Burnham 5B Installationshandbuch

1DNAGNITAREPO,NOITALLATSNIROFSNOITCURTSNIECIVRESB5SEIRESDERIF-SAGRELIOB8141302R18 - 1/15 PRICE - $5.00Commercial Boilerswww.burnhamcommercial.com30505

10SECTION II – GENERAL INFORMATION1. BOILER INSTALLATION must conform to the requirements of the authority having jurisdiction, or in the absence o

100TRANSFORMER & PILOT LINE REGULATORTHERMOCOUPLE CONTROL SYSTEM - CANADAPART NO. ITEM7016001(1) “J” Box Mounti

101TRANSFORMER, PENN #H91WA-4 PILOT SOLENOID VALVE & PILOT LINE REGULATOREP CONTROL SYSTEMPART NO. ITEM7016003

102CONTROL ASSEMBLY AND MOUNTING BRACKETEP CONTROL SYSTEMSSECTION VI - REPAIR PARTS (continued)

103EI CONTROL SYSTEM - HONEYWELL Q3481 PILOT ASSEMBLYEI CONTROL SYSTEM - PILOT ASSEMBLY6236072 EI - 1, NAT., 5006B - 5009B Sections

104EP CONTROL SYSTEM - PILOT ASSEMBLY6236003 NAT. GASNot Available for LPPART NO. ITEM8236017 (1) Flame Recticati

105APPENDIX A - FIGURESFigureNumberPageNumber DescriptionSection I - Equipment Check ListUSA KD Boilers5 & 6 U.S.A.

106FigureNumberPageNumber DescriptionSection III - Installation Instructions (continued)Fig. 36 40 Pilot Piping, Thermoco

107FigureNumberPageNumber DescriptionSection VI - Repair Parts (continued)Honeywell Ignition Module97 Ignition Module #S8

108APPENDIX B - TABLESTableNumberPageNumber DescriptionSection I - Equipment Check ListSection II - General Information

109APPENDIX B - TABLES (continued)TableNumberPageNumber DescriptionSection VI - Repair Parts (continued)Penn Johnson Co

11SECTION III – INSTALLATION INSTRUCTIONSequipment in space. Duct cross-sectional area shall be same as opening free area.3. Horizontal ducts. M

110

111

112

12Center Sections on 11 section and larger boilers. THIS IS IMPORTANT.a. Carefully join a Center Section with nipples in adjoining section and bump

13FIG. 6ARRANGEMENT OF SECTIONS AND CANOPY(S)SECTION III – INSTALLATION INSTRUCTIONS (continued)

14c. Insert short end of draw-up rod through front & rear nipple ports on both sections, see Fig. 5.d. Place two (2) at washers, draw-up chan

15FIG. 8INSTALLATION OF BUILT-IN HEATERFIG. 9TESTING BOILER ASSEMBLY FOR LEAKS Open Steam or Water Trim Carton8. USE THE PLUGS IN THIS CARTON to pl

1613. INSTALL FLUE COVER PLATES over cleanout openings on Front and Rear of Boiler. Use ¼” Carriage Bolts installed at top and bottom of ue opening

17FIG. 12 RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURNI OR 2 SUPPLY CONNECTIONS - 5006B THRU 5014BSECTION III – INSTALLATION INSTRUCTIONS (contin

18FIG. 13 RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN3 SUPPLY CONNECTIONS - 5015B THRU 5020BSECTION III – INSTALLATION INSTRUCTIONS (continued)

19FIG. 14 RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN4 OR 5 SUPPLY CONNECTIONS - 5021B THRU 5026BSECTION III – INSTALLATION INSTRUCTIONS (contin

2The following dened terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important infor

20FIG. 15 TYPICAL STEAM PIPING ARRANGEMENT FOR BOILERS WITH PUMPED CONDENSATE RETURN AND BOILER FEED UNITSECTION III – INSTALLATION INSTRUCTIONS (co

21FIG. 16A RECOMMENDED WATER BOILER PIPING1 SUPPLY CONNECTION & 1 RETURN CONNECTIONSIZES 5006B THRU 5019BFIG. 16B RECOMMENDED WATER BOILER PIPING3

22 There are many possible causes of oxygen contamination such as:1. Addition of excessive make-up water as a result of system leaks.2. Absorptio

23FIG. 19INSTALLATION OF JACKET END PANELSFIG. 20VESTIBULE ATTACHMENT DIAGRAM Attach Hex Couplings to end of Carriage Bolts which secure ue cover pl

