spillage and reset blocked

vent switch.

iii. Flame Roll-out Switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate

and Vent Damper (if used) remains open

with call for heat. Control is single use

device. If ame roll-out switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and replace ame

roll-out switch.

iv. Thermocouple: Senses pilot ame and

causes gas valves to turn off main burner

and pilot burner gas ow should pilot burner

ame extinguish. Circulator continues to

operate and Vent Damper (if used) remains

open with call for heat.

Table 10: Sequence of Operation and Wiring Diagrams

Ignition System Country Fuel Boiler Sizes Wiring Diagram Figure Sequence of

Operation

Continuous Intermittent

Standing Pilot (24V) USA &

Canada

Natural Gas

6 & 7 Sect. Figure 27 Figure 28 Page 35

LP Gas

Intermittent Ignition

(Honeywell EI - 24V)

USA

Natural Gas

5 - 10 Sect. Figure 30 Figure 31

Page 38

LP Gas

Canada

Natural Gas 5 - 10 Sect.

Figure 32 Figure 33

LP Gas 5 - 7 Sect.

Intermittent Ignition

(EP - 120V)

USA &

Canada

Natural Gas 6 - 10 Sect. Figure 34 Figure 35 Page 44

LP Gas Not Available

Intermittent Ignition

(EP-CSD-1 - 120V) USA Natural Gas 8 - 10 Sect. Figure 34 Figure 35 Page 44

36

Figure 27: Wiring Diagram, Standing Pilot (24V), Continuous Circulation (806H - 807HE)

37

Figure 28: Wiring Diagram, Standing Pilot (24V), Intermittent Circulation (806H - 807HE)

38

2. Honeywell EI Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat. Vent Damper (if used) opens.

ii. Ignition Module Terminals PV, MV/PV

and the Ignition Terminal are energized.

Terminals PV and MV/PV power the Pilot

Valve in the Gas Valve supplying gas to

the Pilot. The Ignition Terminal supplies

voltage to the Ignition Electrode creating an

electric spark to ignite the Pilot.

iii. The sensing Circuit between the Q3481B

Pilot Burner and the IGNITION MODULE

proves the presence of the Pilot Flame

Electronically and the Ignition Terminal is

de-energized.

iv. Terminals MV and MV/PV of the

IGNITION MODULE are energized and

supply power to the Main Gas Valve. The

Gas Valve is energized allowing main gas

ow, and ignition of Main Burners.

v. Call for heat ends. Ignition module is de-

energized, de-energizing gas valve, and

extinguishing pilot and main ame. Vent

Damper (if used) closes.

b. Safety Shutdown

i. Limit: Automatically interrupts power

to the Ignition Module and Gas Valve(s),

extinguishing pilot and main ame, when

water temperature exceeds set point.

Maximum allowable temperature is 250°F.

Circulator continues to operate with call for

heat, Vent Damper (if used) closes. Normal

operation resumes when water temperature

falls below set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate and Vent

Damper (if used) remains open with call

for heat. If blocked vent switch is activated

do not attempt to place boiler in operation.

Correct cause of spillage and reset blocked

vent switch.

iii. Flame Roll-out switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate,

Vent Damper (if used) remains open with

call for heat. Control is single use device.

If ame roll-out switch is activated, do not

attempt to place boiler in operation. Correct

cause of spillage and replace ame roll-out

switch.

iv. Pilot

– Pilot failure can occur during the start-up or

the operating cycle of the boiler. Any pilot

failure of the Q3481B Electronic Pilot, after

ignition of pilot ame will close the main

gas valve in 0.8 seconds.

– For approximately 90 seconds after failure

of the Q3481B pilot, the module through

the ignition terminal will try to reestablish

pilot ame. If no pilot ame can be sensed

by the ame rod circuit, terminals PV and

MV/PV are de-energized and 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.

c. Trouble Shooting Guide. See Page 61.

39

Figure 29: Wiring Diagram, Honeywell EI, USA & Canada, 805 Only with Hydrostat 3200 Control

40

Figure 30: Wiring Diagram, Honeywell EI, USA, Continuous Circulation (806 - 810)

41

Figure 31: Wiring Diagram, Honeywell EI, USA, Intermittent Circulation (806 - 810)

42

Figure 32: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation

(Natural: 806H - 810HE; LP: 806H - 807HE)

43

Figure 33: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation

(Natural: 806H - 810HE; LP: 806H - 807HE)

44

6. Electronically Supervised Intermittent Ignition

(EP/EP-CSD-1) Sequence of Operation

a. Normal Operation

i. Thermostat or operating control calls for

heat.

ii. Terminal #6 of RM7890A Burner Control

is energized, initiating a microcomputer

monitored circuit test.

iii. The pilot valve (terminal 8) and ignition

transformer (terminal 10) are energized.

The pilot valve opens and the ignition

electrode sparks, igniting the pilot.

iv. After the pilot ame is proven, the ignition

terminal (10) is de-energized and the main

valve terminal (9) is energized, allowing

main gas ow and ignition of main burners.

“Main” gas light will be illuminated.

v. When the call for heat ends, terminal #6

is de-energized, extinguishing the pilot

and main ames. “Main” gas light is de-

energized.

b. Safety Shutdown

i. Limit: Automatically interrupts main burner

operation when water temperature exceeds

set point. Maximum allowable temperature

is 250°F. Circulator continues to operate

with call for heat. Normal operation

resumes when water temperature falls below

set point.

ii. Blocked Vent Switch: Automatically

interrupts main burner operation when

excessive ue gas spillage occurs.

Circulator continues to operate with call for

heat. If blocked vent switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and reset blocked

vent switch.

iii. Flame Roll-out Switch: Automatically

interrupts main burner operation when

ames or excessive heat are present in

vestibule. Circulator continues to operate

with call for heat. Control is single use

device. If ame roll-out switch is activated,

do not attempt to place boiler in operation.

Correct cause of spillage and replace ame

roll-out switch.

iv. RM7890A Burner Control: Automatically

interrupts main burner operation if a pilot

ame is not detected during the four or ten

second pilot ame establishing period. The

RM7890A will lockout or recycle based

on jumper settings. “Alarm” light will be

illuminated. Refer to instructions supplied

with RM7890A for additional control

information.

