INSTALLATION AND

OPERATING INSTRUCTIONS
FOR
BURNHAM COMMERCIAL
3 SERIES 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.

Ce manuel ne doit être utilisé que par des techniciens qualifiés en entretien et
installation d’appareil de chauffage. Lire l’ensemble des directives et toute autre
information reçue avec la chaudière AVANT l’installation. Conserver ces directives
près de la chaudière afin que le personnel d’entretien puisse s’y référer. Exécuter
les étapes dans l’ordre donné. Ne pas se conformer aux directives peut engendrer
des blessures graves, la mort ou d’importants dommages matériels.

For service and repairs to the heating plant, call your local representatives. When seeking information
on the boiler, provide series and size designation shown on rating plate.

Boiler Number Type Firing Type System

Project

Address Phone No.

1
 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. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment,”
for recommended installation practices.
B. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid
Fuel Burning Appliances,” for venting requirements.
D. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices
for Automatically Fired Boilers,” for assembly and operations of controls and safety devices.
E. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code
and/or Local Regulations.
CANADIAN BOILERS
A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning
Equipment,” for recommended Installation Practices.
B. The equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances
and Equipment, CSA B149, and applicable Provincial Regulations for the class; which should be carefully
followed in all cases. Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code
and/or Local Regulations.

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 Indicates a potentially hazardous situation which, if not
avoided, will result in death, serious injury or substantial avoided, may result in moderate or minor injury or property
property damage. damage.

Indicates a potentially hazardous situation which, if not Indicates special instructions on installation, operation, or
avoided, could result in death, serious injury or substantial maintenance which are important but not related to personal
property damage. injury hazards.

Définitions des dangers

Les termes suivants sont utilisés tout au long de ce manuel afin de souligner la présence de dangers dont le niveau de
risque varie ou de mettre en relief de l’information cruciale quant à la durée de vie du produit.

Indique une situation de danger imminent qui, si elle n’est Indique une situation de danger potentiel qui, si elle n’est pas
pas évitée, peut causer la mort, de graves blessures ou évitée, cause la mort, de graves blessures ou d’importants
d’importants dommages matériels. dommages matériels.

Indique une situation de danger potentiel qui, si elle n’est pas Indique des directives particulières, importantes, mais sans
évitée, peut causer des blessures mineures ou de légers risque de blessure, lors de l’installation, de l’utilisation ou de
dommages matériels. l’entretien.

2
 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.

Cette chaudière est sous garantie limitée, dont un exemplaire apparaît à l’arrière du manuel.
Il incombe à l’installateur de s’assurer que les dispositifs sont correctement fixés et en état de marche au terme de
l’installation. La garantie pour cette chaudière est valable seulement si le produit est installé, entretenu et utilisé selon
les présentes directives.

DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
If you smell gas or fuel oil vapors, do not try to operate the burner/boiler system. Do not touch any electrical
switch or use any phone in the building. Immediately call the gas or oil supplier from a remotely located phone.
Burner/boiler systems produce steam or hot water in a pressurized vessel by mixing extremely flammable
gaseous, liquid or solid fuels with air to produce combustion and very hot products of combustion. Explosions,
fires severe personal injury, death and/or property damage will result from improper, careless or inadequate
installation, operation or maintenance of fuel-burning and boiler equipment.

NE PAS entreposer ou utiliser de l’essence ou toute autre matière inflammable gazeuse ou liquide à proximité de la chaudière ou de tout
autre appareil.
Si vous sentez une odeur de gaz ou de mazout, ne pas tenter d’utiliser le système de brûleur/chaudière. Ne pas toucher les interrupteurs ni
se servir des téléphones du bâtiment. Appeler immédiatement le fournisseur de gaz ou de mazout à partir d’un autre endroit.
Les systèmes de brûleur/chaudière produisent de la vapeur ou de l’eau chaude en mélangeant des carburants hautement inflammables
gazeux, liquides ou solides avec de l’air dans une cuve sous pression pour produire une combustion et des résidus très chauds. Des
explosions, des incendies, des blessures graves, la mort ou d’importants dommages matériels peuvent découler d’une installation, d’une
utilisation ou d’un entretien inadéquat ou négligé de l’équipement de combustion et de la chaudière.
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. Keep
this manual and literature in legible condition and posted near appliance for reference by owner and service
technician.
Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors and liquids.
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.
Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable
installer or service agency.
All heating systems should be designed by competent contractors and only persons knowledgeable in the layout
and installation of heating systems should attempt installation of any boiler.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating
properly when the installation is completed.
Installation is not complete unless a pressure relief valve is installed.
This boiler is NOT suitable for installation on combustible flooring.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to assure that
the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale. The
inside of the combustion chamber should also be cleaned and inspected at the same time.
Have Burner and Controls checked at least once a year or as may be necessitated. Do not operate unit with
jumpered or absent controls or safety devices. Do not operate unit if any control, switch, component, or device
has been subject to water.

