IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR S E R IE S 5 B GA S - F I R E D BO I L E R F o r s e r vi 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. W he n s e e k i ng i nfo rm a ti o n o n b o i le r, p r o vi d e B o i le r M o d e l Num b e r a nd S e ri a l Num b e r a s s ho wn o n Ra ti ng L a b e l.
SECTION I – EQUIPMENT CHECK LIST U.S.A. EQUIPMENT CHECK LIST (For Canadian Equipment Check List, Turn to Pages 4 and 5) This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered. It covers standard equipment for both steam and water boilers without Tankless Heaters. Heaters or optional equipment ordered will be in addition to, or in lieu of, equipment shown below.
U.S.A.
CANADIAN EQUIPMENT CHECK LIST This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler ordered. It covers standard equipment for both steam and water boilers without Tankless Heaters. Heaters or optional equipment ordered will be in addition to, or in lieu of, equipment shown below. By opening cartons in numerical sequence, boiler assembly is simplified. If there is an exception, it will be pointed out in the boiler assembly procedure.
CANADIAN EQUIPMENT CHECK LIST BOILER SIZE 5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B CARTONS, PACKAGES OR BUNDLES 7S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 2 --- --- --- 1 3 --- --- --- --- 1 1 --- --- --- --- --- --- --- --- --- --- --- --
5026B 1. 5006B THRU 5014B BOILERS REQUIRE Boiler Size SINGLE GAS TRAIN LOCATION ON LEFT END OF BOILER (STANDARD) GAS TRAIN MAY BE RELOCATED 5006B TO RIGHT END OF BOILER (EXCEPT 5012B AND 5014B BOILERS). 5007B 2. 5015B THRU 5026B BOILERS REQUIRE 5008B DUAL GAS TRAINS. 5009B 3. GAS SUPPLY PRESSURE, IN W.C. 5010B NATURAL GAS 5011B MAXIMUM: 14” W.C. 5012B MINIMUM: 5.5” W.C. (5009B AND 5011B THRU 5014B AND 5013B 5020B THRU 5026B) 5014B MINIMUM: 5” W.C.
SECTION II – GENERAL INFORMATION 1. 2. BOILER INSTALLATION must conform to the requirements of the authority having jurisdiction, or in the absence of such requirements, to: USA – “National Fuel Gas Code, ANSI Z223.1”. When required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.
equipment in space. Duct cross-sectional area shall be same as opening free area. 3. Horizontal ducts. Minimum free area of 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. Alternate method for boiler located within confined space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space.
Fig. 3 DUAL MANIFOLD BASES - 5015B THRU 5026B SECTION BOILERS a. Carefully join a Center Section with nipples in adjoining section and bump lightly to secure. b. Run nut approximately 8” on two (2) ¾” draw-up rods of equal length. (Note – more than one set of draw-up rods are furnished on 8 section and larger boilers). Place draw-up channel and one flat washer against nut. c. Insert short end of draw-up rod through front & rear nipple ports on both sections, see Fig. 5. d.
Fig.
e. DRAW UP CENTER SECTION SLOWLY AND EVENLY, tightening each DRAW-UP ROD a little at a time so that sections are equally spaced. KEEP NIPPLES ALIGNED WITH NIPPLE PORTS. If necessary, tap Nipples lightly with a blunt tool or rod to keep Nipples from cocking while Sections are being drawn up. DO NOT DRAW UP SECTION(S) WHEN NIPPLES ARE COCKED. Continue tightening Draw-Up Rods equally until Sections meet iron-to-iron on the ground surface.
Fig. 8 INSTALLATION OF BUILT-IN HEATER Open Tankless Heater Carton(s) If Supplied. Open Heater Opening Cover Plate Carton(s). 9. INSTALL BUILT-IN WATER HEATER(S) OR HEATER OPENING COVER PLATE(S), See Fig. 8. Heater may be installed in either End Section or, in some cases, in both End Sections. Heater Opening Cover Plates are used to cover any unused heater openings. a. Place rubber gasket against surface of plate and align holes. b.
Fig. 10 SEALING OF BASE, INSTALLATION OF FLUE COVERS AND CANOPIES a. With Steam Heating System, refer to Fig. 12, 13A, 13B.
Fig.
Fig.
Fig.
Fig.
Fig. 14A RECOMMENDED WATER BOILER PIPING I SUPPLY CONNECTION & I RETURN CONNECTION SIZES 5006B THRU 5019B Fig.
