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 BOI L E R 3050579 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.
SECTION I – EQUIPMENT CHECK LIST (continued) U.S.A.
SECTION I – EQUIPMENT CHECK LIST (continued) 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.
SECTION I – EQUIPMENT CHECK LIST (continued) 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 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. 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.
SECTION II – GENERAL INFORMATION (continued) 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.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Fig. 3 DUAL MANIFOLD BASES - 5015B THRU 5026B SECTION BOILERS Center Sections on 11 section and larger boilers. THIS IS IMPORTANT. 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. Fig.
Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) c. Insert short end of draw-up rod through front & rear nipple ports on both sections, see Fig. 5. d. Place two (2) flat washers, draw-up channel and a nut on each end of draw-up rods and finger tighten. 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.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Fig. 8 INSTALLATION OF BUILT-IN HEATER Open Steam or Water Trim Carton 8. Use the plugs in this carton to plug tappings in End Sections that will not be utilized on final installation, see Fig. 7. Fig. 9 TESTING BOILER ASSEMBLY FOR LEAKS (2) HOT WATER BOILERS: The assembled boiler must be subjected to a hydrostatic test of 75 psig to 85 psig. WARNING Open Tankless Heater Carton(s) If Supplied. Open Heater Opening Cover Plate Carton(s). 9.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Fig. 10 SEALING OF BASE, INSTALLATION OF FLUE COVERS AND CANOPIES 13. INSTALL FLUE COVER PLATES over cleanout openings on Front and Rear of Boiler. Use ¼” Carriage Bolts installed at top and bottom of flue openings and secure with washer and jam nut to provide a fixed stud. Install flue cover plates over studs with insulation against Boiler and secure with washers and nuts, see Fig. 11. 14. CONNECT SUPPLY AND RETURN PIPING TO HEATING SYSTEM.
Fig.
Fig.
Fig.
Fig.
Fig. 16A RECOMMENDED WATER BOILER PIPING 1 SUPPLY CONNECTION & 1 RETURN CONNECTION SIZES 5006B THRU 5019B Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) 1. Repairing system leaks to eliminate the need for addition of make-up water. 2. Eliminating open tanks from the system. 3. Eliminating and/or repairing fittings which allow oxygen absorption. 4. Use of non-permeable materials in the distribution system. 5. Isolating the boiler from the system water by installing a heat exchanger. Open Jacket Parts Carton 15. INSTALLATION OF JACKET PARTS COMMON TO ALL BOILER SIZES Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Attach Hex Couplings to end of Carriage Bolts which secure flue cover plates. NOTE: Select Carriage Bolts which line up with holes in the Vestibule Panel. 18. Secure Vestibule Panel to Hex Couplings using ¼”-20 x 3/8” slotted pan head machine screws. 19. Attach rear top Jacket Panel to Upper End Panels using #8 SMS. Refer to Fig. 21. 20. Installation of Canopy- Draft Hood 5006B thru 5010B Section Boilers, see Fig. 22.
Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Fig.
Fig.
Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) 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. 24. 23. Installation of left and right top side Jacket Panel a. Remove knockout, right or left, only if needed.
Fig. 25 EXPLODED VIEW OF JACKET 5020B THRU 5022B SECT. BOILERS Panel with louvers must be at front of boiler for ventilation of vestibule. Panel with perforations must be at front of boiler for ventilation and combustion air.
Fig. 26 EXPLODED VIEW OF JACKET 5024B AND 5026B SECT. BOILERS CAUTION Panel with louvers must be at front of boiler for ventilation of vestibule. Panel with perforations must be at front of boiler for ventilation and combustion air.
SECTION III – INSTALLATION INSTRUCTIONS (continued) 32. Tighten all sheet metal screws. a. Install the following plates or labels which are found in the Instruction Envelope. See Fig. 25 or 26 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.
Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) 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 or smaller boilers, since any Bottom Blowoff piping or valves for 5009B or smaller boilers must be at least ¾”. Bottom Blowoff piping and valves for Boilers 5010B through 5021B must be at least 1”. Bottom Blowoff piping and valves for 5022B Boilers and larger must be at least 1¼”. g.
SECTION III – INSTALLATION INSTRUCTIONS (continued) 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.
SECTION III – INSTALLATION INSTRUCTIONS (continued) ground joint union, as show in Fig. 1, should be installed in the piping to each gas train for ease of servicing. CONNECT GAS SERVICE FROM METER TO GAS TRAIN in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements to the – USA – “National Fuel Gas Code, ANSI Z223.1”. 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.
SECTION III – INSTALLATION INSTRUCTIONS (continued) WITH GAS SUPPLY “OFF” and Service Piping connected to the boiler, open Manual Valve(s) and pilot valve(s) at end of Gas Train(s) and reduce pressure to ½ lb. gage pressure. Using soap solution or other approved method check gas train piping, pilot piping, bleed piping and orifices for leaks. EI Control System 1. INSTALLATION OF GAS VALVE TRANSFORMER AND PILOT PIPING (for Robertshaw Pilot Piping, see Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Fig. 33 PILOT PIPING - EI CONTROL SYSTEM (V88A) U.S.A. 5010B THRU 5026B - NAT. GAS CANADA - 5006B THRU 5026B - NAT. GAS 4. COMPLETION OF WIRING – Connect power supply fused disconnect switch, service switch, primary side of transformer, gas valves and remaining controls – see Fig. 42, 43 or 44 for wire type and connections to be made. All wiring must be adequately supported and strain relief provided.
SECTION III – INSTALLATION INSTRUCTIONS (continued) tubing to bleed line protruding from inside base, see Fig. 35. On boiler installed in Canada, run bleed line to outdoors. 3. INSTALLATION OF “OP” PANEL AND WIRING OF PILOT AND PILOTSTAT – Attach the OP Control Panel with RM7890 control, see Fig. 36, to the front top jacket panel, preferably on the closest jacket panel to the gas train installed.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Run these wires to outside of jacket on underside of manifold and secure in this position with Wire Ties furnished to provide strain relief. Provide adequate support and strain relief for wiring outside jacket. 4. COMPLETION OF WIRING – Connect power supply fused disconnect switch, service switch, primary and secondary side of gas valve transformer, primary side of ignition transformer, and remaining controls – see Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Note - Pilot Piping duplicated on 15 sect. and larger boilers. Fig. 37 PILOT PIPING EP CONTROL SYSTEM 5. COMPLETION OF WIRING – Connect power supply fused disconnect switch, service switch, primary and secondary side of gas valve transformer, primary side of ignition transformer, and remaining controls – see Fig. 48 & 49 for wire type and connections to be made. All wiring must be adequately supported and strain relief provided.
SECTION III – INSTALLATION INSTRUCTIONS (continued) “THERMOCOUPLE CONTROL SYSTEM” CANADA ONLY Fig. 38 PILOT PIPING THERMOCOUPLE CONTROL SYSTEM CANADA ONLY 2. INSTALLATION OF GAS VALVE TRANSFORMER AND COMPLETION OF WIRING - 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 Figures 38 and 39. Install Transformer on junction box. Fig.
SECTION III – INSTALLATION INSTRUCTIONS (continued) Venting 1. INSTALL VENT CONNECTOR from canopy Draft Hood 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. Vent installation shall be in accordance with local building codes; or the local authority having jurisdiction; or the National Fuel Gas Code, ANSI Z223.
SECTION III – INSTALLATION INSTRUCTIONS (continued) (18) Clearances to combustible material – use of thimbles. (19) Firestops. (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: 1.
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.
SECTION IV - OPERATION (continued) 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.
SECTION IV - OPERATION (continued) 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) 45 5006B-5009B (USA) EI Elec. Ign. 5010B-5026B (USA) 5006B-5026B (CANADA) EI Elec.
SECTION IV - OPERATION (continued) 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.