Toute installation, altération, réparation, ou tout réglage ou entretien inadéquat peut provoquer des dommages
matériels, une blessure ou une perte de vie. Ne pas se conformer aux directives dans l’ordre donné peut causer
des blessures ou la mort. S’assurer de bien les comprendre, y compris celles des manuels du fabricant
accompagnant les composants fournis avant d’installer, d’utiliser, de réparer, de démarrer ou d’entretenir cet
appareil. Conserver ce manuel et toute autre documentation en bonne condition près de l’appareil aux fins de
référence pour le propriétaire ou le technicien en entretien et réparation.
Garder l’espace autour de la chaudière dégagé et exempt de matières combustibles, d’essence et d’autres
vapeurs et liquides inflammables.
Pour fonctionner de façon sécuritaire, cette chaudière nécessite un entretien régulier. Suivre les directives de ce
manuel.
L’installation, les réparations et l’entretien doivent être effectués uniquement par un installateur ou un organisme
de service expérimenté et qualifié.
Tout système de chauffage devrait être conçu par des entrepreneurs compétents, et seules les personnes
qualifiées pour l’installation de tel système devraient s’en charger.
Il incombe à l’installateur de s’assurer que les dispositifs de contrôle sont correctement fixés et en état de marche
au terme de l’installation.
L’installation n’est pas terminée tant qu’une soupape de sûreté n’est pas
fixée. Cette chaudière NE PEUT être installée sur un plancher combustible.
Ne pas modifier la chaudière ou ses commandes. S’assurer que l’unité est correctement réglée et entretenue
auprès d’un entrepreneur ou d’un technicien compétent.
Nettoyer la suie et le tartre accumulés au moins une fois par année, si possible, au début de la saison froide. Au
même moment, nettoyer et inspecter l’intérieur de la chambre de combustion.
Faites vérifier le brûleur et ses commandes au moins une fois par an ou lorsque nécessaire. Ne pas faire
fonctionner si les commandes ou les dispositifs de sûreté sont absents ou installés à l’aide de cavaliers. Ne pas
faire fonctionner si une commande, un interrupteur, un composant ou un dispositif est entré en contact avec de
l’eau.
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. Do not unscrew any pipe fittings nor attempt to
disconnect any components of this boiler without positively assuring the water is cool and has no pressure.
Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald
injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the
boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any
components unless they are cool.
This appliance must be properly vented and connected to an approved vent system in good condition. Do not
operate boiler with the absence of an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of the heating
season and should be inspected periodically throughout the heating season for any obstructions. Clean and
unobstructed venting and air intake systems are necessary to allow noxious fumes that could cause injury or loss
of life to vent safely and will contribute toward maintaining the boiler’s efficiency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If
damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or
appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is
inoperative.
This boiler is designed to burn No. 2 fuel oil, natural and/or LP gas only. Do not use gasoline, crankcase drainings,
or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.
wood, coal). All flammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times.
Keep the boiler area clean and free of fire hazards.
Always keep the oil supply valve shut off if the burner is shut down for an extended period of time.
Probe and float type low water cutoff devices require annual inspection and maintenance. Refer to instructions in
Section IV for inspection and cleaning instructions.