2. Attach Lower Left and Lower Right Jacket End Panels to their respective brackets using #10-32 x ½” self-tapping screws, see Fig. 17. 3. See Fig. 7 “Purpose of Tappings and Their Location” and remove necessary knockouts from Upper Left and from Upper Right Jacket End Panels. 4. Place Upper Right End Panel on top of Lower Right End Panel with lip on bottom of Upper Panel positioned behind Lower Panel. Secure to section using #10-32 x ½” self-tapping screws.
Fig. 17 INSTALLATION OF JACKET END PANELS Fig.
Fig.
Fig.
Fig.
Fig. 22 EXPLODED VIEW OF JACKET 11 THRU 19 SECT.
22. Installation of Top Front Jacket Panel a. Remove knockout for supply piping (right or left for water boilers – both knockouts for steam boilers) refer to recommended boiler piping diagrams in this manual. b. Attach Top Front Jacket Panel to left and right end Jacket Panel and to Top Flange on the Vestibule Panel using #8 SMS. See Fig. 22. 23. Installation of left and right top side Jacket Panel a. Remove knockout, right or left, only if needed. (See Fig.
Fig. 23 EXPLODED VIEW OF JACKET 20 THRU 22 SECT.
Fig. 24 EXPLODED VIEW OF JACKET 24 AND 26 SECT.
32. Tighten all sheet metal screws. a. Install the following plates or labels which are found in the Instruction Envelope. See Fig. 23 or 24 for location. (1) Rating Label (2) Operating Instruction Plate (#8 SMS required to fasten) (3) Combustible Clearance Flooring & Adequate Combustion Plate (4) Minimum Service Clearance Label (5) Burnham Logo – Apply to Top Panel (6) Boiler Ventilation/For Your Safety Label b. Proceed to Paragraph 33 (Steam Boilers) or Paragraph 34 (Water Boilers).
Fig.
g. If boiler has been ordered with 3/8” try-valve tapping, install try-cock. h. Install “Lowest Permissible Water Level Plate” and “Frequent Water Addition – Caution Label” on upper left end jacket panel. i. Proceed directly to Paragraph 36. (40-140ºF) and boiler water temperature of 200ºF.
TABLE I - NATURAL GAS Maximum Capacity of Piping in Cubic Feet of Gas Per Hour (Based on a Pressure Drop of 0.3” Water and 0.
c. Length of piping in feet and number of elbows – for practical purposes each 90º elbow can be considered as the following equivalent in length of straight pipe: 3/4” - 2.1 ft. 2” - 5.2 ft. 1” - 2.6 ft. 2-1/2” - 6.2 ft. 1-1/4” - 3.5 ft. 3” - 7.7 ft. 1-1/2” - 4.0 ft. 4” - 10.1 ft. A pipe thread compound resistant to the action of liquefied petroleum gases must be used on all threaded joints in the gas piping.
EI Control System 1. INSTALLATION OF GAS VALVE TRANSFORMER AND PILOT PIPING (for Robertshaw Pilot Piping, see Fig. 29) – Attach the bracket for mounting of the junction box to the lower front corner of the Jacket Upper End Panel using two #10-32 x ½” MS and nuts. Mount junction box to bracket using #8 SMS, see Fig. 25 or 26. Connect pilot solenoid valve to bottom center knockout of J-box using conduit fittings furnished, (V88 Gas Train only) see Fig. 30. Mount transformer on J-box.
Fig. 30 PILOT PIPING - EI CONTROL SYSTEM (V88A) U.S.A. 5010B THRU 5026B - NAT. GAS CANADA - 5006B THRU 5026B - NAT. GAS 2. INSTALLATION OF BLEED PIPING (V88 Gas Train only) – Using ¼” OD aluminum tubing, install a bleed line on both diaphragm gas valves, connect together, and, on USA boilers, run tubing to bleed line protruding from inside base, see Fig. 30. On boilers installed in Canada, run bleed line to outdoors. 3.
three #8 x ½” SMS. “IN” on pilot safety switch should be pointed in the direction of the Gas Train to which the pilot safety switch is to be connected, see Fig. 31. EO Control System 1. INSTALLATION OF PILOT SAFETY SWITCH AND PILOT PIPING – Using two #10-32 x 2” MS and nuts, install the L62GB-3C pilot safety switch bracket on the manifold just to the right of the main burner with pilot. Install L62GB-3C pilot safety switch on bracket using Fig.
wiring must be adequately supported and strain relief provided. All wiring including ground connections must comply with the requirements of the authority having jurisdiction and, in the absence of such, to the National Electrical Code, ANSI NFPA No. 70-2005, or the Canadian Electrical Code, C22.1, whichever is applicable. MS and nuts in the front holes and two #8 SMS in the rear holes. Connect the two wires from the Q179D pilot to the RA890F Protectorelay Sub base as follows: a.
