INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 8H / 8HE GAS - FIRED BOILER 3050579 This manual must only be used by a qualified 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.
IMPORTANT INFORMATION READ and save these instructions for reference 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.
DO NOT store or use gasoline or other flammable 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.
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 flammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of fire hazards. Float type low water cutoff devices require annual inspection and maintenance.
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.
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.......................................
Figure 1: Dimensional Data Table 1: Dimensional Data Approx. Shipping Weight (LB.) A B C D E Recommended Chimney Size (Round) 252 20 10 7 24-13/16 16-1/8 7” dia. x 15 ft. 11.9 600 610 Boiler Model Input (MBH) 805H Dimensions (Inches) Water Content (Gallons) Packaged Knockdown 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.
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 filed immediately against carrier by consignee.
i. b. If result is less than 50 ft3 per 1,000 Btuh, space is considered a confined 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.
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.
6. Lift boiler with pry bar. Remove wood blocks. Lower boiler. 6. Examine boiler for leaks or damage due to shipment or handling. C. For Packaged Boiler only, proceed to Paragraph E. 7. Remove plugs from Return Tapping B, Tapping C, and Tapping E (if second limit or operating control is used). Also remove fill valve and piping, purge valve and piping, and pressure gauge. D. Test Section Assembly for leaks before connecting to system and installing controls, trim and jacket.
Figure 5: General Assembly (Knockdown Boilers) F. Move boiler to permanent location by sliding or 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). walking. Do not drop. For Packaged Boiler, proceed to Paragraph L. G. Confirm that one (1) Flue Baffle is properly positioned in each Boiler Flueway.
Figure 6: Flame Roll-out Switch Installation Figure 7: Burner/Burner Access Panel Installation 13
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.
Figure 8: Jacket Assembly
Figure 9: EP Control Installation 16
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. C. EP Control System 1. Install Gas Control Assembly on Manifold. See Figure 14. 1. Install Gas Control Assembly on Manifold. See Figure 10. Use thread (joint) compound (pipe dope) resistant to action of liquefied petroleum gas. 2. Install pilot burner piping and controls. See Figure 14. 2.
Figure 10: Schematic Gas Piping, 24V Standing Pilot, 806H - 807HE
Figure 11: Main Gas Piping, Intermittent Ignition (EI)
Figure 12: Schematic Pilot Piping (Honeywell EI), USA
Figure 13: Schematic Pilot Piping (Honeywell EI) Canada: Natural Gas, 805H - 810HE; LP Gas, 806H - 807HE
Figure 14: Schematic Gas Piping, EP Control System (Natural Gas Only), 806H - 810HE
Figure 15: Schematic Gas Piping, EP-CSD-1 Control System, 808HE - 810HE
IV. Water Trim and Piping 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. A.
Figure 17: Drain Piping Installation 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 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.
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 flow 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.
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 flow through the boiler. See Figure 21. b.
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.
Table 6: Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0.5 psig or Less Length (Feet) ½ 0.3 Inch w.c. Pressure Drop ¾ 1 1¼ ½ 0.5 Inch w.c.
VI. Venting 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.
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.
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.
VII. Electrical 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. 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.
E. Alliance SL™ Water Heater (if used). May be used 5. When the call for heat is satisfied, 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. with Intermittent Circulation only. Refer to Alliance SL™ Installation, Operating and Service Instructions for wiring, piping and additional information.
Table 10: Sequence of Operation and Wiring Diagrams Ignition System Country Fuel Standing Pilot (24V) USA & Canada Natural Gas USA Intermittent Ignition (Honeywell EI - 24V) Canada LP Gas Natural Gas LP Gas Continuous Intermittent 6 & 7 Sect. Figure 27 Figure 28 Page 35 5 - 10 Sect. Figure 30 Figure 31 Natural Gas 5 - 10 Sect. LP Gas 5 - 7 Sect. 6 - 10 Sect.
Figure 27: Wiring Diagram, Standing Pilot (24V), Continuous Circulation (806H - 807HE)
Figure 28: Wiring Diagram, Standing Pilot (24V), Intermittent Circulation (806H - 807HE) 37
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.
Figure 29: Wiring Diagram, Honeywell EI, USA & Canada, 805 Only with Hydrostat 3200 Control 39
Figure 30: Wiring Diagram, Honeywell EI, USA, Continuous Circulation (806 - 810)
Figure 31: Wiring Diagram, Honeywell EI, USA, Intermittent Circulation (806 - 810) 41
Figure 32: Wiring Diagram, Honeywell EI, Canada, Continuous Circulation (Natural: 806H - 810HE; LP: 806H - 807HE)
Figure 33: Wiring Diagram, Honeywell EI, Canada, Intermittent Circulation (Natural: 806H - 810HE; LP: 806H - 807HE) 43
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.