24FIG. 21EXPLODED VIEW OF JACKET5006B THRU 5010B SECTION BOILERSSECTION III – INSTALLATION INSTRUCTIONS (continued)

25FIG. 22SECURING OF CANOPY/DRAFT HOODSECTION III – INSTALLATION INSTRUCTIONS (continued)

26FIG. 23CANOPY/DRAFT HOOD MOUNTING DIAGRAMSECTION III – INSTALLATION INSTRUCTIONS (continued)

27FIG. 24EXPLODED VIEW OF JACKET5011B THRU 5019B SECTION BOILERSSECTION III – INSTALLATION INSTRUCTIONS (continued)

2822. INSTALLATION OF TOP FRONT JACKET PANELa. Remove knockout for supply piping (right or left for water boilers – both knockouts for steam boilers

29FIG. 25EXPLODED VIEW OF JACKET5020B THRU 5022B SECT. BOILERSSECTION III – INSTALLATION INSTRUCTIONS (continued)Panel with louvers must be at front

3Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow

30FIG. 26EXPLODED VIEW OF JACKET5024B AND 5026B SECT. BOILERSSECTION III – INSTALLATION INSTRUCTIONS (continued)Panel with louvers must be at front

31FIG. 27STEAM TRIM AND CONTROLS32. TIGHTEN ALL SHEET METAL SCREWS.a. Install the following plates or labels which are found in the Instruction Enve

32FIG. 28MOUNTING ELEVATIONS OF M&M 150 AND A 67M FLOAT LWCOSECTION III – INSTALLATION INSTRUCTIONS (continued)

33 A Bottom Blowoff using a valve must also be connected to one of the return tappings. The ¾” Drain Valve may be used for Bottom Blowoff for 5009B

34FIG. 30RECOMMENDED PIPING TOBUILT-IN TANKLESS HEATERSTABLE I - NATURAL GASMaximum Capacity of Piping in Cubic Feet of Gas Per Hour(Based on a Pressu

3538. THE INSTALLATION OF THE REMAINDER OF THE GAS CONTROLS IS DEPENDENT ON THE CONTROL SYSTEM FURNISHED. REFER TO THE TABLE BELOW FOR THE FIGURES IN

36FIG. 31INSTALLATION OF S8610M MODULE EI Control System1. INSTALLATION OF GAS VALVE TRANSFORMER AND PILOT PIPING (for Robertshaw Pilot Piping, see

37FIG. 33PILOT PIPING - EI CONTROL SYSTEM (V88A)U.S.A. 5010B THRU 5026B - NAT. GASCANADA - 5006B THRU 5026B - NAT. GAS4. COMPLETION OF WIRING – Con

38SECTION III – INSTALLATION INSTRUCTIONS (continued)FIG. 34INSTALLATION OF EP CONTROL PANELFIG. 35PILOT PIPING - EP CONTROL SYSTEMNOTE - PILOT PIPI

394. INSTALLATION OF IGNITION TRANSFORMER AND WIRING OF PILOT – If space permits, mount the ignition transformer on the Jacket above the Gas Train

4Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, ald

40“THERMOCOUPLE CONTROL SYSTEM”CANADA ONLYFIG. 36PILOT PIPINGTHERMOCOUPLE CONTROL SYSTEMCANADA ONLYFIG. 37NOTE - TWO PILOT SAFETY SWITCHES REQUIRED

41Venting1. INSTALL VENT CONNECTOR from canopy Draft Hood or damper to chimney maintaining 6” clearances from combustible materials.2. INSTALL V

42(18) Clearances to combustible material – use of thimbles.(19) Firestops.(20) Flashing and storm collars.(21) Guying or bracing of commo

43SECTION IV - OPERATION Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler whe

44b. Draw about 5 gallons of hot water from boiler into a container and dissolve into it the appropriate amount of a recommended boilout compound.

453. CONDENSATION Following a cold start, condensation (sweating) may occur in a gas red boiler to such an extent that it CONTROL VARIATIONSNATUR

464. EI CONTROL SYSTEM – The EI control system utilizes a solid state ignition control which lights the pilot burner by spark. Pilot gas is ignited

47FIG. 40SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (ROBERTSHAW7000 GAS VALVE)U.S.A. 5006B THRU 5009BSECTION IV - OPERATION (continued)

48FIG. 41SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (V88 GAS TRAIN)U.S.A. 5010B THRU 5014BCANADA 5006B THRU 5014BEI SEQUENCE OF OPERATION - 5006B TH

49FIG. 42SCHEMATIC WIRING DIAGRAM - 5015B THRU 5026B SECTION BOILERS EI CONTROL SYSTEMSECTION IV - OPERATION (continued)