Note - Pilot Piping duplicated on 15 sect. and larger boilers. Fig. 34 PILOT PIPING EE CONTROL SYSTEM 3. INSTALLATION OF BLEED PIPING – Using ¼” OD aluminum tubing, install a bleed line on both diaphragm valves, connect together, see Fig. 25 or 26, and, on USA boilers, run tubing to bleed line protruding from inside base, see Fig. 34. On boilers installed in Canada, run bleed line to outdoors. 4.
x ½” MS and nuts. Mount junction box to bracket using #8 SMS. Install RV-12LT Regulator, (Packed in Gas Train Carton) and 1/8” tee in the ¼” OD pilot tubing as shown in Fig. 36. Install 24V/40VA Transformer on J-box. 3. Fig. 35 INSTALLATION OF PILOT SAFETY SWITCH EOP CONTROL SYSTEM Install AT72D Transformer on J-box. Wire L62G13-3C Pilot Safety Switch to the 24V/40VA transformer and to the V88A Gas Valves using the 105ºC wire furnished, see Fig. 51 or 52.
made. All wiring must be adequately supported and strain relief provided. 3. INSTALLATION OF BLEED PIPING – Using ¼” OD aluminum tubing, install a bleed line on both diaphragm valves, connect together, see Fig. 25 or 26, and, on USA boilers, run tubing to bleed line protruding from inside base, see Fig. 37. On boilers installed in Canada, run bleed line to outdoors. 4.
“THERMOCOUPLE CONTROL SYSTEM” CANADA ONLY Fig. 38 PILOT PIPING THERMOCOUPLE CONTROL SYSTEM CANADA ONLY in the gas train, to the inlet of the RV-12LT regulator (packed in Gas Train Carton). Regulator should be above Gas Train and near front of boiler, see Figure 38. Install 3/8” tee into outlet of regulator (USA boilers) and, using ¼” OD aluminum tubing, connect outlet of tee to “IN” connection on pilot safety switch, see Figure 38.
Upper End Panel using two #10-32 x ½” MS and nuts. Mount junction box to bracket using #8 SMS, see Figure 25 or 26. Install Transformer on junction box. Venting 1. INSTALL VENT CONNECTOR from canopy Drafthood or damper to chimney maintaining 6” clearances from combustible materials. 2. INSTALL VENT SYSTEM – Typical vent systems are shown in Fig. 40 and 41. Some of the factors affecting vent sizing and construction accompany these figures.
(20) Flashing and storm collars. (21) Guying or bracing of common vent pipe above roof. (22) Securing and gas tightness of joints. (23) Lightning arrester if top of metal vent is one of highest points on the roof. Where choice is possible, many advantages can be listed for the UL Listed double wall metal type B vent: 2. Type B vents permit closer clearance to combustible material than single wall metal vents unless special precautions are taken with the latter. 3.
SECTION IV - OPERATION Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13. 1. GENERAL a. INITIAL FILL – Before putting water into a new boiler, make certain that the firing equipment is in operating condition to the extent that this is possible, without actually firing into an empty boiler.
b. Draw about 5 gallons of hot water from boiler into a container and dissolve into it the appropriate amount of a recommended boilout compound. Remove safety valve from boiler and pour this solution into boiler, then reinstall safety valve. c. Turn on burner and keep operating while feeding water to boiler slowly. This will raise water level in boiler slowly into supply main and back through return main, flowing from drain hose at about 180ºF.
3. CONDENSATION appears that the boiler is leaking. This condensation can be expected to stop after the boiler is hot. Following a cold start, condensation (sweating) may occur in a gas fired boiler to such an extent that it CONTROL VARIATIONS NATURAL GAS MODEL NO. CONTROL SYSTEM TYPE OF PILOT GAS VALVES PILOT MAIN (1) 7000DERHC-S7C OPTIONAL MAIN VALVES REFERENCE PAGE (B) 47 5006B-5009B (USA) EI Elec. Ign. 5010B-5026B (USA) 5006B-5026B (CANADA) EI Elec. Ign.