Les matériaux d’assemblage de l’appareil, les produits de combustion et le combustible contiennent de l’alumine,
de la silice, des métaux lourds, du monoxyde de carbone, des oxydes d’azote, des aldéhydes ou d’autres
substances toxiques ou dangereuses pouvant causer la mort ou des blessures graves, et qui ont été reconnues
par l’État de la Californie comme causes de cancer, d’anomalies congénitales et d’autres problèmes de l’appareil
reproducteur. Toujours utiliser des vêtements, des appareils respiratoires et de l’équipement de sécurité
appropriés lors du travail ou de l’entretien près de l’unité.
Cette chaudière contient de l’eau très chaude sous haute pression. Ne pas dévisser les raccords de tuyau ni tenter
de retirer tout composant sans s’assurer hors de tout doute que l’eau est froide et la pression inexistante.
Toujours porter des vêtements et de l’équipement de protection pour installer, démarrer ou réparer cet appareil
afin d’éviter les échaudures. Ne pas se fier aux jauges de pression et de température de la chaudière pour
déterminer ces variables. Certains composants de cet appareil deviennent très chauds lors du fonctionnement. Ne
pas toucher les composants qui ne sont pas froids.
Cet appareil doit être installé dans un endroit bien aéré et raccordé à un système de ventilation certifié en bonne
condition. Ne pas faire fonctionner sans ventilation.
Pour fonctionner de façon sécuritaire, cette chaudière nécessite de l’air frais et doit être installée de façon à ce que
les conditions de combustion et de ventilation soient adéquates.
L’intérieur des prises d’air et des conduites d’évacuation doit être inspecté et nettoyé avant la saison froide, puis
inspecté régulièrement en cours de saison pour prévenir les engorgements. La propreté et l’absence d’obstruction
des prises d’air et des conduites d’évacuation sont nécessaires à l’évacuation sécuritaire des émanations toxiques
pouvant causer des blessures ou la mort, et contribuent à maintenir l’efficacité de la chaudière.
Cette chaudière est munie de commandes pouvant provoquer un arrêt qui l’empêchera de redémarrer si elle n’est
pas réparée. Si le gel des tuyaux peut causer un bris, ne pas laisser le système de chauffage sans surveillance en
temps froid, ou encore, installer une alarme ou une protection appropriée au système afin de prévenir des
dommages si la chaudière est inefficace.
Cette chaudière est conçue pour n’utiliser que du mazout lourd no 2, du gaz naturel ou du gaz de pétrole liquéfié.
Ne pas utiliser d’essence, de vidanges de carter de moteur ou toute huile contenant de l’essence. Ne pas faire
brûler de déchets ni de papier dans la chaudière. Ne pas utiliser de combustible solide (bois, charbon). Tenir tout
débris, tissu, papier, résidu de bois ou autre loin de la chaudière en tout temps. Garder l’espace autour de
l’appareil propre et sans risque d’incendie.
Toujours fermer la vanne d’alimentation de mazout si le brûleur est arrêté pour une durée prolongée.
Les interrupteurs à bas niveau d’eau de type sonde ou de type flotteur doivent être inspectés et entretenus
annuellement. Voir les directives de la section IV concernant l’inspection et le nettoyage.
Burner/boiler system, as used throughout this manual, shall mean all mechanical and/or electrical equipment including
the boiler, burner, pumps, compressors, feed water systems and all associated piping, electrical and control systems
used and maintained in the boiler room.

Le terme « système de brûleur/chaudière » utilisé dans ce manuel signifie tout équipement mécanique ou électrique, y
compris la chaudière, le brûleur, les pompes, les compresseurs, le système d’eau d’alimentation et sa tuyauterie, ainsi
que les systèmes électriques et de contrôle utilisés ou conservés dans la chaufferie.
 TABLE OF CONTENTS
SECTION I General information
Introduction..................................................................................................................................... 8
Setting the Unit............................................................................................................................... 8-9
Flue Outlet, Stack, and Breeching..................................................................................................9
Combustion Air Requirements........................................................................................................9-10

SECTION II Installation Instructions

Boiler Piping................................................................................................................................... 11
High Pressure Steam Piping...........................................................................................................12
Tankless Heater Piping................................................................................................................... 12
Flow Regulation.............................................................................................................................. 12
Hot Water Tempering...................................................................................................................... 13
Heater Flushing.............................................................................................................................. 13
Hard Water...................................................................................................................................... 13
Bottom Blowdown Piping................................................................................................................ 13
Boiler Installation............................................................................................................................ 14-16

SECTION III Operating Instructions

Filling System................................................................................................................................. 17
Adjusting Burner............................................................................................................................. 17
Testing Controls.............................................................................................................................. 17-18
Initial Cleaning, Steam Boilers........................................................................................................18
Initial Cleaning, Water Boilers......................................................................................................... 18-20
Water Boiler Operation.................................................................................................................... 19
Boiler Water Treatment................................................................................................................... 19
pH or Alkalinity Test........................................................................................................................ 19
Warnings about Frequent Water Addition.......................................................................................19-20
Minimum Water Quality Requirements............................................................................................20