Fig. 42 SCHEMATIC WIRING DIAGRAM - EI CONTROL SYSTEM (ROBERTSHAW7000 GAS VALVE) U.S.A.
SECTION IV - OPERATION (continued) 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.
SECTION IV - OPERATION (continued) 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.
SECTION IV - OPERATION (continued) TROUBLE SHOOTING GUIDE BOILERS EQUIPPED WITH S8610M INTERMITTENT ELECTRIC IGNITION 49
SECTION IV - OPERATION (continued) 5. OP CONTROL SYSTEM – 5006B thru 5014B The OP Control System utilizes an RM7890C microprocessor based integrated burner control and a Q179D Rectification Pilot (standing or continuous burning pilot) to which has been added a Q309 thermocouple. The RM7890C 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.
Fig.
SECTION IV - OPERATION (continued) failure on one OP Control System occur, the other OP Control System would not be affected. Thus main burners on the unaffected side would ignite on a “call for heat” and would continue to operate until the operating control was satisfied. The OP Control System utilizes an RM7890C microprocessor based integrated burner control and a Q179D Rectification Pilot (standing or continuous burning pilot) to which has been added to a Q309 Thermocouple.
Fig.
SECTION IV - OPERATION (continued) and the relay will lock out on safety within 15 seconds. Assuming the pilot on the opposite side is burning, the gas valves on that side will open and main flame will be ignited on that side only. 7.
SECTION IV - OPERATION (continued) Fig.
Fig.
SECTION IV - OPERATION (continued) (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 the pilot failure has been corrected, resume normal operation by following the Lighting Instructions. (3) SHUTDOWN INSTRUCTIONS (a) Close manual shut-off valves and pilot valves. (b) Turn off main electric switch. 8.
SECTION IV - OPERATION (continued) Pilots, after ignition of pilot flame will close the pilot valve and the main gas valves controlled by that particular RM7890A relay in 0.8 second. The burners controlled by the other RM7890A will continue to burn. (b) For 15 seconds after failure of a Q179C pilot, the relay through terminals #8 and #10 will attempt to re-establish pilot flame.
SECTION IV - OPERATION (continued) When operating control (A) calls for heat, it energizes main gas valves (B), starting burner operation. The burners will operate until operating control (A) 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). Low water cut-off (D) will stop burner operation if the water level in boiler drops below the lowest safe level.
SECTION IV - OPERATION (continued) 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).
SECTION IV - OPERATION (continued) 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.
SECTION IV - OPERATION (continued) 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.
SECTION IV - OPERATION (continued) Fig. 53 LOW FIRE ADJUSTMENT - V4062 ACTUATOR (3) Remove the lead to V9055A terminal R. Jumper terminal R to W. This will prevent the actuator from going to the high fire position. (4) Energize the system and light the main burner. (5) Use a Phillips screwdriver, or standard type with a blade no more than 3/16 inch wide, to turn the low fire adjusting screw for the desired low fire position. DO NOT PUSH INWARD ON SCREW. (6) Shut down the burner, and then restart.
SECTION IV - OPERATION (continued) 18. CHECK THERMOSTAT OPERATION. Raise and lower thermostat setting as required to start and stop burners. 19. CHECK HIGH LIMIT CONTROL. Jumper Thermostat terminals or thermostat connections in Limit Control. Allow burners to operate until shutdown by limit. REMOVE JUMPER. 20. TEST IGNITION SYSTEM SAFETY SHUT-OFF DEVICE AS FOLLOWS: Place the boiler into operation by following the appropriate lighting instructions in this manual. Proceed with test as follows: a.
SECTION V – SERVICE DANGER This boiler used flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service.
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.
SECTION V – SERVICE (continued) Remove the Front Cleanout Panels first by removing the upper and lower nuts and washers securing these panels to the boiler sections, see Fig. 56. Fig. 56 ATTACHMENT OF FLUE COVERS 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. Using a flashlight, examine all flue passageways.
Fig.