4. EI CONTROL SYSTEM – The EI control system utilizes a solid state ignition control which lights the pilot burner by spark. Pilot gas is ignited and burns during each running cycle (intermittent electric pilot). Main burner and pilot gas are extinguished during the “off” cycle. This system permits the main gas valves [Robertshaw7000 for 5006B thru 5009B, (2) V88A’s for 5010B thru 5014B] to open, and the pilot line gas valve to remain open, only when the Pilot Burner is proven to be lit.
Fig. 42 SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (ROBERTSHAW7000 GAS VALVE) U.S.A.
SEQUENCE OF OPERATION When operating control closes, the electric spark and pilot valve are automatically energized. The sensing probe proves the presence of the pilot flame. Internal switch action de-energizes the spark and energizes the main gas valves starting main burner operation. When the operating control is satisfied the pilot gas valve and the main gas valves are de-energized stopping the burner operation.
Fig. 44 SCHEMATIC wiring diagram - 15 THRU 26 SECT.
SEQUENCE OF OPERATION When operating control closes, the electric spark and pilot valve on each side are automatically energized. The sensing probe on each of the pilots proves the presence of the pilot flame. Internal switch action in each ignition module de-energizes the spark and energizes the main gas valves for its respective gas train, starting main burner operation.
TROUBLE SHOOTING GUIDE BOILERS EQUIPPED WITH S8610M INTERMITTENT ELECTRIC IGNITION 51
5. EO CONTROL SYSTEM – 5006B thru 5014B The EO Control System utilizes an RA890F Protectorelay and a Q179D Rectification Pilot (standing or continuous burning pilot) to which has been added a Q309 thermocouple. The RA890F Protectorelay Primary Control is a non-programming, amplifying relay which, when used with the Q179D Pilot, provides solid state electric Flame Safeguard Protection during a “call for heat” pilot failure. Main burners will shut down within 0.
Fig. 46 wiring diagram - 6 THRU 14 SECT.
to a Q309 Thermocouple. The RA890F Protectorelay Primary Control is a non-programming, amplifying relay which when used with the Q179D Pilot provides solid state electronic Flame Safeguard Protection during a “call for heat” pilot failure. Main burners will shut down within 0.8 second and the Protectorelay will lock out on safety shutdown within 15 seconds.
Fig. 47 wiring diagram - 15 THRU 26 SECT.
the Q179C Pilot provides solid state electronic Flame Safeguard Protection that will not allow the main gas valves to open on “call for heat” for that will shut down main burners within 0.8 second if pilot flame is not “proved”. Protectorelay will lockout on safety shutdown within 15 seconds if there is a pilot flame failure on start or, if during the “run” cycle, pilot flame is not re-established.
Fig. 48 wiring diagram - 6 THRU 14 SECT.
Fig. 50 wiring diagram - 15 THRU 26 SECT.
burners on the unaffected side would ignite on a “call for heat” and would continue to operate until the operating control was satisfied. The EE Control System utilizes and RA890F Protectorelay and a Q179C Rectification Pilot, which in addition to a pilot burner and rectifying flame rod flame detector to prove pilot, includes an ignition electrode for spark ignition of the pilot. A Webster 612-6A7 Transformer supplies the high voltage spark potential.
Fig. 51 WIRING DIAGRAM - 6 THRU 14 SECT.
(6) A defective RA890 may be the cause but items (1) thru (5) should be followed first. Refer also to RA890 relay literature furnished with the control. (d) By referring to the Sequence of Operations step by step operation of the system can be controlled and the cause of pilot failure can be readily found. After the cause of pilot failure has been corrected, resume normal operation by following the Lighting Instructions. d. SHUTDOWN INSTRUCTIONS (1) Close manual shut-off valves and pilot valves.
Fig. 52 WIRING DIAGRAM - 15 THRU 26 SECT.
This thermocouple will cool in 45 to 90 seconds allowing the pilot line safety valve to close. This shuts off the flow of gas to the pilot. It is in this manner that 100% shut-off is achieved. If the operating control calls for heat during this period and the “Power On” switch is still in the “ON” position this relay will automatically sense the absence of pilot flame and the “Pilot Failure Alarm Lamp” will be activated as described in paragraph (a) above. d.
Fig. 53 WIRING DIAGRAM - 6 THRU 14 SECT.