45

Figure 34: Wiring Diagram, EP Ignition System, Natural Gas Only, Continuous Circulation

(EP-CSD-1; Natural Gas, USA Only, 808HE - 810HE)

46

Figure 35: Wiring Diagram, EP Ignition System, Natural Gas Only, Intermittent Circulation

(EP-CSD-1; Natural Gas, USA Only, 808HE - 810HE)

47

Figure 36: McDonnell & Miller 751P-MT (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits

(806H - 810HE)

Figure 37: McDonnell & Miller 751P-MT (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits (EP)

(808HE - 810HE)

48

Figure 38: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 24V Limit Circuits

(806H - 810HE)

Figure 39: Hydrolevel OEM - 170/550/650/750 (120V) L.W.C.O. Wiring for Boilers with 120V Limit Circuits

(808HE - 810HE)

49

Completely read, understand and follow all

instructions in this manual before attempting

start-up.

A. Safe operation and other performance criteria were met

with the gas manifold and control assembly provided

on boiler when boiler underwent tests specied in

American National Standard for Gas-Fired Low-

Pressure Steam and Hot Water Boilers, ANSI Z21.13.

B. Check Main Burners. Main burners must be properly

located on support bracket in Base Rear Panel, seated

on Main Burner Orices, and secured with hitch pin

clips.

C. Verify that the venting, water piping, gas piping

and electrical system are installed properly. Refer to

installation instructions contained in this manual.

D. Conrm all electrical, water and gas supplies

are turned off at the source and that vent is clear of

obstructions.

E. FILL ENTIRE HEATING SYSTEM WITH WATER

and vent air from system. Use following procedure on

a Series Loop or multi-zoned system installed as per

Figure 21 to remove air from system when lling.

The maximum operating pressure of this boiler is

50 psig. Never exceed this pressure. Do not plug

or modify pressure relief valve.

1. Close full port ball valve in boiler supply piping.

2. Isolate all zones by closing zone valves or shut-off

valves in supply and return of each zone(s).

3. Attach a hose to the vertical purge valve located

prior to the full port ball valve in the system supply

piping. (Note - Terminate hose in ve gallon bucket

at a suitable oor drain or outdoor area).

4. Starting with one circuit at a time, open zone valve

or shut-off valve in system supply and return piping.

5. Open purge valve.

6. Open ll valve (Make-up water line should be

located directly after full port ball valve in system

supply piping between air scoop and expansion

tank).

7. Allow water to overow from bucket until discharge

from hose is bubble free for 30 seconds.

8. Close the open zone valve or shut-off valve for the

zone being purged of air, then open the zone valve

or shut-off valve for the next zone to be purged.

Repeat this step until all zones have been purged. At

completion, open all zone valves or shut-off valves.

VIII. System Start-Up

9. Close purge valve, continue lling the system

until the pressure gauge reads the desired cold ll

pressure. Close ll valve.

(Note - If make-up water line is equipped with

pressure reducing valve, adjust pressure reducing

valve to desired cold ll pressure. Follow ll valve

manufacturer’s instructions).

10. Open isolation valve in boiler supply piping.

11. Remove hose from purge valve.

F. Conrm that the boiler and system have no water

leaks.

G. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot)

from gas supplier.

2. Connect manometer to pressure tap on gas valve.

Use 1/8 NPT tapping provided.

3. Temporarily turn off all other gas-red appliances.

4. Turn on gas supply to the boiler gas piping.

5. Conrm that the supply pressure to the gas valve is

14 in. w.c. or less.

6. Open the eld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

7. Using soap solution, or similar non-combustible

solution, electronic leak detector or other approved

method. Check that boiler gas piping, valves, and

all other components are leak free. Eliminate any

leaks.

8. Purge gas line of air.

H. Follow Lighting or Operating Instructions to place

boiler in operation. Refer to label on inside of Front

Removable Panel or appropriate Figure as listed in

Table 11.

Do not use matches, candles, open ames or

other ignition source to check for leaks.

Ignition System

Lighting or

Operating

Instructions

Pilot Flame

Illustration

Standing Pilot (24) Figure 40 Figure 44

Honeywell EI Figure 41 Figure 45

EP Figure 42 Figure 46

EP-CSD-1 Figure 43 Figure 46

Table 11: Lighting and Operating Instructions

50

Figure 40: Lighting Instructions (24V Standing Pilot)

51

Figure 41: Operating Instructions (EI)

52

Figure 42: Operating Instructions (EP)

53

BOILER OPERATING INSTRUCTIONS

TO SHUT DOWN:

1. Close manual main shut-off valve(s) and pilot

valve(s).

2. Turn off main electric switch.

TO START UP:

1. Make sure that both the main manual and the pilot

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

2. Turn room thermostat and all operating controls to

lowest setting.

3. Remove burner access panel(s).

4. Open manual pilot valve(s).

5. Turn on main electric switch.

6. Reset safety switch on ame safeguard relay.

7. Intermittent electric ignition rectication pilot(s)

Q179C light up automatically when thermostat or

operating control calls for heat.

8. Replace burner access panel(s).

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

10. Adjust room thermostat and operating controls to

desired setting.

Figure 43: Lighting / Operating Instructions (EP-CSD-1)

54

I. Check pilot burner ame and main burner ames

through observation port.

1. Check pilot ame. Refer to Table 11 for appropriate

pilot detail.

2. Adjust thermostat to highest setting.

3. Check main burner ames. See Figure 47. Flame

should have clearly dened inner cones with no

yellow tipping. Orange-yellow streaks caused

by dust should not be confused with true yellow

tipping.

Yellow-tipping indicates lack of primary air.

Improper burner alignment on Main Burner Orice

will also affect primary air injection. Adjust primary

air as follows:

Figure 45: Honeywell Q3481B Pilot Flame

(24V Electronic Ignition)

Figure 44: Honeywell Q314 Pilot Flame

(24V Standing Pilot)

Figure 46: Honeywell Q179C Pilot Flame (EP)

Figure 47: Main Burner Flame

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.

a. Loosen lock screw.

b. Close air adjustment until yellow tips appear on

ames.

c. Slowly open air adjustment until clearly dened

inner cones are visible.

d. Tighten lock screw.