5BOILER SIZE5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B(1) LEH1 1 1 1 1 1 1

50EI SEQUENCE OF OPERATION - 5010B THRU 5014BWHEN OPERATING CONTROL CLOSES, THE ELECTRIC SPARK AND PILOT VALVE ON EACH SIDE ARE AUTOMATICALLY ENERGIZE

51TROUBLE SHOOTING GUIDEBOILERS EQUIPPED WITH S8610M INTERMITTENT ELECTRIC IGNITIONSECTION IV - OPERATION (continued)

52SECTION IV - OPERATION (continued)7. EP CONTROL SYSTEM – 5006B thru 5014B The EP Control System utilizes an RM7890A Relay Module and a Q179C Rect

53can be readily found. After the cause of the pilot failure has been corrected, resume normal operation by following the Lighting Instructions.(3)

54FIG. 44WIRING DIAGRAM - 5006B THRU 5014B SECTION BOILERS EP CONTROL SYSTEMSECTION IV - OPERATION (continued)

55FIG. 45WIRING DIAGRAM - 5015B THRU 5026B SECTION BOILERS EP CONTROL SYSTEMSECTION IV - OPERATION (continued)

56a. OPERATING INSTRUCTIONS(1) Make sure all Manual Main Shut-off Valves and all Pilot Valves have been off for at least ve minutes.(2) Set O

579. THERMOCOUPLE CONTROL SYSTEM (Canada Only) The 5006B thru 5014B boilers are equipped with a Thermocouple Control System that utilizes a consta

58When operating control (A) calls for heat, it energizes main gas valves (B), starting burner operation.The burners will operate until operating cont

59When the operating control (A) calls for heat, it energizes the main gas valves (B) in both gas trains starting burner operation. The burners will

6BOILER SIZE5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026BCARTONS, PACKAGES OR BUND

6010. CHECK GAS INPUT RATE TO BOILER(1) Input Rate and Maximum Inlet Pressure shown on Rating Plate must not be exceeded. Inlet pressure must not b

61The following procedures should only be performed by a qualied service technician.11. MINIMUM INPUT ADJUSTMENTS This section covers Minimum Input

62FIG. 49LOW FIRE ADJUSTMENT - V4062 ACTUATOR(3) Remove the lead to V9055A terminal R. Jumper terminal R to W. This will prevent the actuator from

6314. CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and stop burners.15. CHECK HIGH LIMIT CONTROL. Jumper Th

641. GENERAL – “Inspection should be conducted annually. Service as frequently as specied in paragraphs below.” While service or maintenance is b

65Important Product Safety InformationRefractory Ceramic Fiber ProductThe Repair Parts list designates parts that contain refractory ceramic fibers (R

66 Remove the Front Cleanout Panels rst by removing the upper and lower nuts and washers securing these panels to the boiler sections, see Fig. 52.

67THIS PAGE LEFT BLANK INTENTIONALLY

68SECTION V – SERVICE (continued)FIG. 54-1PILOT LOCATIONS

69SECTION V – SERVICE (continued)FIG. 54-2PILOT LOCATIONS

7BOILER SIZE5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B (1) LEH1 1

70 If Burners must be removed, use the following procedure:a. Mark location on manifold of all burners with pilots.b. Using a pair of pliers, rem

71SECTION V – SERVICE (continued)FIG. 57PILOT FLAMEHONEYWELL Q179C PILOTFIG. 58PILOT FLAMEHONEYWELL Q327A PILOT W/THERMOCOUPLE7. LOW WATER CUT-OFF –a

72SECTION V – SERVICE (continued)Do not drain water below gauge glass.- Main burners should turn off when water level drops below low water cut-off

73,reliobnonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorpreb

74REPAIR PARTS INDEX ITEM PAGE NOS.Base Parts ...

75FIG. 59BASE PARTS (5006B THRU 5014B)SECTION VI - REPAIR PARTS (continued)

76SECTION VI - REPAIR PARTS (continued)TABLE 2ASERIES 5B BASE PARTS - 5006B thru 5014BNumber in ( ) in Table Relates to Corresponding Number in in

77FIG. 60BASE PARTS (5015B THRU 5026B)SECTION VI - REPAIR PARTS (continued)

78TABLE 2BSERIES 5B BASE PARTS - 5015B Thru 5026BNumber in ( ) in Table Relates to Corresponding Number in in Figure 61PART NUMBERITEM PART SIZ