(2) PILOT FAILURE (a) Flame rod supervision of the Q179D pilots occurs only during the activating cycle (call for heat) since it is during this period that the operating control is energizing the RA890F relays. If pilot failure occurs during this period on one of the Q179D pilots the main gas valves controlled by that particular RA890F will close within 0.8 second. The RA890F will lock out of safety within 15 seconds and the “Pilot Flame Failure Lamp” will be activated.
(8) When the operating control is satisfied, terminals #6 in the panel and relay are deenergized. Terminal #5, “Main Gas Valve” lamp, Main Gas Valves, and Pilot Line Solenoid Valve are all de-energized and main burner and pilot burner flames are extinguished. (9) “Main Power” lamp remains lighted. c. SAFETY SHUTDOWN (1) SAFETY SWITCH CIRCUIT If limit control, Low Water Cut-Off or any other electrical safety switch opens, power to terminal #6 in Panel is interrupted thus de-energizing terminal #5 in Panel.
Fig. 54 WIRING DIAGRAM - 15 THRU 26 SECT.
(5) Turn on Main Power Switch on both panels. Main Power Lamp on each panel will light. (6) Turn on manual pilot valves. Both pilots should light. (7) Turn on Manual Main Gas Valves. (8) Turn on Main Gas Valve Switch on both panels to light burners. Main Gas Valve Lamp on each panel will light. Proceed To Paragraph 15- Minimum Input Adjustments (for diaphragm “Lo-Hi-Lo” or motorized type gas valves) SEQUENCE OF OPERATION EEP – See Fig. 54 b.
thermocouple proves pilot flame and, in the absence of such, will cool and, within 45 to 90 seconds, will cause the L62GB-3C Pilot Safety Switch to which it is connected, to break the electrical circuit to the main gas valves as well as shut off the flow of gas to the pilot. Thus, 100% shut-off is achieved. The 5015B thru 5024B boilers utilize two Thermocouple Control Systems that are interconnected electrically thru all operating and safety controls.
When the operating control (A) calls for heat, it energizes the main gas valves (B) in both gas trains starting burner operation. The burners will operate until the operating control is satisfied. The high limit control (C) will stop burner operation in case of excessive steam pressure (steam boiler) or excessive boiler water temperature (water boiler). The low water cut-off (D) will stop burner operation if the water level in the boiler drops below the lowest safe level.
14. 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 be lower than minimum inlet pressure shown on Rating Plate. (2) All Rate checks and all adjustments are to be made while boiler is firing – all other appliances connected to the same meter as the boiler must be off. (3) Water Manometer or water column gauge should be connected to a shut-off valve installed in the 1/8” pipe tapping in each manifold – boiler off.
CAUTION The following procedures should only be performed by a qualified service technician. 15. MINIMUM INPUT ADJUSTMENTS This section covers Minimum Input Adjustments on Honeywell V8944B Diaphragm Type “Lo-Hi-Lo” Gas Valves, Honeywell V5055B Fluid Power Gas Valves equipped with either a V4062A “Lo-Hi-Lo” Actuator or a V9055A “Modulating” Actuator. a.
Fig. 58a LOW FIRE ADJUSTMENT - V4062 ACTUATOR (6) Shut down the burner, and then restart. Repeat several times to be sure the low fire setting is that desired and suitable for correct burner light off. (7) Turn off power supply. Remove R-W jumper, and reconnect the lead to terminal R on the V9055A. (8) Replace the wiring compartment cover. 16. MAIN BURNER FLAMES should have a clearly defined inner cone, see Fig. 63 with no yellow tipping.
Proceed with test as follows: a. Thermocouple Pilot System Using a 3/8” wrench loosen the thermocouple lead at the gas valve. Main gas and pilot gas must shut off. If not, replace gas valve. b. EI Pilot System Carefully remove ignitor sensor wire from ignition module Main gas and pilot gas must shut off immediately. If not, replace the module. c. EO, EOP, EE and EEP Pilot Systems Carefully remove the flame rod wire from terminal “F” on the RA890F protectorelay. Main gas and pilot gas must shut off.
SECTION V – SERVICE 1. GENERAL – “Inspection should be conducted annually. Service as frequently as specified in paragraphs below.” While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be “off”. CAUTION CARE SHOULD BE EXERCISED IN REMOVING THE CLEANOUT PLATES FROM THE BOLTS SO THAT THE INSULATION IS NOT DAMAGED. IF DAMAGED, ALL EDGES OF THE CLEANOUT PLATES SHOULD BE SEALED WITH BOILER PUTTY WHEN REINSTALLED UNTIL INSULATION CAN BE REPLACED.