4. Adjust thermostat to normal setting.

55

J. Check thermostat or operating control operation.

Raise and lower temperature setting to start and stop

boiler operation.

K. Check ignition system shut-off.

1. Standing Pilot (24V): Disconnect thermocouple

lead at Gas Valve. Gas Valve must close and pilot

and main burners extinguish. If not, replace the gas

valve.

2. Honeywell EI: Disconnect ignitor/sensor cable from

ignition module. Gas valve must close and pilot and

main burners extinguish. If not, measure voltage

across gas valve terminals “TH” and “TR”.

a. If voltage is not present, replace gas valve.

b. If voltage is present, replace ignition module.

3. EP: Refer to instructions supplied with the

Honeywell RM7890 Burner Control.

L. Check Limit(s). NOTE: If using Model 805, see

Installation and Operating manual for Hydrostat 3200,

packed in envelope taped to top of boiler for packaged

boilers and in parts and control carton for KD boilers

for maintenance.

1. Adjust thermostat to highest setting.

2. Observe temperature gauge. When temperature

exceeds limit set point main burners should

extinguish.

3. Adjust limit to setting above observed reading. Main

burners should reignite.

4. Adjust thermostat to lowest setting. Adjust limit to

desired setting.

M. Adjust gas input rate to boiler. Natural Gas.

1. Adjust thermostat to highest setting.

2. Check manifold gas pressure. Manifold pressure

is listed on rating label. Adjust gas valve pressure

regulator as necessary (turn adjustment screw

counterclockwise to decrease manifold pressure, or

clockwise to increase manifold pressure). If pressure

can not be attained, check gas valve inlet pressure.

If less than minimum gas supply pressure listed on

rating label, contact gas supplier for assistance.

3. Clock gas meter for at least 30 seconds. Use Table

12 to determine gas ow rate in Cubic Feet per

Hour.

4. Determine Input Rate. Multiply gas ow rate by gas

heating value.

Failure to properly adjust gas input rate will result

in over ring or under ring of the appliance.

Improper and unsafe boiler operation may result.

5. Compare measured input rate to input rate stated on

rating label.

Seconds

for One

Revolution

Size of Gas Meter Dial

One-Half

Cu. Ft.

One

Cu. Ft.

Two

Cu. Ft.

Five

Cu. Ft.

30 60 120 240 600

32 56 113 225 563

34 53 106 212 529

36 50 100 200 500

40 45 90 180 450

38 47 95 189 474

40 45 90 180 450

42 43 86 172 430

44 41 82 164 410

46 39 78 157 391

48 37 75 150 375

50 36 72 144 360

52 35 69 138 346

54 33 67 133 333

56 32 64 129 321

58 31 62 124 310

60 30 60 120 300

62 29 58 116 290

64 29 56 112 281

66 29 54 109 273

68 28 53 106 265

70 26 51 103 257

72 25 50 100 250

74 24 48 97 243

76 24 47 95 237

78 23 46 92 231

80 22 45 90 225

Table 12: Input Rate

a. Boiler must not be overred. Reduce input rate

by decreasing manifold pressure. Do not reduce

more than 0.3 inch w.c. If boiler is still overred,

contact your Burnham distributor or Regional

Ofce for replacement Gas Orices.

b. Increase input rate if less than 98% of rating

plate input. Increase manifold gas pressure no

more than 0.3 inch w.c. If measured input rate is

still less than 98% of rated input:

i. Remove Main Burners per procedure in

Section IX: Service.

ii. Remove gas orices. Drill one (1) drill size

larger (drill size is stamped on orice, or see

Key No. 4E).

iii. Reinstall gas orices and main burners.

Measure input rate.

6. Recheck Main Burner Flame.

7. Return other gas-red appliances to previous

conditions of use.

56

N. Adjust gas input rate to boiler. LP/Propane.

1. Set thermostat to highest setting.

2. Adjust tank regulator for gas valve inlet pressure of

13.5 inches w.c. or less.

3. Gas valve has step opening regulator which initially

opens to 1.4 or 2.5 inch w.c. and steps to full

pressure after approximately 30 seconds. Check

manifold pressure after step has occurred. Adjust gas

valve pressure regulator as necessary for 10.0 inches

w.c. (turn adjustment screw counterclockwise to

decrease manifold pressure, or clockwise to increase

manifold pressure). If 10.0 inches w.c. can not be

attained, check gas valve inlet pressure. If less than

11.0 inches w.c., contact gas supplier for assistance.

O. Clean Heating System

Oil, grease, and other foreign materials which

accumulate in new hot water boilers and a new or

reworked system should be boiled out, and then

thoroughly ushed. 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.

P. Check Damper Operation - If boiler is equipped with

vent damper, vent damper must be in open position

when boiler main burners are operating. Start boiler,

refer to instructions on damper to determine if damper

is in full open position.

Q. Install Front Removable Panel.

1. Engage top ange (longer of 2 anges) behind

Upper Front Panel.

2. Swing lower portion of door toward boiler.

3. Lower door to engage bottom ange behind Lower

Front Tie Bar.

R. Combustion Chamber Burn-Off

1. 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.

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

maximum setting, set the thermostat to call for heat.

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

the odor from the cornstarch has dissipated.

4. Return the high limit and thermostat to their desired

settings.

S. Review User’s Information Manual and system

operation with owner or operator.

Model 805 Only:

IMPORTANT

This boiler is equipped with a feature that saves energy by reducing the boiler water temperature

as the heating load decreases. This feature is equipped with an override which is provided

primarily to permit the use of an external energy management system that serves the same

function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler

water temperature as the heating load decreases.

• This boiler is not used for any space heating.

• This boiler is part of a modular or multiple boiler system having a total input

of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

57

IX. Service

A. General. Inspection and service must be conducted

annually. Turn off electrical power and gas supply while

conducting service or maintenance. Follow instructions

TO TURN OFF GAS TO APPLIANCE. See Lighting/

Operating Instructions on inside of Front Removable

Door.

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation. Verify proper

operation after servicing.

B. Maintenance of Low Water Cut-off (if used). Follow

instruction manual provided with low water cut off.