SECTION V – SERVICE (continued) 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, remove hitch pin clips (shaped like a hairpin) from groove in main burner orifices. SAVE ALL CLIPS. c.
SECTION V – SERVICE (continued) regulator 5.5” WC in pilot line so that a medium hard center flame envelops flame rod, see Fig. 61. 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. 61 PILOT FLAME HONEYWELL Q179D PILOT w/THERMOCOUPLE The EP 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.
SECTION V – SERVICE (continued) WARNING Before returning boiler to service: Follow this low water cut-off procedure: - check out Set thermostat to the highest setting. While boiler is operating, open drain valve and slowly drain down boiler water. the concentration becomes high enough, can corrode the cast iron through from the inside. Since neither of these failure types are the result of a casting defect the warranty does not apply.
SERVICE RECORD DATE 72 SERVICE PERFORMED
SECTION VI - REPAIR PARTS REPAIR PARTS INDEX ITEM PAGE NOS. Base Parts....................................................................................................................... 74 thru 77 Integral Draft Hoods & Sections...................................................................................... 78 thru 80 Base/Pilot Assemblies................................................................................................................. 81 Jackets..................
Fig.
SECTION VI - REPAIR PARTS (continued) TABLE 2A SERIES 5B BASE PARTS - 5006B thru 5014B Number in ( ) in Table Relates to Corresponding Number in PART NUMBER ITEM 7181301 High Base End Panel 7201319 High Base End Panel Insul.
Fig.
High Base End Panel High Base End Panel Insul.
Fig.
SECTION VI - REPAIR PARTS (continued) TABLE 3A SERIES 5B INTEGRAL CANOPY Draft HoodS - BOILER SIZES PART SIZE PART NO. Canopy Draft Hood No.
CX Center Section Tapped - Not Plugged CXP Center Section Tapped - Plugged 7171304 6171301 Nipple Lubricant, Loctite #592, 50 ml Nipple Lubricant, Loctite® #592, 250 ml 8056254 8056255 ® REH Section 7171302 Nipple Gauge, 3” & 7” C Center Section Plain 7171303 806600023 LEH Section ITEM 7171301 PART NO.
618130611 Complete Base Ass’y w/EP Pilot Ass’y 5015B 61813067 Complete Base Ass’y w/OP Pilot Ass’y 618130871 61813088 618130821 618131541 61813159 61813155 61813157 618130881 618130801 618131511 61813156 Right Base Subass’y w/Thermocouple Pilot Ass’y Right Base Subass’y w/OP Pilot Ass’y Right Base Subass’y w/EP Pilot Ass’y Left Base Subass’y w/EI Pilot Ass’y Left Base Subass’y w/Thermocouple Pilot Ass’y Left Base Subass’y w/OP Pilot Ass’y Left Base Subass’y w/EP Pilot Ass’y Right Base Suba
Fig.
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.
SECTION VI - REPAIR PARTS (continued) TABLE 4F Water Trim Water Trim Carton Number: 7W2 7W3 7W4 5006-11 5012-22 5024-26 PART NO.
SECTION VI - REPAIR PARTS (continued) TABLE 4G Steam Trim Steam Trim Carton Number: 7S1 7S2 7S3 7S4 5006-8 5009-11 5012-20 5021-26 PART NO. Pressuretrol, Honeywell L404F1060 1 1 1 1 80160942 Steam Gauge, 4" Dia.
SECTION VI - REPAIR PARTS (continued) 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 8226161 822645 8226011 8226012 822614 8226010 8226006 822607 81660008 81660009 822605 PART NO. Diaphragm Gas Valve 1” Honeywell V88A1618 1¼” Honeywell V88A1626 Bleed Valve Assembly - Honeywell #126590 Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” LP Gas Regulator HO1 Blue Spring 5.5” to 12.0” WC 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.