Important Product Safety Information refractory Ceramic Fiber Product Warning: 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 about 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.
Fig. 61 CLEANING OF FLUEWAYS d. Remove all burners with pilots by first tracing all electrical leads coming from pilot to their points of connection, remove leads from terminals to which they are connected, and then tag each lead with respective terminal designation. Disconnect Pilot Tubing at nearest connection to pilot and remove burner as outlined in paragraph c. above. e. When replacing burners, reverse procedure used in removal of burners.
Fig.
5. MAIN BURNER FLAMES – Main Burner Flames should be checked at initial start-up, annually thereafter, or after flueway cleaning, or after an extended shutdown period. Main Burner Flame should have a clearly defined inner cone, see Fig. 63, with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. Yellow-tipping indicates a lack of primary air and normally can be corrected by opening the air shutter.
The EE and EEP Control Systems utilize a Honeywell Q179C Flame Rectification Pilot. Adjust pilot line regulator (5.5” WC in pilot line) so that a medium hard center flame envelops flame rod, see Fig. 66. If flame is yellow, primary air opening may be covered with dirt or lint. This can be removed with a soft brush or by vacuuming. Fig. 67 PILOT FLAME HONEYWELL Q327A PILOT w/THERMOCOUPLE 7. Fig.
10. Clean the pipe threads of the probe to remove old, hardened pipe dope and other foreign matter. 11. Apply a moderate amount of good quality pipe dope to the pipe threads on the probe, leaving the two end threads bare. 12. Screw the probe into the boiler tapping. 13. Mount the low water cut-off control on the probe. 14. Reconnect the control to probe wiring. 15. Fill the boiler to its normal waterline. 16. Restore gas supply to the boiler. 17.
SECTION VI - REPAIR PARTS REPAIR PARTS INDEX ITEM PAGE NOS. Base Parts....................................................................................................................... 83 thru 86 Integral Drafthoods & Sections........................................................................................ 87 thru 89 Base/Pilot Assemblies................................................................................................................. 90 Jackets..................
High Base End Panel High Base End Panel Insul.
Fig.
High Base End Panel High Base End Panel Insul.
Fig.
TABLE 3A SERIES 5B INTEGRAL CANOPY DRAFTHOODS - BOILER SIZES PART SIZE PART NO. Canopy Drafthood No.
Fig.
(3) Nipple Lubricant, Loctite® #592, 250 ml 8056254 8056255 CXP Center Section Tapped - Plugged 6171301 (1) CX Center Section Tapped - Not Plugged 7171304 (1) Nipple Lubricant, Loctite® #592, 50 ml REH Section 7171302 (4) (1) 5006B Nipple Gauge, 3” & 7” C Center Section Plain 7171303 806600023 LEH Section ITEM 7171301 PART NO.
618130651 61813069 618130631 618130661 Complete Base Ass’y w/Thermocouple Pilot Ass’y Complete Base Ass’y w/EO-EOP Pilot Ass’y Complete Base Ass’y w/EE-EEP Pilot Ass’y Complete Base Ass’y w/Thermocouple Pilot Ass’y 618130871 618131541 61813155 61813157 61813159 618130801 618130841 618130881 Right Base Subass’y w/EE-EEP Pilot Ass’y Right Base Subass’y w/Thermocouple Pilot Ass’y Left Base Subass’y w/EI Pilot Ass’y Left Base Subass’y w/EO-EOP Pilot Ass’y Left Base Subass’y w/EE-EEP Pilot Ass’y
Front Top Int. Panel Center Top Int. Panel Rear Top Int. Panel *5005B Upper Rear Panel 5006B Upper Rear Panel 5007B Upper Rear Panel 5008B Upper Rear Panel 5009B Upper Rear Panel 5010B Upper Rear Panel *5005B Lower Rear Panel 5006B Lower Rear Panel 5007B Lower Rear Panel 5008B Lower Rear Panel 5009B Lower Rear Panel 5010B Lower Rear Panel Upper Rear Int. Panel Lower Rear Int.
Knobs Dimco - Black #516 Machine Screw #10-32 x 3/16” Lg. Slotted Rd.
