INSTALLATION AND OPERATING INSTRUCTIONS FOR BURNHAM COMMERCIAL FIRETUBE BOILERS Commercial Boilers 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.
This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in accordance with these instructions. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other 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. This boiler contains very hot water under high pressure.
TABLE OF CONTENTS SECTION I General information Introduction....................................................................................................................................... 6 Setting the Unit................................................................................................................................. 6 Air Supply/Venting............................................................................................................................
SECTION I — GENERAL INFORMATION INTRODUCTION 1. Refer to burner manufacturer’s installation manual provided for proper venting of the gas train components that require atmospheric pressure to balance a diaphragm. 2. All cover plates, enclosures and guards must be in place at all times, except during maintenance and service. 3. Insulate all steam and hot water piping, fittings and connections and all other hot components and equipment from personnel contact.. 4.
5. AIR SUPPLY A sufficient air supply must be maintained at all times to the boiler room for proper performance of the unit. A permanent opening or duct should be provided so that the boiler input will not exceed 4,000 Btuh/in2 of free area. Example: Firing Rate (Gas) = 528 MBH 528,000 BTUH = 132 In2 Free Area 4,000 BTUH/In2 Follow local building codes if they exceed these minimum requirements.
SECTION II — INSTALLATION INSTRUCTIONS 1. BOILER PIPING Attach supply and return piping lines and insert plugs and bushings in connections as required. Supply and return piping headers are detailed in Figure 2. It is important to comply with the minimum piping requirements in order to ensure maximum performance and reliability on steam boilers, particular attention should be given to the construction of the supply header.
5. TEMPERING OF HOT WATER Installation of an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents excessive and possibly scalding hot water. Higher temperature hot water is possible by piping the hot water from the heater prior to entering the mixing valve. The mixing valve should be “trapped” by installing it below the cold water inlet to heater to prevent lime formation in the valve. 6.
INSTALLATION INSTRUCTIONS FIGURE 3 FIGURE 4 10 TS-71-131-D TS-71-130-D
INSTALLATION INSTRUCTIONS FIGURE 5 TS-71-124-D PREFERRED HARTFORD RETURN CONNECTION GRAVITY RETURN ALTERNATE HARTFORD RETURN CONNECTION GRAVITY RETURN FIGURE 6 TS-71-157-C 11
INSTALLATION INSTRUCTIONS FIGURE 7 12 TS-71-127-B
FIGURE 8 INSTALLATION INSTRUCTIONS TS-71-174-D
SECTION III — OPERATING INSTRUCTIONS 1. Always inspect installation before starting burner. 2. Fill heating system with water. Any time that raw water is introduced to the boiler it must be heated to at least 180ºF immediately to dissipate the dissolved gases which can otherwise cause internal corrosion to the boiler. A. Steam Boilers Fill boiler to normal water line. Water should be visible in the gauge glass.
5. CLEANING A NEW STEAM BOILER 6. CLEANING A WATER BOILER Oil, grease & sediments which accumulate in a new boiler and piping must be removed from the system in order to prevent an unsteady water line and carryover of the water into the supply main above the boiler. Operate the boiler with steam in the entire system for a few days allowing the condensate to return to the boiler.
8. BOILER WATER TREATMENT Boiler water treatment will help maximize the effectiveness and prolong the life of pressure vessels. The general objectives of boiler water treatment are: A. Remove corrosive gases from feedwater and boiler water. and eventually cracks. The presence of free oxygen in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the cast iron through from the waterside.
SECTION IV — SERVICE INSTRUCTIONS See item 10 under Operating Instruction if it becomes necessary to add water to the boiler more frequently than once a month. 1. GENERAL G. When boiler and water are below 120°F, shut off power to the unit and lock out the circuit breakers. Inspection should be conducted annually. Service as frequently as specified in paragraphs below. Before service or maintenance is performed complete boiler shutdown/cooldown procedure. 2.
Clean firetubes with flue brush and reinstall turbulators. If turbulators are corroded or deteriorated, replacing them will ensure a high level of boiler efficiency. Remove soot and rust and reseal the boiler. 4. MAINTENANCE OF LOW WATER CUTOFF DEVICES 11. Screw the probe into the boiler tapping. 12. Mount the low water cutoff control on the probe. 13. Reconnect the control to probe wiring. 14. Fill the boiler to its normal waterline. 15.
9. ATTENTION TO THE BOILER WHILE NOT IN OPERATION. If a boiler is not used during the winter months, and it is in a place subject to freezing, it must be fully drained to prevent freezing damage. A. Steam Boilers Procedure for taking steam boilers off line at the end of heating season: Drain off boiler water until it runs clear while holding the boiler temperature between 180 and 200ºF. Then refill to top of gauge glass. B.
PERIODIC TESTING RECOMMENDED CHECK LIST ITEM FREQUENCY ACCOMPLISHED BY REMARKS Gauges, monitors, and Daily Operator indicators Make visual inspection and record readings in log Instrument and equipment Daily Operator settings Make visual check against recommended specifications Firing rate control Verify factory settings Verify factory settings Check with combustion test Weekly Semi-annually Annually Operator Service Technician Service Technician Igniter Weekly
PERIODIC TESTING RECOMMENDED CHECK LIST ITEM Atomizing Air/Steam FREQUENCY Annually ACCOMPLISHED BY REMARKS Service Technician Refer to burner instructions High and Low Gas Monthly Operator Pressure Interlocks Refer to burner instructions High and Low Oil Pressure Interlocks Monthly Operator Refer to burner instructions High and Low Oil Temperature Interlocks Monthly Operator Refer to burner instructions Fuel Valve Interlock Switch Annually Service Technician Ref
Commercial Boilers LIMITED WARRANTY LIMITED WARRANTY Subject to the terms and conditions herein, Seller warrants to the original owner at the original installation site that products manufactured by Seller (“Products”) comply, at the time of manufacture, with recognized hydronics industry regulatory agency standards and requirements therein effect and will be free from defects in materials and workmanship for a period of 12 months after the date of start-up or 18 months after the date of shipment, whichever