822619 822620 822615 8226161 822645 8226006 822607 822614 8226010 81660008 81660009 822605 PART NO. Diaphragm Gas Valve 1” Honeywell V88A1618 1¼” Honeywell V88A1626 Bleed Valve Assembly - Honeywell #126590 Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC 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.
822615 8226161 822645 8226011 8226012 822614 8226010 8226006 8226012 81660088 81660086 81660012 81660013 81660014 81660010 81660011 PART NO. 6 --7 4B --5 --- 4A --- 3 --- 1 --- 5006B - 5008B Fluid Power Gas Valve 1” - Honeywell V5055B1002 1¼” - Honeywell V5055B1010 Actuators for Fluid Power Valves “Lo-Hi-Off” Honeywell V4055A1007 - 5026B Sec. Opening Time - 120V 60HZ “Lo-Hi-Lo” Honeywell V4062A1008 - 5026B Sec. Opening Time - 120V 60HZ “Modulating” Honeywell V9055A1055 - 5026B Sec.
822615 8226161 822645 81660081 81660094 81660149 81660150 PART NO. “Lo-Hi-Lo” Gas Valve 1” Honeywell V8944B1019 1¼” Honeywell V8944B1027 Solenoid Gas Valve 1” - ITT Gen. K8A461 1¼” - ITT Gen.
822619 822620 822645 822615 8226161 822614 8226010 8226011 8226012 8226006 8226012 81660081 81660094 81660149 81660150 PART NO. “Lo-Hi-Lo” Gas Valve 1” Honeywell V8944B1019 1¼” Honeywell V8944B1027 Solenoid Gas Valve 1” - ITT Gen. K8A461 1¼” - ITT Gen. K8A771 Nat. Gas Regulator - Std. Cad Plate Spring 3.0” x 6.0” WC Maxitrol RV-61 1” x 1” Maxitrol RV-81 1¼” x 1¼” LP Gas Regulator HO1 Blue Spring 5.5” to 12.
822615 8226161 822645 822619 822620 8226011 8226012 822614 8226010 8226006 822607 81660088 81660094 81660012 81660013 81660014 81660010 81660011 PART NO. 5006B - 5008B 1” - Honeywell V5055B1002 1 1¼” - Honeywell V5055B1010 --Actuators for Fluid Power Valves “Lo-Hi-Off” Honeywell V4055A1007 - 5026B Sec. Opening Time - 120V 60HZ “Lo-Hi-Lo” Honeywell V4062A1008 - 5026B Sec. Opening Time - 120V 60HZ - LP Only “Modulating” Honeywell V9055A1055 - 5026B Sec.
Manifold Module Support Bracket Assembly Description Honeywell S8610M3009 Ignition Module 100958-01 IGNITION MODULE #S8610M & SUPPORT BRACKET EI CONTROL SYSTEM 6011301 PART NO.
L62GB-3C Pilot Safety Switch Manifold Module Support Bracket Assembly Description PILOTSTAT #L62GB & SUPPORT BRACKET OP - THERMOCOUPLE CONTROL SYSTEM (2) 80160138 (1) 6011301 ITEM PART NO.
SECTION VI - REPAIR PARTS (continued) TRANSFORMER, Penn #h91wg PILOT SOLENOID VALVE & PILOT LINE REGULATOR EI CONTROL SYSTEM U.S.A. - 5010B-5026B NAT. GAS CANADA - 5006B-5026B NAT. GAS PART NO. 98 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.
SECTION VI - REPAIR PARTS (continued) TRANSFORMER & PILOT LINE REGULATOR OP CONTROL SYSTEM PART NO. ITEM 7016003 (1) EP & OP 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.
SECTION VI - REPAIR PARTS (continued) TRANSFORMER & PILOT LINE REGULATOR THERMOCOUPLE CONTROL SYSTEM - CANADA PART NO. 100 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.
SECTION VI - REPAIR PARTS (continued) TRANSFORMER, penn #h91wa-4 PILOT SOLENOID VALVE & PILOT LINE REGULATOR EP CONTROL SYSTEM PART NO. ITEM 7016003 (1) EP & OP 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.