SECTION IV Service Instructions

Boiler Shutdown and Cool Down Procedures.................................................................................21
Cleaning Boiler Heating Surfaces...................................................................................................21-22
Turbulators..................................................................................................................................... 22
Maintenance of Low Water Cutoff Devices.....................................................................................22-23
Checking Burner & Controls........................................................................................................... 23
Lubrication...................................................................................................................................... 23
Checking Safety Valve.................................................................................................................... 23
Attention to Boiler while not in Operation........................................................................................23-24
Ordering Repair Parts..................................................................................................................... 24
Periodic Testing Recommended Check List....................................................................................25-26

WARRANTY............................................................................................. Back Cover

 SECTION I — GENERAL INFORMATION
INTRODUCTION 2. INSPECT SHIPMENT carefully for any signs of
1. Refer to burner manufacturer’s installation damage.
manual provided for proper venting of the A. All Equipment is carefully manufactured,
gas train components that require atmospheric inspected and packed. Our responsibility
pressure to balance a diaphragm. ceases upon delivery of boiler to the carrier
2. All cover plates, enclosures and guards must be in good condition.
in place at all times, except during maintenance B. Any Claims for damage or shortage in
and service. shipment must be filed immediately against
3. Insulate all steam and hot water piping, fittings the carrier by the consignee. No claims for
and connections and all other hot components variances from, or shortage in, orders will be
and equipment from personnel contact. allowed by the manufacturer unless presented
within sixty (60) days after receipt of goods.
4. Assure all pipes, fittings, electrical controls and
all other associated burner/boiler equipment is of C. Boiler model explanation is as follows:
proper design and construction for the intended Series 3: 3W-200-50-GO-PF
use and provides adequate protection from 1 2 3 4 5
electrical shock and harmful physical contact to 1. Medium: “W” for 30 psig water boiler,
personnel. “PW” for 31 thru 160 psig water boiler,
5. A leak-tight fuel delivery conduit and “L” for 15 psig steam boiler, “P” for over
control system must be maintained at all 15 psig steam boiler.
times. 2. Boiler horsepower output for Series 3.
6. Products of combustion must be transported
3. Heating surface: “50” designates 5.0
from the boiler/burner system to the outdoors
in an approved, leak tight, insulated venting sq ft heating surface per boiler
system. The boiler room must be positively horsepower.
ventilated to prevent a concentration of products 4. Fuel: “G” for natural gas, “O” for #2
of combustion and a reduction in the amount of fuel oil, “GO” for combination gas/oil.
oxygen in the air.
5. Burner manufacturer: “PF” for Power
7. For optimum performance and serviceability
Flame, “WEB” for Webster, “WHT” for
from this unit adhere to the following
Weishaupt.
recommendations:
A. Clean firetubes at least once a year, 3. SETTING THE UNIT
preferably at the end of the heating season Most boilers are equipped with lifting lugs to be
to remove soot and scale. Inside surfaces of used in maneuvering the boiler into position. On large
the furnace, front and rear smokeboxes, and boilers, where four lifting lugs are supplied, all four
reversing chamber should also be cleaned at lugs should be used when lifting the boiler.
the same time.
A. Lifting and Rigging
B. Have the burner and controls checked at
least once a year or as necessary. Use of a spreader beam is preferred but not
mandatory. An approved, inspected, and rated
C. Retain your contractor or a competent
sling suitable for the total published boiler
serviceman to assure that the unit is properly
weight shall be used. The correct WLL
adjusted and maintained.
(working load limit) shall be calculated based
1. GENERAL INFORMATION on the sling angle used, and the WLL must not
The boiler is designed specifically for forced draft exceed the sling rated capacity. The sling
firing, is available with oil, gas or combination gas/oil angle (angle between the sling and the load)
burners, and operates with a combustion efficiency of must not be less than 60 deg. The boiler must
over 80%. be lifted as level as practical (less than 5
degree tilt). Refer to the boiler submittal
This manual gives the necessary information for the
drawing for dry boiler weight.
proper installation, operation, maintenance and service
of units. For special installation problems, contact
Burnham Commercial, P.O. Box 3939 Lancaster, PA
17604, Phone: 888-791-3790.
 appliances. The boiler flue outlets are generally
sized for the correct stack diameter, but there
are exceptions to this.
The 3 Series boilers are equipped with a flanged
flue outlet connection. The flanges are provided less
holes, and will need to be field match-drilled with the
mating stack flange connection.
The boilers are optimally designed to run with a flue
Scotch boilers can also be rolled into position outlet pressure of .10-.30”wc pressure. The stack
using roller skids under the leg supports, pipe design, taking into account the draft effect and all
rollers may cause damage. The unit should
friction losses, should arrive at 0.0"wc +/- .10"wc
be located in the boiler room so as to provide
pressure at the inlet. Horizontal runs should be kept
ease of venting and adequate clearance for
to a minimum. This will ensure the boiler will meet
maintenance, serviceability and installation
the maximum capacity, and will light off and have
of piping.
stable and consistent combustion.
The tube pull space listed in the Burnham
Commercial product catalog must be provided On installations where a natural draft stack is used,
at the front of the boiler. The coil pull space must causing high breeching drafts, the boiler locking
be maintained at the front of units equipped with blade damper (on boilers equipped with one) may
tankless coils. Floor construction should have require adjusting, or one may need to be installed at
adequate load bearing characteristics to bear the boiler breeching. In multiple boiler installations,
the weight of the boiler filled with water. A boiler or in installations where the breeching draft may vary
foundation is recommended if the boiler room considerably, automatic draft controls in combination
floor is weak, uneven or if a water condition with a motorized damper may be required.
exists. These boilers are not for installation on 5. COMBUSTION AIR REQUIREMENTS
combustible flooring.
All boiler rooms must be adequately vented to
B. Installation Clearance provide enough combustion air to the boiler for proper
Minimum clearances to combustible walls shall tuning and operation, to prevent oxygen depletion,
be as follows: possible carbon monoxide formation, possible
1. Series 3: 18" sides, rear, above, and to accumulation of fuel fumes, and possible equipment
chimney connector. 48" to front. explosions. A free flow of combustion air will aid the
proper operation of the burner and allow for proper
2. Minimum recommended service clearances: venting of the boiler. The instructions below must be
18". followed to properly size make-up air openings in the
See boiler submittal drawings for tube pull boiler room. Consult NFPA-54 National Fuel Gas Code,
clearance requirements. NFPA-31 Installation of Oil Burning Equipment for more
If desiccant package was ordered, be sure detailed explanations, and local codes for additional
to remove from the boiler furnace using the guidance for boiler rooms below grade and other
specific situations.
rear access, and from the waterside using the
manhole cover.
Two general methods may be used:
4. FLUE OUTLET, STACK, AND BREECHING 1. When one permanent opening is used: The
The maximum weight limit on the boiler flue outlets opening shall commence within 12" of the top
is as follows: of the enclosure (boiler room) and the opening
1. Series 3: 500 lb, but can be increased to 1000 lb shall communicate directly with the outdoors,
by special order. All stack/economizer weights or through a vertical or horizontal duct with the
exceeding the limits above will need to be outdoors. The opening shall have a minimum
independently supported. free area of 1 sq in per 3,000 BTU/hr total input
of all equipment in the enclosure, and not less
Stack design: The stacks shall be installed in than the sum of the areas of all equipment vent
compliance with NFPA 54, ANSI Standard connectors.
Z223.1, state and local codes, using a category 2. When two permanent openings are used: One
III product for positive, non-condensing opening location shall begin within 12" of the
top of the enclosure, and the other opening
location shall begin within 12" of the bottom of
the enclosure. When communication is directly
with the outdoors, or through vertical ducts, each
opening shall have a minimum free area of 1 sq
in per 4,000 BTU/hr total input of all equipment
 in the enclosure. Where communicating with the 6. LOCATION OF ASME STAMPING DATA
outdoors through horizontal ducts, each opening
The ASME stamping data is located as follows:
shall have a minimum free area of 1 sq in per
2,000 BTU/hr total input of all equipment in the 1. Series 3: On the left side of the boiler shell, 24" to
enclosure. the rear of the front tubesheet, at approximately
Duct size, if used, shall have a minimal cross 10 o’clock, under a 3 x 6 cover plate.
sectional area equal to the opening size. 7. NORMAL BOILER WATER LEVEL
Outside air openings may be protected by mesh, The normal boiler water level is the water height
grills, or louvers. When doing so, the free area sizing where the steam boiler water level should operate at. If
must be compensated for the blocking effect of such using an on/off pump control, this will correspond with
obstructions. Protective mesh must be no smaller the “pump-off” level. The following dimensions represent
than 1/4". If the free area of the grilles and louvers the vertical distance from the reference point to the
is unknown, use 20-25% free area for wood louvers, Normal Water Level.
and use 60-75% free area for metal louvers and
grilles. Series 3 Boilers – Reference point is from the floor level