79FIG. 61INTEGRAL CANOPY DRAFT HOODS & SECTIONSSECTION VI - REPAIR PARTS (continued)

8BOILER SIZE5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026BCARTONS, PACKAGES OR BUND

80TABLE 3ASERIES 5B INTEGRAL CANOPY DRAFT HOODS - BOILER SIZESPART SIZE PART NO.Canopy - Draft Hood No.BOILER SIZE (QUANTITY)5006B 5007B 5008B 5009B 5

81TABLE 3BSERIES 5B SECTION REPLACEMENT CHARTRefer to Fig. 61PART NO. ITEMBOILER SIZE (QUANTITY)5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B

82TABLE 3CSERIES 5B BASE / PILOT ASSEMBLIES5006B THRU 5014B BOILERS - SINGLE BASE REQUIRED(NATURAL GAS) 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013

83FIG. 62JACKETSSECTION VI - REPAIR PARTS (continued)

84TABLE 4ASERIES 5B JACKETSNumber in ( ) in Table Relates to Corresponding Number in in Figure 63PART NUMBERITEM PART SIZEBOILER SIZE5006B 5007

85TABLE 4BSERIES 5B JACKETSNumber in ( ) in Table Relates to Corresponding Number in in Figure 63PART NUMBERITEM PART SIZEBOILER SIZE5006B 5007

86TABLE 4CSERIES 5B JACKETSNumber in ( ) in Table Relates to Corresponding Number in in Figure 63PART NUMBERITEM PART SIZEBOILER SIZE5016B 5017

87TABLE 4DSERIES 5B JACKETSNumber in ( ) in Table Relates to Corresponding Number in in Figure 63PART NUMBERITEM PART SIZEBOILER SIZE5016B 5017

88SECTION VI - REPAIR PARTS (continued)TABLE 4FWater TrimWater Trim Carton Number: 7W2 7W3 7W4Description 5006B-5011B 5012B-5022B 5024B-5026B PART NO.

89Steam TrimSteam Trim Carton Number: 7S1 7S2 7S3 7S4Description 5006B-5008B 5009B-5011B 5012B-5020B 5021B-5026B PART NO.Pressuretrol, Honeywell L404F

9FIG. 1DIMENSIONAL DATABoiler SizeJacket Overall Length ‘A’Draft Hood Height, Size and LocationTop Supplyand Rear ReturnLocationSupply Conn. Qty &

907000DERHC GAS TRAIN - EI - 5006B THRU 5009B - USAPART NO. ITEMBOILER SIZE5006B 5007B 5008B 5009B81660151 Robertshaw 7000DERHC-S7C 1” x 1” Gas Valve

91V88A GAS TRAINS - USAPART NO. ITEMBOILER SIZE5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026BDiaphragm Gas Valve81660008 1” Honeywell V88A1618

92V88A GAS TRAINS - CANADANATURAL GAS ONLYPART NO. ITEMBOILER SIZE5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026BDiaphragm Gas Valve81660008 1”

93FLUID POWER GAS TRAINS - USA(See Page 94 for “LO-HI-LO” Natural Gas Diaphragm Type Valves)PART NO. ITEMBOILER SIZE5006B - 5008B 5009B - 5014B 5015B

94DIAPHRAGM VALVE “LO-HI-LO” GAS TRAINUSA - NATURAL GAS ONLYPART NO. ITEMBOILER SIZE5006B 5009B 5015B 5016B 5017B“Lo-Hi-Lo” Gas Valve81660149 1” Honey

95DIAPHRAGM VALVE “LO-HI-LO” GAS TRAINCANADA - NATURAL GAS ONLYPART NO. ITEMBOILER SIZE5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026B“Lo-Hi-Lo”

96FLUID POWER GAS TRAINS - CANADAPART NO. ITEMBOILER SIZE5006B - 5008B 5009B - 5014B 5015B 5016B 5017B - 5026BFluid Power Gas Valve81660010 1” - Honey

97PART NO. 6011301 100958-01Description Manifold Module Support Bracket Assembly Honeywell S8610M3009 Ignition ModuleIGNITION MODULE #S8610M & SUP

98PILOTSTAT #L62GB & SUPPORT BRACKETTHERMOCOUPLE CONTROL SYSTEMSECTION VI - REPAIR PARTS (continued)ITEM (1) (2)PART NO. 6011301 80160138Descripti

99TRANSFORMER, PENN #H91WG PILOT SOLENOID VALVE & PILOT LINE REGULATOREI CONTROL SYSTEMU.S.A. - 5010B-5026B NAT. GASCANADA - 5006B-5026B NAT. GASP