Front Top Int. Panel Center Top Int. Panel Rear Top Int. Panel *5004B Upper Rear Panel *5005B Upper Rear Panel 5006B Upper Rear Panel 5007B Upper Rear Panel 5008B Upper Rear Panel 5009B Upper Rear Panel *5004B Lower Rear Panel *5005B Lower Rear Panel 5006B Lower Rear Panel 5007B Lower Rear Panel 5008B Lower Rear Panel 5009B Lower Rear Panel Right Side Top Panel Upper Rear Int. Panel Lower Rear Int.
60413068 60413078 60413088 5006B 5007B 5008B 5009B 5010B 5011B BOILER SIZE Knobs Dimco - Black #516 Machine Screw #10 -32 x 3/16” Lg. Slotted Rd. Head 80860926 80860800 PART NO. #16 Left to Right Channel #17 Left to Right Channel #18 Left to Right Channel #19 Left to Right Channel #20 Left to Right Channel #26 Left to Right Channel #27 Left to Right Channel #28 Left to Right Channel 7041307 7041308 7041309 7041310 7041311 7041312 7041313 7041314 BOILER SIZE 1 x 21 Front Int.
Fig.
7000DERHC GAS TRAIN - EI - 5006B THRU 5009B - USA PART NO. 81660151 ITEM 5006B BOILER SIZE 5007B 5008B 5009B Robertshaw 7000DERHC-S7C 1” x 1” Gas Valve (Nat.) (1) (1) (1) (1) 81660158 Robertshaw 7000DERHC-LP-S7C 1” x 1” Gas Valve (LP) (1) (1) (1) (1) 806604002 1” Ground Joint Union (2) (2) (2) (2) 806600027 1” x 3” Lg.
822615 822616 822645 8226011 8226012 822614 8226010 8226006 822607 81660008 81660009 822605 PART NO. ConBraCo 50-403-02 1” x 1” ConBraCo 50-503-02 1¼” x 1¼” Pilot Valve Manual Shutoff Valve Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” Leak Limiter - Maxitrol #12A04 (incl. w / RV-61) Leak Limiter - Maxitrol #12A34 (incl. w / RV-81) LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.
822619 822620 822615 822616 822645 8226006 822607 822614 8226010 81660008 81660009 822605 PART NO. Newman-Milliken 200M - 1” Newman-Milliken 200M - 1¼” Lubricated Plug Valve ConBraCo 50-403-02 1” x 1” ConBraCo 50-503-02 1¼” x 1¼” Pilot Valve Manual Shutoff Valve Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” Leak Limiter - Maxitrol #12A04 (incl. w / RV-61) Leak Limiter - Maxitrol #12A34 (incl. w / RV-81) Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.
822615 822616 822645 8226011 8226012 822614 8226010 8226006 8226012 81660088 81660086 81660012 81660013 81660014 81660010 81660011 PART NO. ConBraCo 50-403-02 1” x 1” ConBraCo 50-503-02 1¼” x 1¼” Pilot Valve Manual Shutoff Valve Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” Leak Limiter - Maxitrol #12A04 (included w/ RV-61) Leak Limiter - Maxitrol #12A34 (included w/ RV-81) LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” Nat.
1¼” Honeywell V8944B1027 1¼” - ITT Gen. K8A771 81660094 Pilot Valve ConBraCo 50-503-02 1¼” x 1¼” 822645 ConBraCo 50-403-02 1” x 1” 822616 ITEM 822615 Manual Shutoff Valve 1” - ITT Gen. K8A461 81660081 Solenoid Gas Valve 1” Honeywell V8944B1019 81660150 “Lo-Hi-Lo” Gas Valve 81660149 PART NO.
822619 822620 822645 822615 822616 822614 8226010 8226011 8226012 8226006 8226012 81660081 81660094 81660149 81660150 PART NO. Newman-Milliken 200M - 1” Newman-Milliken 200M - 1¼” Manual Valve 1/8”MPT x ¼” OD Tube Pilot Valve ConBraCo 50-403-02 1” x 1” ConBraCo 50-503-02 1¼” x 1¼” Manual Valve Maxitrol #12A04 (included w/ RV-61) Maxitrol #12A34 (included w/ RV-81) Leak Limiter Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” LP Gas Regulator HO1 Blue Spring 5.5” to 12.
822615 822616 822645 822619 822620 8226011 8226012 822614 8226010 8226006 822607 81660088 81660094 81660012 81660013 81660014 81660010 81660011 PART NO.
Manifold Module Support Bracket Assembly Description 100958-01 Honeywell S8610M3009 Ignition Module IGNITION MODULE & SUPPORT BRACKET EI CONTROL SYSTEM 6011301 PART NO.