Figure 34: Wiring Diagram, EP Ignition System, Natural Gas Only, Continuous Circulation (EP-CSD-1; Natural Gas, USA Only, 808HE - 810HE) 45
Figure 35: Wiring Diagram, EP Ignition System, Natural Gas Only, Intermittent Circulation (EP-CSD-1; Natural Gas, USA Only, 808HE - 810HE)
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.
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.
VIII. System Start-Up 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 specified in American National Standard for Gas-Fired LowPressure Steam and Hot Water Boilers, ANSI Z21.13. B. Check Main Burners.
Figure 40: Lighting Instructions (24V Standing Pilot) 50
Figure 41: Operating Instructions (EI) 51
Figure 42: Operating Instructions (EP) 52
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 five 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 flame safeguard relay. 7.
Avoid operating this boiler in an environment where saw dust, loose insulation fibers, 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. Figure 44: Honeywell Q314 Pilot Flame (24V Standing Pilot) a. Loosen lock screw. b. Close air adjustment until yellow tips appear on flames. c. Slowly open air adjustment until clearly defined inner cones are visible. d. Tighten lock screw. 4.
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. Table 12: Input Rate Size of Gas Meter Dial Seconds for One One-Half One Two Five Revolution Cu. Ft. Cu. Ft. Cu. Ft. Cu. Ft.
P. Check Damper Operation - If boiler is equipped with 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.
IX. Service Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids. Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air.
Figure 48: Boiler Flueway Cleaning 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 Orifices, and secured with hitch pin clips.
Honeywell EI Ignition Module Yellow LED Flame Codes Yellow LED Flash Codea Indicates Recommended Service Action Heartbeat Normal Flame Signal N/A 2 Weak Flame Signal System will operate reliably but flame signal is less than desired. Note: This indication may flash temporarily during or shortly after lightoff on some applications. Perform routine maintenance to assure optimum flame signal. 1 Marginal Flame Signal (less than 1.1 µA) System may not operate reliably over time.
Honeywell EI Ignition Module Green LED Status Codes Green LED Flash Code (X + Y)a Next System Action Recommended Service Action No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None OFF If system fails to light on next trial for ignition check gas supply, pilot burner, spark and flame sense wiring, flame rod contamination or out of position, burner ground connection.
Honeywell EI Trouble Shooting Guide 61
X. Repair Parts F o r s e rvi c e o r re p a i rs to b o i le r, c a ll yo ur he a ti ng c o ntra c to r. Whe n s e e k i ng i nfo rma ti o n o n b o i le r, p ro vi d e B o i le r Mo d e l Numb e r a nd S e ri a l Numb e r a s s ho wn o n Ra ti ng L a b e l.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 6171605 1 6171606 --- 6171607 --- 6171608 --- 6171609 6171610 809HE 810HE --- --- 1 --- --- --- --- --- --- --- ----- 1 --- --- --- --- 1 --- --- --- --- --- --- --- --- --- 1 --- --- --- 1 1.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 809HE 810HE 6111605 1 --- --- --- --- --- 6111606 --- 1 --- --- --- --- 61116071 --- --- 1 --- --- --- 6111608 --- --- --- 1 --- --- 61116091 --- --- --- --- 1 --- 61116110 --- --- --- --- --- 1 80860115 2 2 2 2 2 2 2.
Item No. Description Part No.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 809HE 810HE 8231602 8 10 12 15 17 19 4.
Item No. Description Part No.
Item No. Description Part No. Size Gas Valve, Robertshaw 7000DERHC, Natural Gas, 1” NPT 81660151 805H - 810HE Gas Valve, Robertshaw 7000DERHC-LP, LP Gas, 1” NPT 81660158 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 B Manual Shut-Off Valve, Conbraco #50GB501A, 1” NPT C Nipple, 1’ NPT x 2” Lg.
Item No. Description Part No.
Item No. Description Part No.
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 Pilot Burner, Honeywell Q314A3687, Natural Gas 8236033 Pilot Burner, Honeywell Q314A3828, LP Gas 8236034 B Thermocouple, Honeywell Q309A1996 w/36” Lg.
Item No. Description Part No.
Item No. Description Part No.
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 1 B Flame Rod Lead, Honeywell R1298020, 4 Ft. Lg. 71362561 1 C Rajah Connector, Honeywell 37356 8236021 D Ignition Lead, Honeywell R1061012, 3 Ft. Lg.
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 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.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 809HE 810HE 1 --- --- --- --- ----- 6.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 809HE 810HE 6.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 809HE 810HE 7. Trim and Miscellaneous Controls A 80 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.
Item No. Description Part No. Quantity 805H 806H 807HE 808HE 809HE 810HE 8111605 1 --- --- --- --- --- 8111604 --- 1 1 --- --- --- 8111602 --- --- --- 1 --- --- 8111601 --- --- --- --- 1 1 8116324 1 --- --- --- --- --- 8116325 --- 1 1 --- --- --- 8116326 --- --- --- 1 --- --- 8116327 --- --- --- --- 1 1 8.