If model 805, see Installation and Operating manual

for Hydrostat 3200, packed in envelope taped to top

of boiler for packaged boilers and in parts and control

carton for KD boilers for maintenance.

C. Vent System. Check for:

1. obstructions

2. accumulations of soot

3. deterioration of vent pipe or vent accessories due to

condensation or other reasons

4. proper support—no sags, particularly in horizontal

runs

5. 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.

D. Remove Main Burners for cleaning, changing orice

plugs, or repairs.

1. Shut down gas boiler in accordance with Lighting/

Operating Instructions on inside of Front Removable

Door. Close Manual Shut-off Valve.

2. Remove Front Removable Door. Raise Lower Front

Tie Bar.

3. Disconnect ignition system.

4. Remove burner access panel(s).

5. Mark location of Main Burner with Pilot Bracket on

manifold.

6. Remove hitch pin clips from Main Burner Orices.

7. Hold Main Burner on throat. Lift slightly to raise

rear of burner. Push to rear of boiler until burner

clears Main Burner Orice. Lift burners out.

8. Check burners to be sure they do not contain foreign

matter or restrictions. Clean burners with a soft

bristle brush, blow any dirt out with compressed air

or use a vacuum cleaner. See Figure 48.

E. Clean Boiler Flueways. See Figure 48.

1. Shut down gas boiler in accordance with Lighting/

Operating Instructions on inside of Front Removable

Door. Close Manual Shut-off Valve.

2. Disconnect vent system. Remove Draft Hood.

3. Remove Jacket Top Panel.

4. Remove Canopy from top of boiler.

5. Remove ue bafes. Refer to Figure 48 for

instructions on how to remove bafes from

ueways. Remove any accumulated scale or soot.

6. Thoroughly clean ueways with ue brush,

removing all scale and soot. See Figure 48.

7. Clean boiler heating surface accessible from

combustion chamber with straight handle wire

brush.

8. Reinsert bafes into ueways by reversing steps

given in Figure 48. Tabs at top of each bafe should

rest on top of ue pins.

Service on this boiler should be undertaken only by trained and skilled personnel from a qualied service

agency. Inspections should be performed at intervals specied in this manual. Maintain manual in a

legible condition.

Keep boiler area clear and free of combustible materials, gasoline and other ammable vapors and

liquids.

Do not place any obstructions in boiler room that will hinder ow of combustion and ventilation air.

The service instructions contained in this manual are in addition to the instructions provided by the

manufacturer of the boiler components. Follow component manufacturer’s instructions. Component

manufacturer’s instructions were provided with the boiler. Contact component manufacturer for replace-

ment if instructions are missing. Do not install, start up, operate, maintain or service this boiler without

reading and understanding all of the component instructions. Do not allow the boiler to operate with

altered, disconnected or jumpered components. Only use replacement components identical to those

originally supplied by Burnham Commercial.

58

9. Install Canopy. See Section II: Boiler Assembly,

Paragraph G.

10. Install Jacket Top Panel, Draft Hood, Vent Damper

(if used) and Vent System.

F. Clean Combustion Chamber by vacuuming. Exercise

care to avoid damaging Base Insulation.

G. Install Burners by reversing procedures used to

remove burners. Verify Main Burners are properly

located on support bracket in Base Rear Panel, seated

on Main Burner Orices, and secured with hitch pin

clips. Verify Main Burner with Pilot Bracket is in

proper location. See Table 13.

H. Lubrication. Manufacturers Instruction should be

followed on all parts installed on boiler requiring

Boiler Model Pilot Located Between Burners*

805H 4 & 5

806H 5 & 6

807HE 6 & 7

808HE 6 & 7

809HE 7 & 8

810HE 8 & 9

* Burners numbered left to right as viewed from front of boiler.

Table 13: Pilot Burner Location

Figure 48: Boiler Flueway Cleaning

lubrication. This includes type of lubricant to be used,

frequency of lubrication, and points to lubricate.

I. Check operation. Refer to Section VIII: System Start-

up.

59

Yellow LED

Flash CodeaIndicates Recommended Service Action

Heartbeat Normal Flame Signal N/A

2

Weak Flame Signal -

System will operate reliably but ame signal is less than

desired.

Note: This indication may ash temporarily during or

shortly after lightoff on some applications.

Perform routine maintenance to

assure optimum ame signal.

1

Marginal Flame Signal (less than 1.1 µA) -

System may not operate reliably over time. Service call

recommended.

Note: This indication may ash temporarily during or

shortly after lightoff on some applications.

Check gas supply, pilot burner, ame

sense wiring, contamination of ame rod,

burner ground connection.

OFF No Flame or Flame Signal -

below minimum threshold for system operation. N/A

aFlash Code Descriptions

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- The ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then repeats

sequence.

Honeywell EI Ignition Module Yellow LED Flame Codes

60

Green LED

Flash Code

(X + Y)a

Indicates Next System Action Recommended Service Action

OFF No “Call for Heat” N/A None

Flash Fast Startup - Flame sense

calibration N/A None

Heartbeat Normal operation N/A None

2

5 minute Retry Delay-

Pilot ame not detected

during trial for ignition

Initiate new trial for ignition after

retry delay completed.

If system fails to light on next trial for

ignition check gas supply, pilot burner,

spark and ame sense wiring, ame rod

contamination or out of position, burner

ground connection.

3Recycle- Flame failed

during run

Initiate new trial for ignition. Flash

code will remain through the ignition

trial until ame is proved.

If system fails to light on next trial

for ignition check gas supply, pilot

burner, ame sense wiring, ame rod

contamination, burner ground connection.

4Flame sensed out of

sequence

If situation self corrects within 10

seconds, control returns to normal

sequence. If ame out of sequence

remains longer than 10 seconds,

control goes to Flash code 6+4 (see

below)

Check for pilot ame. Replace gas valve

if pilot ame present. If no pilot ame,

cycle “Call for Heat.” If error repeats,

replace control.

7Flame sense leakage to

ground

Control remains in wait mode.

When the fault corrects, control

resumes normal operation after a

one minute delay.