L62GB-3C Pilot Safety Switch Manifold Module Support Bracket Assembly Description PILOTSTAT & SUPPORT BRACKET EO - EOP - THERMOCOUPLE CONTROL SYSTEM (2) 80160138 (1) 6011301 ITEM PART NO.
TRANSFORMER, PILOT SOLENOID VALVE & PILOT LINE REGULATOR EI CONTROL SYSTEM U.S.A. - 5010B-5026B NAT. GAS CANADA - 5006B-5026B NAT. GAS PART NO. ITEM 7136001 (1) “J” Box Mounting Bracket 24V 100 VA Transformer - 120 60HZ Primary 80160016 (2) Penn Y64T22-0 Plate Mounted 822666 (3) Penn Pilot Solenoid Valve H91WG-6 8226005 Pilot Line Regulator Nat.
TRANSFORMER & PILOT LINE REGULATOR EO CONTROL SYSTEM PART NO. 106 ITEM 7016003 (1) EE & EO Control Mounting Bracket 24V - 40 VA Transformer - 120V 60HZ Primary 80160039 (2A) USA - Honeywell Plate Mounted AT140D1012 80160014 (2B) Canada - Honeywell Foot Mounted AT72D1089 8226005 (3) Pilot Line Regulator Nat.
TRANSFORMER & PILOT LINE REGULATOR EOP CONTROL SYSTEM - U.S.A. THERMOCOUPLE CONTROL SYSTEM - CANADA PART NO. ITEM 7016001 (1) “J” Box Mounting Bracket 24V - 40 VA Transformer - 120 60HZ Primary 80160039 (2A) USA - Honeywell Plate Mounted AT140D1012 80160014 (2B) Canada - Honeywell Foot Mounted AT72D1089 8226005 (3) Pilot Line Regulator Nat.
TRANSFORMER, PILOT SOLENOID VALVE & PILOT LINE REGULATOR EE CONTROL SYSTEM PART NO. 108 ITEM 7016003 (1) EE & EO Control Mounting Bracket 24V - 40 VA Transformer - 120V 60HZ Primary 80160039 (2A) USA - Honeywell Plate Mounted AT140D1012 80160014 (2B) Canada - Honeywell Foot Mounted AT72D1089 822662 (3) Penn Pilot Solenoid Valve H91WA-4, 120V 8226005 (4) Nat.
TRANSFORMER, PILOT SOLENOID VALVE & PILOT LINE REGULATOR EEP CONTROL SYSTEM PART NO. ITEM 7136001 (1) “J” Box Mounting Bracket 24V -40 VA Transformer - 120 60HZ Primary 80160039 (2) USA - Honeywell Plate Mounted AT140D1012 822662 (3) Penn Pilot Solenoid Valve H91WA-4, 120V 8226005 Pilot Line Regulator (4) Nat.
CONTROL ASSEMBLY & MOUNTING BRACKET EO - EE CONTROL SYSTEMS TRANSFORMER, PILOT SOLENOID VALVE & PILOT LINE REGULATOR EE CONTROL SYSTEM PART NO.
EOP & EEP CONTROL PANEL EOP & EEP CONTROL PANEL PART NO.
EI CONTROL SYSTEM - Honeywell Q3481 PILOT ASSEMBLY EI CONTROL SYSTEM - PILOT ASSEMBLY 100331-01 EI - 1, NAT., 5006B - 6009B Sections 100332-01 EI - 2, NAT., 5010B - 5026B Sections 100331-01 EI - 2, NAT., 5010B - 5026B Sections Not Available ........LP, 5010B - 5026B Sections PART NO. 100331-01 ITEM (1) Pilot Burner/Igniter/Sensor Honeywell Q3481B1172, Nat.
EO - EOP CONTROL SYSTEM - PILOT ASSEMBLY EO-EOP CONTROL SYSTEM - PILOT ASSEMBLY 6236007 NAT. GAS 6236008 EI GAS PART NO.
EE - EEP CONTROL SYSTEM - PILOT ASSEMBLY EE-EEP CONTROL SYSTEM - PILOT ASSEMBLY 6236003 NAT. GAS Not Available for LP PART NO.
SERVICE RECORD DATE SERVICE PERFORMED 115
For Commercial Grade Boilers Limited Warranty Using Cast Iron, Carbon Steel, or Stainless Steel Heat Exchangers and Parts / Accessories Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and/or accessories manufactured and shipped on or after October 1, 2009: ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILE
