MULTIPLE - MODULAR MANUAL FOR GAS - FIRED BOILER SERIES 8H / 8HE SIZES 5 THRU 10 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 Hazard definitions The following defined 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.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance.
Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance. These boilers contain very hot water under high pressure.
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.
LIST OF FIGURES PAGE SECTION 1.0 COMBUSTION, VENTILATION, VENT SYSTEMS.............................. 8 Fig. 1 — 1 Complete Combustion of Natural Gas........................................10 — 2 Confined Space, Ventilation From Inside Building...................... 11 — 3 Confined Space, Ventilation From Outdoors.............................. 11 — 4 Unconfined Space, Ventilation From Outdoors..........................
LIST OF FIGURES (continued) SECTION 3.0 WATER PIPING (continued) Fig. 3 — 11 — 12 — 13 — 14 — 15 — 16 — 17 SECTION 4.0 PAGE Net Expansion Factors for Water................................................46 Acceptance Factors for Diaphragm Type Tanks.........................47 Module Data-Water Side............................................................47 Water Piping for Service Water Heater.......................................
SECTION 1.0 COMBUSTION, VENTILATION & VENT SYSTEMS 1.
(continued) Excess pressure resulting from larger than necessary volumes of fresh air will cause excessive dilution of the flue products resulting in low flue gas temperatures. If lowered below the dew point, condensation of the moisture in the flue gases will occur and, if continued over an extended period of time, will corrode vents, drafthoods, heat exchangers, and burners.
wind effects or pressure areas which may reduce or impede vent flow. This does not imply that terminations at these locations will assure proper venting in every instance. Because winds fluctuate in velocity, direction, and turbulence, and because these same winds impose varying pressures on the entire structure, no simple method of analysis or reduction to practice exists for this complex situation. Manifold vents may be run horizontally or sloped upwards toward the common vent.
CONFINED SPACE, VENTILATION AIR PROVIDED FROM INSIDE OF BUILDING FIGURE 1-2 CONFINED SPACE, VENTILATION AIR PROVIDED FROM OUTDOORS FIGURE 1-3 11
2) support of common vent where it passes thru a ceiling or roof 3) clearances to combustible material – use of thimbles 4) firestops 5) flashing and storm collars 6) guying or bracing of common vent pipe above roof 7) securing and gas tightness of joints 8) lightning arrester if top of metal vent is one of the highest points on the roof 9) proper termination of vent connection at masonry chimney – vent should enter chimney at a point above the extreme bottom of chimney – vent should be flu
FIGURE 1-5 CONSTANT DIAMETER MANIFOLD VENT OR BREECHING TWO THROUGH EIGHT MODULES
FIGURE 1-6 TWO THROUGH EIGHT MODULES GRADUATED DIAMETER MANIFOLD VENT OR BREECHING
FIGURE 1-7 TWO THROUGH EIGHT MODULES INDIVIDUAL VENTS
SECTION 2.0 VENTS Inspect existing chimney before installing boilers. Failure to clean or replace perforated pipe or tile lining will cause severe injury or death. 2.1 Vents, or breeching ducts, are generally less flexible in design location than are water pipes, gas pipes or electrical lines. To avoid conflicts for a given location, design and layout the vents in this section before proceeding to other sections of this manual. 2.2 Obtain a scaled drawing of the boiler room.
2.7.1 If the minimum ceiling height is available, proceed to size the common vent CV in Figure 2-13. Enter the left hand column at the desired total input and move right to the column corresponding to your H, least total vent height, and read the diameter of the common vent. If more than one elbow is used, increase CV by one pipe size for each elbow more than one. Proceed to size the connector rise diameter CN by entering Figure 2-14 at H available and move right to the column headed F.
7) If a tapered or graduated manifold vent is desired, such as in Figure 1-6 the horizontal and vertical portion of the vent serving five modules is also complete with 6) above. However, to size the manifold vent at an intermediate position such as CV3 in Figure 2-4, use Figure 2-13 for the MBH Input of the modules served by that position of the manifold vent. The Input MBH of each module can be determined from Figure 2-3. In this case CV3 serves two modules having an input of 920 MBH.