Check ame sense lead wire for damage

or shorting. Check that ame rod is in

proper position. Check ame rod ceramic

for cracks, damage or tracking.

8Low secondary voltage

supply- (below 15.5 Vac)

Control remains in wait mode.

When the fault corrects, control

resumes normal operation after one

minute delay.

Check transformer and AC line for proper

input voltage to the control. Check with

full system load on the transformer.

6 + 2

5 minute Retry Delay-

On every third retry on

same “Call for Heat”

Initiate new trial for ignition after

retry delay completed.

Check gas supply, pilot burner, spark

and ame sense wiring, ame rod

contamination or out of position, burner

ground connection.

6 + 3

On every 6th ame

failure during run on the

same “Call for Heat”

5 minute retry delay, then initiate

new trial for ignition.

Check gas supply, pilot burner, ame

sense wiring, contamination of ame rod,

burner ground connection.

6 + 4

Flame sensed out of

sequence- longer than

10 seconds

Control waits until ame is no

longer sensed and then goes to

soft lockout. Flash code continues.

Control auto resets from soft

lockout after one hour.

Check for pilot ame. Replace gas valve

if pilot ame present. If no pilot ame,

cycle “Call for Heat.” If error repeats,

replace control.

ON

Soft lockout due to error

detected during self

check sequences

Control auto resets from soft

lockout after one hour.

Reset by cycling “Call for Heat.” If error

repeats, replace the control

aFlash Code Descriptions:

- Flash Fast: rapid blinking

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then

repeats the sequence.

- X + Y ash codes signify that the LED ashes X times at 2Hz, remains off for two seconds, ashes Y times at

2 Hz, remains off for three seconds, and then repeats the sequence.

Honeywell EI Ignition Module Green LED Status Codes

61

Honeywell EI Trouble Shooting Guide

62

All Series 8H / 8HE 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.

X. Repair Parts

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63

Item No. Description Part No. Quantity

805H 806H 807HE 808HE 809HE 810HE

1. Heat Exchanger Assembly

1Complete (Less Flue Bafes)

6171605 1 --- --- --- --- ---

6171606 --- 1 --- --- --- ---

6171607 --- --- 1 --- --- ---

6171608 --- --- --- 1 --- ---

6171609 --- --- --- --- 1 ---

6171610 --- --- --- --- --- 1

1A Left End Section 7171601 1 1 1 1 1 1

1B Intermediate Section 7171603 3 4 5 6 7 8

1C Right End Section 7171602 1 1 1 1 1 1

1D Tie Rod

80861032 1 --- --- --- --- ---

80861033 --- 1 --- --- --- ---

80861013 --- --- 1 --- --- ---

80861034 --- --- --- 1 --- ---

80861035 --- --- --- --- 1 ---

80861036 --- --- --- --- --- 1

1E Washer 80860600 4 4 4 4 4 4

1F Nut 80860400 4 4 4 4 4 4

1G Slip Nipple, 3” 7066002 8 10 12 14 16 18

1H Flue Bafe 7111622 4 5 --- --- --- ---

7111623 --- --- 6 7 8 9

64

Item No. Description Part No. Quantity

805H 806H 807HE 808HE 809HE 810HE

2. Canopy

2A Canopy

6111605 1 --- --- --- --- ---

6111606 --- 1 --- --- --- ---

61116071 --- --- 1 --- --- ---

6111608 --- --- --- 1 --- ---

61116091 --- --- --- --- 1 ---

61116110 --- --- --- --- --- 1

2B Bolt, Carriage, ¼ - 20 x 1” 80860115 2 2 2 2 2 2

2C Washer, ¼” Flat 80860603 2 2 2 2 2 2

2D Nut, ¼” - 20 80860407 2 2 2 2 2 2

65

Item

No. Description Part No.

Quantity

805H 806H 807HE 808HE 809HE 810HE

3. Base Assembly

3A Base End Panel 7181601 2 2 2 2 2 2

3B Base Channel Assembly

61816052 2 --- --- --- --- ---

61816062 --- 2 --- --- --- ---

61816072 --- --- 2 --- --- ---

61816082 --- --- --- 2 --- ---

61816092 --- --- --- --- 2 ---

61816102 --- --- --- --- --- 2

3C Base Rear Panel Assembly

61816051 1 --- --- --- --- ---

61816061 --- 1 --- --- --- ---

61816071 --- --- 1 --- --- ---

61816081 --- --- --- 1 --- ---

61816091 --- --- --- --- 1 ---

61816101 --- --- --- --- --- 1

3D Base Front Panel Assembly

61816053 1 --- --- --- --- ---

61816063 --- 1 --- --- --- ---

61816073 --- --- 1 --- --- ---

61816083 --- --- --- 1 --- ---

61816093 --- --- --- --- 1 ---

61816103 --- --- --- --- --- 1

3E Burner Access Panel Assembly

61816054 1 --- --- --- --- ---

61816064 --- 1 --- --- --- ---

61816074 --- --- 1 --- --- ---

61816084 --- --- --- 2 --- ---

61816094 --- --- --- --- 2 ---

61816104 --- --- --- --- --- 2

3F Jacket Attachment Bracket 7041601 4 4 4 4 4 4

3G Bolt, Carriage, ¼ - 20 x 1¼” 80860106 4 4 4 4 4 4

3H Washer, ¼” Flat 80860603 4 4 4 4 4 4

3J Nut, ¼ - 20 80860407 4 4 4 4 4 4

3K Screw, Self Tapping, ¼ - 20 x ½” 80860700 3 4 4 5 5 6

3L Screw, Cap, Hex Head, 5/16” - 18 x ¾” 80861302 2 2 2 2 2 2

3M Screw, Cap, Hex Head, 5/16 - 18 x 1¼” 80861311 6 6 6 6 6 6

3N Screw, Sheet Metal, #8 x ½” 80860000 8 8 8 8 8 8

3P Washer, 3/8” Flat 80860600 6 6 6 6 6 6

3Q Nut, 5/16” 80860403 6 6 6 6 6 6

3R Screw, Self Tapping, ¼ - 20 x ¾” 80860702 10 10 10 10 10 10

66

Item

No. Description Part No.

Quantity

805H 806H 807HE 808HE 809HE 810HE

4. Manifold and Main Burners

4A Main Burner 8231602 8 10 12 15 17 19

4B

Main Burner with Pilot Bracket, Standing Pilot (24V) 8231601 --- 1 1 1 1 1

Main burner with Pilot Bracket, Honeywell EI 8231604 1 1 1 1 1 1

Main burner with Pilot Bracket, EP 8231603 --- 1 1 1 1 1

4C Manifold

82216051 1 --- --- --- --- ---

82216061 --- 1 --- --- --- ---

82216071 --- --- 1 --- --- ---

82216081 --- --- --- 1 --- ---

82216091 --- --- --- --- 1 ---

82216101 --- --- --- --- --- 1

4D Pipe Plug, 1/8 NPT (Included with 4C) --- 1 1 1 1 1 1

4E

Main Burner Orice, #39 (Natural Gas Only)* 822603 9 11 --- --- --- ---

Main Burner Orice, #41 (Natural Gas Only) * 822627 --- --- 13 16 18 20

Main Burner Orice, #53 (LP/Propane Only) * 8226002 9 11 13 16 18 20

4F Hitch Pin Clip 822604 9 11 13 16 18 20

* Main burner orice sizes shown for normal altitude (0-2000 feet). For High Altitude consult factory.

67

Item

No. Description Part No. Size Quantity

5-1 Gas Train -- Standing Pilot (24V)

24V: USA & Canada, 6 & 7 Section, Natural & LP Gas

A

Gas Valve, Robertshaw 7000ERHC-S7C, Natural Gas, 1” NPT 81660156

806H - 810HE 1

Gas Valve, Robertshaw 7000ERHC-LP-S7C, LP Gas, 1” NPT 81660157

B

Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT 81660235 806H - 807HE 1

Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 808HE - 810HE 1

C Manual Shut-Off Valve, Conbraco #50GB501A, 1” NPT 822615 808HE - 810HE

Canada Only 1

D Hex Bushing, 1” NPT x ¾” NPT 806600501 806H & 807HE 1

E

Nipple, ¾” NPT x 2” Lg. 806600003 806H & 807HE 1

Nipple, 1” NPT x 2” Lg. 806600004 808HE - 810HE 2

F

Street Elbow, 1” NPT x ¾” NPT 806601512 806H - 807HE

1

Street Elbow, 1¼” NPT x 1” NPT 806601513 808HE - 810HE

68

Item

No. Description Part No. Size Quantity

5-2 Gas Train -- Intermittent Ignition (EI)

USA: 5 - 10 Section, Natural and LP Gas

Canada: 5 - 10 Section, Natural Gas

7 Section, LP Gas

A

Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT 81660151 805H - 810HE

1

Gas Valve, Robertshaw 7000DERHC-LP, LP Gas, 1” NPT 81660158 USA: 805H - 810HE

Canada: 805H - 807HE

B Manual Shut-Off Valve, Conbraco #50GB501A, 1” NPT 822615

808HE - 810HE 1

C Nipple, 1’ NPT x 2” Lg. 806600004

D

Street Elbow, 1” NPT 806601514 805H - 807HE

1

Street Elbow, 1¼” NPT x 1” NPT 806601513 808HE - 810HE

69

Item

No. Description Part No. Size Quantity

5-3 Gas Train -- Intermittent Ignition (EP)

USA & Canada: 6 - 10 Section, Natural Gas Only

A Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 806H - 810HE 1

B

Solenoid Gas Valve, Honeywell V8295A1024, ¾” NPT 81660235 806H - 807HE

1

Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 808HE - 810HE

C Manual Shut-Off Valve, Conbraco #50GB501A, 1” NPT 822615 806H - 810HE 1

D Hex Bushing, 1” NPT x ¾” NPT 806600501 806H - 807HE 1

E

Nipple, ¾” NPT x 2” Lg. 806600003 806H - 807HE 1

Nipple, 1” NPT x 2” Lg. 806600004 808HE-810HE 2

F

Street Elbow, 1” NPT x ¾” NPT 806601512 806H - 807HE

1

Street Elbow, 1¼” NPT x 1” NPT 806601513 808HE-810HE

70

Item

No. Description Part No. Quantity

5-4 Gas Train -- Intermittent Ignition (EP-CSD-1)

USA Only: 8 - 10 Section, Natural Gas Only

A Gas Valve, Robertshaw 7000GVERHC-S7C, Natural Gas, 1” NPT 81660168 1

B Solenoid Gas Valve, Honeywell V8295A1032, 1” NPT 81660236 1

C Manual Shut-Off Valve, Conbraco #50-403-02, 1” NPT 822615 1

D Leak Test/Shut-Off Valve, Conbraco #50GB501A, 1/8” x 1/8” 822679 2

E Pipe Plug, 1/8” 806603594 2

F Hex Bushing, 1/4” x 1/8” 806600520 1

G Nipple, 1” x 2” Long 806600004 2

H Street Elbow, 90° x 1” 806601514 1

J Close Nipple, 1” 806600033 1

K Malleable Coupling, 1-1/4” x 1” 806602502 1

L Wiring Harness, Gas Valve to Solenoid Valve 6136230 1

M Pilot Outlet Plug, Honeywell #394424 8226051 1

71

Item

No. Description Part No. Size Quantity

5-5 Pilot Assembly and Piping -- Standing Pilot (24V)