SECTION VI - REPAIR PARTS (continued) Control assembly and mounting bracket OP - EP CONTROL SYSTEMS 102
SECTION VI - REPAIR PARTS (continued) EI CONTROL SYSTEM - Honeywell Q3481 PILOT ASSEMBLY EI CONTROL SYSTEM - PILOT ASSEMBLY 6236072 EI - 1, NAT., 5006B - 6009B Sections 6236075 EI - 2, NAT., 5010B - 5026B Sections 6236076 EI - 2, NAT., 5010B - 5026B Sections Not Available ........LP, 5010B - 5026B Sections PART NO. ITEM 100331-01 (1) Pilot Burner/Igniter/Sensor Honeywell Q3481B1172, Nat.
SECTION VI - REPAIR PARTS (continued) OP CONTROL SYSTEM - PILOT ASSEMBLY 6236007 NAT. GAS 6236008 LP GAS PART NO.
SECTION VI - REPAIR PARTS (continued) EP CONTROL SYSTEM - PILOT ASSEMBLY 6236003 NAT. GAS Not Available for LP PART NO.
APPENDIX A - FIGURES Figure Number Page Number Description Section I - Equipment Check List USA KD Boilers 2&3 U.S.A. Equipment Check List Canada KD Boilers 4&5 Canadian Equipment Check List Figure 1 6 Dimensional Data Section II - General Information Section III - Installation Instructions Fig. 2 8 Single Manifold Base 5006B Thru 5014B Section Boilers Fig. 3 9 Dual Manifold Bases - 5015B Thru 5026B Section Boilers Fig. 4 9 LEH Section on Base Fig.
APPENDIX A - FIGURES (continued) Figure Number Page Number Description Section III - Installation Instructions (continued) Fig. 38 38 Pilot Piping, Thermocouple Control System - Canada Only Fig. 39 38 Installation of Pilot Safety Switch, Thermocouple Control System Fig. 40 39 Single Vent System Fig. 41 39 Manifold Vent System Section IV - Operation Fig. 42 45 Schematic Wiring Diagram - EI Control System (Robertshaw7000 Gas Valve) USA 5006B Thru 5009B Fig.
APPENDIX A - FIGURES (continued) Figure Number Page Number Description Section VI - Repair Parts (continued) Honeywell Ignition Module 96 Ignition Module #S8610M and Support Bracket EI Control System Johnson PSS 97 Pilotstat #L62GB and Support Bracket OP Thermocouple Control System Penn Pilot Solenoid Valve Ass’y 98 Transformer, Penn #H91WG-5 Pilot Solenoid Valve and Pilot Line Regulator EI Control System, USA (5010B - 5026B) Natural Gas; Canada (5006B - 5026B) Natural Gas Maxitrol Pilot Reg Ass
APPENDIX B - TABLES Table Number Page Number Description Section I - Equipment Check List Section II - General Information Reference 7 Clearances for Boiler Room Space Section III - Installation Instructions Table I 31 Natural Gas (Maximum Capacity of Piping in Cubic Feet of Gas Per Hour) Table II 31 Multipliers to be Used with Table I when Pressure Drop is Not 0.3” WC Table III 31 Multipliers to be Used with Table I when Specific Gravity Other than 0.
APPENDIX B - TABLES (continued) Table Number Page Number Description Section VI - Repair Parts (continued) Maxitrol Pilot Reg Ass’y 100 Transformer and Pilot Line Regulator, Thermocouple Control System (Canada) Penn Pilot Solenoid Valve Ass’y 101 Transformer, Penn #H91WA-4 Pilot Solenoid Valve and Pilot Line Regulator, EP Control System Honeywell Q3481 Pilot Ass’y 103 EI Control System - Honeywell Q3481 Pilot Assembly Honeywell Q179D Pilot Ass’y 104 OP Control System - Pilot Assembly Honeywel
SERVICE RECORD DATE SERVICE PERFORMED 111