Recommended Number of Modules Total Input MBH 805H 806H 807HE 808HE 809HE 810HE 504 2 567 1 Total Input MBH Recommended Number of Modules 808HE 809HE 810HE 2300 5 1 2345 4 1 630 2 2390 3 2 655 1 1 2435 2 3 680 2 2480 1 4 750 1 1 2525 820 2 2610 3 3 870 1 1 2660 2 4 920 2 2710 1 5 965 1 1010 5 1 2760 6 2 2805 5 1 1090 2 1 2850 4 2 1160 1 2 2895 3 3 1230 3 2940 2 4 1280 2 1 2985 1 5 1330 1 2 3030 1380 3 3070 3 4 1425
"E" Recommended Chimney Size (Round) Water Content (Gallons) Approx. Shipping Weight (LB) 24-13/16 16-1/8 7" dia. x 15 ft. 11.9 680 8 27-13/16 18 8" dia. x 15 ft. 13.9 770 13-3/4 9 27-13/16 18 8" dia. x 15 ft. 15.9 870 31-1/4 15-5/8 9 30-13/16 20 8" dia. x 15 ft 17.9 950 460 35 17-1/2 10 33-1/2 22 10" dia. x 15 ft 19.9 1040 505 38-3/4 19-3/8 10 33-1/2 22 10" dia. x 15 ft 21.
FIGURE 2-4 FIGURE 2-5 21
FIGURE 2-6 FIGURE 2-7 22
FIGURE 2-8 FIGURE 2-9 23
Drafthood & Vent Connector Top of Jacket Front Side Rear 5 6 Sideby-Side 6 Back-toBack 6 Front-toFront To Combustible Construction 1 6" 2 36" 1 18" 1 6" 1 6" N/A N/A N/A Recommended For Servicing N/A 1 24" 1 24" 8 18" 24" 1 1" 26" 7 36" To Combustible Construction 1 6" 2 51½" 1 18" 1 6" 1 6" N/A N/A N/A Recommended For Servicing N/A 7 24" 7 24" 8 18" 24" 1 1" 26" 7 36" 805-806-807 808-809-810 N/A: Not Applicable, 1 USA & Canada, 2 USA Only: 18" in Canada, 5 or a
1 30 20 15 10 8 6 Least Total Vent Height H, Ft. 1 7 30 NR 8 7 7 7 7 6 NR 8 8 8 7 7 6 NR 8 8 8 8 7 7 NR 8 8 8 8 7 NR 10 8 8 7 NR 10 8 8 Dia., In. Single Wall Metal Vent 7 7 7 7 7 7 6 NR 8 8 7 7 7 7 NR NR 8 8 8 7 7 NR NR 8 8 8 7 NR NR 9 8 7 NR 9 9 8 Dia., In. Type B, Double Wall Vent NR 8 8 8 8 7 7 NR 10 8 8 8 8 7 NR 10 10 10 8 8 8 NR 10 10 10 10 8 NR 10 10 10 8 NR 10 10 10 Dia., In.
- 2 8 2 - 8 CV - Diameter of Common Vent, Inches H - Least Total Vent Height (Ft) Input MBH 6 504 10 15 14 630 30 10 12 567 20 10 12 655 12 680 750 14 820 16 12 14 870 920 965 14 1010 18 1090 16 16 1160 14 1230 1280 20 1330 18 16 1380 1425 18 1470 22 1515 20 16 1570 1640 18 1740 1790 1840 24 1885 22 20 1930 1975 18 2020 20 2100 2150 26 24 22 2200 NOTE: Shaded Area indicates acceptable applications for Single Wall Metal Vent of the same diameter as
2 - 8 Input MBH 2 6 2250 2300 2345 2390 2435 2480 2525 2610 2660 2710 2760 2805 2850 2895 2940 2985 3030 3070 3170 3220 3265 3310 3355 3400 3445 3490 3535 3630 3680 3725 3770 3815 3860 3905 3950 3995 4040 - H - Least Total Vent Height (Ft) 10 15 20 30 20 22 28 26 8 24 22 24 30 28 26 24 26 32 30 28 28 26 30 NOTE: Shaded Area indicates acceptable applications for Single Wall Metal Vent of the same diameter as Type B vent. Otherwise, Single Wall Metal Vent is not recommended.
2 - 8 - 2 8 Least Total Vent Connector Height Rise H F 6 8 10 15 20 30 40 2 1 2 3 805H DW SW 10 10 9 9 9 9 806H DW SW 12 NR 10 10 10 9 4 6 1 2 3 4 6 1 2 3 4 6 1 2 3 4 6 1 2 3 4 6 1 2 3 4 6 1 2 3 4 6 NR NR 10 9 8 NR NR 9 9 8 NR NR 9 8 8 NR NR 9 8 8 NR NR 9 8 8 NR NR 9 8 7 NR NR NR NR NR NR NR NR NR NR NR NR 12 NR 12 NR NR 10 10 10 10 12 8 9 10 10 12 NR NR 12 NR 12 NR NR 12 NR 12 12 10 12 NR NR 10 10 10 10 12 9 9 10 10 10 NR NR 12 NR 12 NR NR 12 NR 12 10 10 12 NR NR 9 9 10 10 12 9 9 10 10
1 1 - 8 1 - Individual Vent Dia. From Figure 2-8 or Common Vent Dia. CV - From Figure 2-9 Inside Area - Sq. In. Tile Lined Masonry Chimney 6 34. 7 46. 8 60. 10 94. 12 136. 14 185. 16 241. 18 305. 20 377. 22 452. 24 531. 26 616. 28 707. 30 804. 32 907.
AREA OF TYPICAL MASONRY FLUE TILES FIGURE 2-16 30
SECTION 3.0 WATER PIPING 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 flue gas condensation and/or thermal shock.
3.2.3 Primary-secondary pumping is preferred as it does accomplish the desired fuel economy. To get the same economy from parallel pumping it is necessary to install some mechanism which will prevent flow through unfired modules as well as to install separate supply and return headers. Thus, the total installed cost of primary-secondary pumping may not be more than that of a properly controlled parallel pumping system. 3.2.
3.4 TEMPERATURE DROP—Selection of temperature drop has received attention in recent years as a means of reducing piping or pumping costs. Over several previous decades the 20°F water temperature drop had been standard for the hydronics industry. Recently, temperature drops of 30°F, 40°F and even 50°F have been used successfully when the distribution system and terminal units are properly sized for these larger temperature drops.
3.6.1.1 Use Figure 3-13 to calculate the volume of the modules. Example: Find the volume of water in four 806H modules. Solution: From Figure 3-13 find that the water volume of one 806H is 13.9 gallons and multiply by the number of modules: 13.9 x 4 = 55.6 gallons in the modules. 3.6.1.2 The water side of terminal units must be known in order to determine their volume.
3.8 RELIEF VALVE—Each Series 8H/8HE module is supplied with its own pressure relief valve. No additional relief valves need be installed on the manifolds. If domestic water heating is added to a module, it is recommended that a relief valve be installed as shown in Figure 3-14. 3.9 LIMIT CONTROL—Each Series 8H/8HE module is supplied with its own high limit control.
10) The water heating load of 299,880 Btuh could be handled by any one of the 810HE modules: 299,880 = (1) 810HE module 406,000 Example #2: an apartment building has 12 basins, 12 kitchen sinks, 14 showers, 12 dishwashers and 2 slop sinks. The design space heating load is 772,000 Btuh. Size the water heater and boiler.
Pipe Size 1-1/2" 2" 4" Nominal Laying Length (Gap) Max. Min. 3/4" 1" 2-3/8" 1-3/16" 1-5/8" 3" 1/4" 3/8" 1-3/4" 3.16.6 Misalignment 3.16.3 Coupler Installation Install both V-couplings, encompassing the retainer, gasket and sleeve. Do not tighten either coupling until entire joint has been assembled. Tighten nuts of 4” couplings to 280-300 inch-lbs. and 1½” and 2” couplings to 140-160 inch-lbs., or to a minimum of 1/16” clearance between coupling lugs, whichever occurs first.
3.19.2 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 fittings. c. Oxygen permeable materials in the distribution system. 3.19.3 In order to insure long product life, oxygen sources should be eliminated. This can be accomplished by taking the following measures: 38 a. Repairing system leaks to eliminate the need for addition of make-up water. b.