USA & Canada: 6 & 7 Section, Natural and LP Gas

A

Pilot Burner, Honeywell Q314A3687, Natural Gas 8236033

807HE 1Pilot Burner, Honeywell Q314A3828, LP Gas 8236034

B Thermocouple, Honeywell Q309A1996 w/36” Lg. Lead 8236004

C Brass Compression Union, 1/4” OD Tube 8236008 806H - 807HE 1

D Regulator, Maxitrol RV12LT, Natural Gas 8226005 Canada: 806H - 807HE

Natural Gas Only 1

E Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630 Canada: 806H - 807HE

Natural Gas Only 2

72

Item

No. Description Part No. Size Quantity

5-6 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) USA

5 - 10 Section, Natural and LP Gas

A

Pilot Burner, Honeywell Q3481B1206, Natural Gas 103704-01

805H - 810HE

1

Pilot Burner, Honeywell Q3481B1420, LP Gas 103705-01

B Brass Compression Union, 1/4” OD Tube 8236008 1

73

Item

No. Description Part No. Size Quantity

5-7 Pilot Assembly and Piping -- Intermittent Ignition (Honeywell EI) Canada

5 - 10 Section, Natural Gas

5 Section, LP Gas

APilot Burner, Honeywell Q3481B1206, Natural Gas 103704-01 805H - 810HE 1

Pilot Burner, Honeywell Q348A1010, LP Gas 103705-01 807HE

B Brass Compression Union, 1/4” OD Tube 8236008 807HE 1

C Shut-Off Valve, Essex P2L 822645

808HE - 810HE 1D Pipe Tee, 1/8” NPT, Malleable 806601005

E Pipe Plug, 1/8” NPT, Sq. Head 806603508

F Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630

807HE Natural Gas 2

808HE - 810HE

Natural Gas 3

807HE LP Gas 1

G Solenoid Gas Valve, Johnson H91WG-6 822666

All

1H Junction Box, 4” Sq. x 1-1/2” Deep 8136259

I Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg. 8136019

J Conduit Locknut, 1/2” 8136220 2

K Plastic Insulating Bushing, 1/2” 8136034 1

L Regulator, Maxitrol RV12LT, Natural Gas 8226005 805H - 810HE

Natural Gas Only 1

74

Item

No. Description Part No. Size Quantity

5-8 Pilot Assembly and Piping -- Intermittent Ignition (EP)

USA & Canada: 6 - 10 Section, Natural Gas Only

A Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017

806H - 810HE

1

B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1

C Rajah Connector, Honeywell 37356 8236021 2

D Ignition Lead, Honeywell R1061012, 3 Ft. Lg. 7136247 1

EGround Wire Assembly 6136259 1

F Brass Compression Coupling, 1/4” OD Tube 8236008

806H - 807HE

USA & Canada

808HE - 810HE

USA Only

1

G Shut-Off Valve, Essex P2L 822645

808HE-810HE

Canada Only 1H Pipe Tee, 1/8” NPT, Malleable 806601005

J Pipe Plug, 1/8” NPT, Sq. Head 806603508

K Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630

806H - 807HE

Canada Only 2

808HE - 810HE

Canada Only 3

L Solenoid Gas Valve, Johnson H91WA-4 822662

806H - 810HE

1

M Junction Box, 4” Sq. x 1-1/2” Deep 8136259 1

N Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg. 8136019 1

P Conduit Locknut, 1/2” 8136220 2

Q Plastic Insulating Bushing, 1/2” 8136034 1

R Regulator, Maxitrol RV12LT, Natural / LP Gas 8226005 806H - 810HE

Canada Only 1

75

Item

No. Description Part No. Size Quantity

5-9 Pilot Assembly and Piping -- Intermittent Ignition (EP-CSD-1)

USA Only: 8 - 10 Section, Natural Gas Only

A Pilot Burner, Honeywell Q179C1009, Natural Gas 8236017

808HE - 810HE

1

B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1

C Rajah Connector, Honeywell 37356 8236021 2

D Ignition Lead, Honeywell R1061012, 3 Ft. Lg. 7136247 1

EGround Wire Assembly 6136259 1

F Brass Compression Coupling, 1/4” OD Tube 8236008 1

G Conbraco Leak Test / Shut-Off Cock, 1/8” x 1/8” 822679 1

H Brass Compression Adapter, 1/4” OD Tube x 1/8” NPT 822630 2

J Solenoid Gas Valve, Johnson H91WA-4 822662 1

K Junction Box, 4” Sq. x 1-1/2” Deep 8136259 1

L Rigid Conduit Nipple, 1/2” NPT x 1-1/2” Lg. 8136019 1

M Conduit Locknut, 1/2” 8136220 2

N Plastic Insulating Bushing, 1/2” 8136034 1

P Regulator, Maxitrol RV12LT, Natural / LP Gas 8226005 1

76

77

Item

No. Description Part No. Quantity

805H 806H 807HE 808HE 809HE 810HE

6. Jacket

6 Complete

60416111 1 --- --- --- --- ---

60416121 --- 1 --- --- --- ---

604160711 ---- --- 1 --- --- ---

604160811 --- --- --- 1 --- ---

604160911 --- --- --- --- 1 ---

604161011 --- --- --- --- --- 1

6A Jacket Top Panel

70416053 1 --- --- --- --- ---

70416063 --- 1 --- --- --- ---

70416073 --- --- 1 --- --- ---

70416083 --- --- --- 1 --- ---

70416093 --- --- --- --- 1 ---

70416103 --- --- --- --- --- 1

6B Jacket Top Panel Main Insulation

7201625 1 --- --- --- --- ---

7201627 --- 1 ---- --- --- ---

7201611 --- --- 1 --- --- ---

7201613 --- --- --- 1 --- ---

7201615 --- --- --- --- 1 ---

7201617 ---- --- --- --- --- 1

6C Jacket Upper Rear Panel

70416056 1 --- --- --- --- ---

70416066 --- 1 --- --- --- ---

70416076 --- --- 1 --- --- ---

70416086 --- --- --- 1 --- ---

70416096 --- --- --- --- 1 ---

70416106 --- --- --- --- --- 1

6D Jacket Upper Rear Panel Insulation

72016059 1 --- --- --- --- ---

72016069 --- 1 --- --- --- ---

72016079 --- --- 1 --- --- ---

72016089 --- --- --- 1 --- ---

72016099 --- --- --- --- 1 ---

72016109 --- --- --- --- --- 1

6E Jacket Lower Rear Panel

60416056 1 --- --- --- --- ---

60416066 --- 1 --- --- --- ---

60416076 --- --- 1 --- --- ---

60416086 --- --- --- 1 --- ---

60416096 --- --- --- --- 1 ---

60416106 --- --- --- --- --- 1

6F Jacket Upper Front Panel

70416051 1 --- --- --- --- ---

70416061 --- 1 --- --- --- ---

70416071 --- --- 1 --- --- ---

70416081 --- --- --- 1 --- ---

70416091 --- --- --- --- 1 ---

70416101 --- --- --- --- --- 1

6G Jacket Front Removable Panel

7041605 1 --- --- --- --- ---

7041606 --- 1 --- --- --- ---

7041607 --- --- 1 --- --- ---

7041608 --- --- --- 1 --- ---

7041609 --- --- --- --- 1 ---

7041610 --- --- --- --- --- 1

78

79

Item

No. Description Part No.

Quantity

805H 806H 807HE 808HE 809HE 810HE

6. Jacket (Continued)

6H Jacket Left Side Panel 6041601 1 1 1 1 1 1

6J Jacket Left Side Panel Main Insulation Piece 72016021 111111

6K Jacket Left Side Panel Upper Corner Insulation Piece 72016023 111111

6L Jacket Left Side Panel Lower Corner Insulation Piece 72016022 111111

6M Jacket Right Side Panel 6041602 1 1 1 1 1 1

6N Jacket Right Side Panel Main Insulation Piece 72016011 111111

6P Jacket Right Side Panel Lower Corner Insulation Piece 72016012 111111

6Q Jacket Vestibule Panel

70416055 1 --- --- --- --- ---

70416065 --- 1 --- --- --- ---

70416075 --- --- 1 --- --- ---

70416085 --- --- --- 1 --- ---

70416095 --- --- --- --- 1 ---

70416105 --- --- --- --- --- 1

6R Jacket Vestibule Panel Upper Insulation Piece

72016057 1 --- --- --- --- ---

72016067 --- 1 --- --- --- ---

72016077 --- --- 1 --- --- ---

72016087 --- --- --- 1 --- ---

72016097 --- --- --- --- 1 ---

72016107 --- --- --- --- --- 1

6S Jacket Vestibule Panel Lower Insulation Piece

72016056 1 --- --- --- --- ---

72016066 --- 1 --- --- --- ---

72016076 --- --- 1 --- --- ---

72016086 --- --- --- 1 --- ---

72016096 --- --- --- --- 1 ---

72016106 --- --- --- --- --- 1

6T Jacket Lower Front Tie Bar

70416052 1 --- --- --- --- ---

70416062 --- 1 --- --- --- ---

70416072 --- --- 1 --- --- ---

70416082 --- --- --- 1 --- ---

70416092 --- --- --- --- 1 ---

70416102 --- --- --- --- --- 1

6U Jacket Lower Rear Panel Insulation

7201623 1 --- --- --- --- ---

7201624 --- 1 --- --- --- ---

7201619 --- --- 1 --- --- ---

7201620 --- --- --- 1 --- ---

7201621 --- --- --- --- 1 ---

7201622 --- --- --- --- --- 1

6V Jacket Top Panel Front Insulation

7201626 1 --- --- --- --- ---

7201628 --- 1 --- --- --- ---

7201612 --- --- 1 --- --- ---

7201614 --- --- --- 1 --- ---

7201616 --- --- --- --- 1 ---

7201618 --- --- --- --- --- 1

80

Item

No. Description Part No.

Quantity

805H 806H 807HE 808HE 809HE 810HE

7. Trim and Miscellaneous Controls

A

Limit, 140-220°F, Honeywell

L4080D1218 (EI & Standing Pilot);

L4080B1212 (EP)

80160251

80160474

--- 1 1 1 1 1

Immersion Well, ¾” NPT x 1½” Insul. Depth 80160426 1 1 1 1 1 1

Hydrostat 3200 with Sensor (805) 104873-01 1 --- --- --- --- ---

LWCO Well for Hydrostat 3200 (if used) 105203-01 1 --- --- --- --- ---

B Limit, Manual Reset, Honeywell L4006E1133 80160703 1 1 1 1 1 1

B1 Immersion Well, ¾” NPT x 3” Insul. Depth 80160452 1 1 1 1 1 1

C Temperature - Pressure Gauge 100282-01 1 1 1 1 1 1

C1 Nipple, 2 NPT x 10” w/Gauge Tapping 8061601 1 1 1 1 1 1

D Safety Relief Valve, ¾ NPT, 50 psi 81660302 1 1 1 1 1 1

D1 Nipple, ¾ NPT x 3½” 806600038 1 1 1 1 1 1

E Drain Valve, ¾ NPT, Conbraco 35-302-03 806603061 1 1 1 1 1 1

E1 Nipple, ¾ NPT x 3½” 806600038 1 1 1 1 1 1

E2 Coupling, ¾ NPT 806602561 1 1 1 1 1 1

F Blocked Vent Switch Replacement Assembly 6016058 1 1 1 1 1 1

G Flame Roll-out Switch 80160044 1 1 1 1 1 1

G1 Flame Roll-out Switch Mounting Bracket 7181612 1 1 1 1 1 1

H Junction Box 8136010 1 1 1 1 1 1

JControl Center, Honeywell R8285D500

(Intermittent Circulation builds) 80160155U --- 1 1 1 1 1

K Transformer, 50VA (Continuous Circulation builds) 80160249 --- 1 1 1 1 1

L Ignition Module, Honeywell S8610M3009 100958-01 1 1 1 1 1 1

MVestibule Wiring Harness, Complete with Vent Damper

Bypass Plug (EI and Standing Pilot) (Not Depicted)

81316010 --- 1 1 --- --- ---

81316011 --- --- --- 1 1 1

NJ-Box to 3200 and Auxiliary Limit Wiring Harness

(not depicted) 81316017 1 --- --- --- --- ---

81

Item

No. Description Part No.

Quantity

805H 806H 807HE 808HE 809HE 810HE

8. Draft Hood and Automatic Vent Damper

8A Draft Hood

8111605 1 --- --- --- --- ---

8111604 --- 1 1 --- --- ---

8111602 --- --- --- 1 --- ---

8111601 --- --- --- --- 1 1

8B

Automatic Vent Damper, 7”

Efkal RVGP-7 8116324 1 --- --- --- --- ---

Automatic Vent Damper, 8”

Efkal RVGP-8 8116325 --- 1 1 --- --- ---

Automatic Vent Damper, 9”

Efkal RVGP-9 8116326 --- --- --- 1 --- ---

Automatic Vent Damper, 10”

Efkal RVGP-10 8116327 --- --- --- --- 1 1

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