Figure 3-1 Piping Diagram (2 Boilers), Parallel With Blend Pump and System Pump
Figure 3-2 Piping Diagram (2 Boilers), Primary/Secondary with By-Pass And System Pump
Figure 3-3 Piping Diagram - Zone Pumps, Primary/Secondary W/ Alliance DHW & Recirc.
Module Size 805H 806H 807HE 808HE 809HE 810HE Flow Rate (GPM) Temp. Rise Thru Module Min.
HEAT CONVEYED PER HOUR, MBH, WITH 20°F TEMPERATURE DROP FRICTION VS WATER FLOW - IRON PIPE To use this Figure: (1) Enter horizontal scale at desired flow, (2) Move down vertically to upper limit of unshaded area, (3) Pick off minimum pipe size on diagonal lines sloping upward to the right. (4) Pick off water velocity on diagonal lines sloping upward to the left.
HEAT CONVEYED PER HOUR, MBH, WITH 20°F TEMPERATURE DROP FRICTION VS WATER FLOW - COPPER PIPE To use this Figure: (1) Enter horizontal scale at desired flow. (2) Move down vertically to upper limit of unshaded area, (3) Pick off minimum pipe size on diagonal lines sloping upward to the right. (4) Pick off water velocity on diagonal lines sloping upward to the left. FIGURE 3-6 Pipe Size 2½ 3 3½ Vol. Fps ½ ¾ 1 1¼ 1½ 2 4 5 6 8 10 12 1 2 3 4 5 1.2 1.4 1.5 1.5 1.6 1.7 1.9 2.0 2.1 2.2 2.2 2.5 2.
Size ½ ¾ 1 1¼ 1½ 2 2½ 3 4 5 6 8 10 12 Copper Tube .012 .025 .043 .065 .092 .161 .250 .357 .625 1.00 1.40 2.43 3.78 5.40 Steel Pipe .016 .028 .045 .078 .102 .172 .250 .385 .667 1.00 1.50 2.63 4.20 5.90 VOLUME OF WATER IN STEEL PIPE AND COPPER TUBE - GAL/FT To use this table: (1) Enter left hand column at desired type of pipe, (2) Move to the right to the desired pipe size, (3) Read the resulting gallons per foot of pipe.
----- 60 psi 70 psi --- --- --- --- 5.0 3.65 2.55 Allowable System Pressure Increase* --- --- --- 5.3 4.2 3.1 2.2 1.43 1.05 .68 --- --- --- 4.6 3.6 2.65 1.94 1.25 .92 .62 --- --- --- 4.1 3.1 2.38 1.75 1.15 .85 .59 --- --- --- 4.5 3.9 2.5 1.9 1.52 1.15 .8 .65 .49 5.2 3.8 3.1 2.25 1.8 1.35 .98 .75 .6 .48 3.9 3.1 2.6 1.95 1.43 1.12 .8 .63 .5 .48 3.5 2.7 2.3 1.7 1.25 1.02 .72 .55 .5 .48 140° - .0133 170° - .0231 200° - .
FINAL PRESSURE PSIG (not necessarily relief valve setting) ACCEPTANCE FACTORS FOR DIAPHRAGM TYPE TANKS To use this Figure: (1) Enter the horizontal scale at the final system pressure. (2) Move up vertically to the curved line for the initial charge pressure. (3) Read the acceptance factor on the vertical scale. (4) Divide acceptance volume from Figure 3-11 by the acceptance factor to obtain diaphragm type tank volume. FIGURE 3-12 Module Size Heating Surface, Ft2 Water Volume, Gallon 805H 34.4 11.
RECOMMENDED WATER PIPING FOR DOMESTIC WATER HEATER 48 FIGURE 3-14
Apartment Hotels and Industrial Club Gymnasium Hospital House Dormitories Plant Office Bldg.
SIZING FACTORS FOR COMBINATION HEATING / SERVICE WATER BOILERS To use this Figure: (1) Calculate ratio of hot water heating load to heating load. (2) Enter horizontal scale and move upward to the curve. (3) Read hot water heating load factor on the vertical scale. (4) Multiply factor by the heating load to obtain the hot water "added boiler capacity." (5) Select modules with total net rating equal to heating load plus hot water "added boiler capacity.
SECTION 4.0 – 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. Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas.
5) The next piping segment, D7, serves seven modules. 7 x 460 = 3220 MBH – Total Input thru D7. 6) Enter Figure 4-3 with 3220 Total Input MBH and again pick off a pipe/fitting size of 4”. Record this as D7. 7) In like manner: D6 = 3” D3 = 2½” 5 D = 3” D2 = 2” 4 D = 3” D1, C1 = 1½” 8) Since all modules require the same input MBH, D1 – 1½” applies to the vertical drops to each module.
Z223.1) and all requirements of the gas supplier and municipality. 4.5.1 Please consider the serviceman who must periodically clean and adjust the modules, and repair accessories. Do not block passageways with piping. Do not block access panels on the module jackets. 4.5.2 Material – Use only Schedule 40 black iron pipe. Make sure all threads are fully formed and free of burrs. Threaded joints should be sealed with an approved compound to prevent leaks. 4.5.
RECOMMENDED GAS SUPPLY PIPING - 1 THRU 8 MODULES IN LINE OR CORNERED.
RECOMMENDED GAS SUPPLY PIPING - TWO ROWS OF 1 THRU 4 MODULES EACH BACK-TO-BACK OR CORNERED, OR 1 THRU 8 MODULES IN LINE.
NOTICE Total Input MBH of Pipe/Fitting Size (NPT) Module(s) Served Natural Gas Propane Gas by Pipe/Fitting Use this table only if all of the following conditions are met: 1) 50 Ft. maximum plus 3 ells from Meter to furthest Module Gas Connection 2) 0.5 PSIG Maximum Gas Pressure 3) 0.3 Inch Water Column Pressure Drop 4) Specific Gravity of Natural Gas = 0.64 to 0.70 Propane = 1.50 to 1.
Nominal Iron Pipe Size, In. Internal Dia., In. 10 20 30 40 50 60 70 80 90 100 125 150 175 200 1/4 .364 32 22 18 15 14 12 11 11 10 9 8 8 7 6 3/8 .493 72 49 40 34 30 27 25 23 22 21 18 17 15 14 1/2 .622 132 92 73 63 56 50 46 43 40 38 34 31 28 26 3/4 .824 278 190 152 130 115 105 96 90 84 79 72 64 59 55 1 1.049 50 350 285 245 215 195 180 170 160 150 130 120 110 100 1-1/4 1.
Size of Pipe (Inches) Spacing of Supports (Feet) ½ 6 ¾ or 1 8 1¼ or larger (horizontal) 10 1¼ or larger (vertical) Every floor level SUPPORT OF PIPING FIGURE 4-7 all pipe and fittings to be sized according to module supply pipe size moisture and dirt trap for gAs SUPPLY TO EACH MODULE SERIES 8H/8HE MODULAR GAS BOILER FIGURE 4-8 58
SECTION 5.0 – 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. 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.
Boiler Staging Control Features Feature: Tekmar Control Model Number: 261 263 274 268 Number of Stages 2 2 4 9 Boiler Differential A/M A/M A/M A/M Boiler Minimum Supply M M M M Boiler Operation Boiler Outdoor Reset o o o o Boiler Post Purge F M M M Characterized Heating Curve o o o o Equal Run Time Rotation o o o o PID Staging o o o o Fire Delay M M M M Interstage Delay A A A/M A/M o o o o o DHW Priority With Reset Override o o o DHW External
Figure 5-1 tekmar 261, two-stage, ei, for parallel piping
Figure 5-2 tekmar 261, two-stage, ei, for primary secondary piping
Figure 5-3 tekmar 263, two-stage, ei, for parallel piping
Figure 5-4 tekmar 263, two-stage, ei, for Primary Secondary piping
Figure 5-5 tekmar 274, FOUR-stage, ei, for parallel piping
Figure 5-6 tekmar 274, fOUR-stage, ei, for primary secondary piping
Figure 5-7 tekmar 268, eIGHT-stage, ei, for parallel piping
Figure 5-8 tekmar 268, EIGHT-stage, ei, for primary secondary piping
section 6.0 start-up and 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.
adjusting screw counterclockwise to decrease manifold pressure (gas rate) or clockwise to increase. Adjustment of Regulator must be within limitations set forth by Gas Supplier. If necessary to increase or decrease manifold pressure more than 0.
IX. Repair Parts 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 (717) 481-8400 or Fax (717) 481-8408.