Closeable louvers must be electrically interlocked

with the burner to prevent the burner from firing if the
louvers fail to open or remain open.
The boiler room should not be under negative
pressure at any time.
Adjustment to air opening and duct size shall be
made to boilers at higher altitude installations (above
1,000 ft). An adjustment of 3.5% per 1,000 ft of
elevation is recommended.
3L-40/60 57-5/16" 3P-40/60 59-1/8"
3L-70/100 61-5/16" 3P-70/100 63-1/8"
3L-125/200 72" 3P-125/200 73-
13/16"
3L-250/300 79-5/8" 3P-250/300 81-
7/16"
3L-350/400 89- 3P-350/400 91-1/2"
11/16"
3L-500/700 99- 3P-500/700 101-
11/16" 1/2"
3L-800 102-5/8" 3P-800 104-
7/16"
3L-900/1000 106- 3P- 108-
9/16" 900/1000 3/8"
 SECTION II — INSTALLATION INSTRUCTIONS
1. BOILER PIPING L’écart de température nominale de l’eau d’alimentation
A. Water Boiler et de l’eau de retour recommandé pour les chaudières
Attach supply and return piping lines and insert ignitubulaires Burnham est de 11° C (20°F). Afin de
plugs and bushings in connections as required. prévenir un choc thermique, cet écart ne devrait jamais
Supply and return piping headers are detailed in dépasser 22°C (40°F).
Figure 2. La chaudière ne devrait fonctionner en aucun moment à
une température favorisant la formation de condensation
dans les tubes ou la boîte à fumée. Cette obligation
It is important to comply with the minimum piping force généralement un réglage minimal d’environ 600°C
requirements in order to ensure maximum performance (140°F) comme limite inférieure sur les systèmes dont
and reliability on steam boilers, particular attention l’écart nominal est de 11°C (20°F). Lors d’un démarrage à
should be given to the construction of the supply froid, un effet de condensation est à prévoir jusqu’à ce
header. que la chaudière se réchauffe. Si la formation de
condensat persiste, la limite inférieure de température
Il est important de respecter les exigences minimales en doit être ajustée à la hausse jusqu’à ce qu’il n’y ait plus
matière de tuyauterie pour assurer une efficacité et une de condensation.
fiabilité optimales des chaudières à vapeur, en portant
une attention particulière à l’assemblage du collecteur Les chaudières à eau et les chaudières à vapeur basse
d’alimentation. pression doivent avoir une température à faible risque
d’incendie (LFH) paramétrée à un minimum de 67°C
(120°F) afin d’éviter la condensation. Les chaudières à
vapeur haute pression doivent avoir une température
LFH minimale de 100°C (180°F).
The nominal temperature differential between supply
and return water recommended for Burnham firetube Flow Rate Based On Delta-T
water boilers is 20°F. As a precaution against thermal APPROXIMATE BOILER WATER FLOW
shock, this differential should never exceed 40°F. RATE REQUIRED (GPM) – SERIES 3
The boiler should not be operated for any length of time BOILER
at a temperature setting that allows the formation of 20º Delta T 30º Delta T 40º Delta T
SIZE
condensation in the tubes or smokebox. This generally (bhp)
dictates a minimum setting of approximately 140°F on 40 137 92 69
the low limit on systems with a 20°F system differential.
50 173 115 86
On cold start up, condensation can be expected until the
boiler warms up. If formation of condensate persists, the 60 209 139 104
low limit should be adjusted upward until condensate no 70 240 160 120
longer forms. 80 277 185 138
Water boilers and low pressure steam boilers must have 90 315 210 157
a set LFH at 120° minimum to avoid condensation. High 100 353 235 176
pressure steam should have a minimum LFH 125 428 285 214
temperature of 180°F.
150 524 349 262
175 618 412 309
200 712 475 356
250 871 580 435
300 1060 707 530
350 1215 810 607
400 1405 937 702
500 1754 1169 877
600 2132 1422 1066
700 2508 1672 1254
800 2676 1784 1338
900 3010 2007 1505
1000 3345 2230 1672
Boiler Waterside Pressure Drop B. Steam Supply Connection & Piping
Due to the large internal water reservoir and Most steam boilers are supplied with a flanged steam
a design having very little flow restriction, the outlet connection, with the exception of the smallest
waterside flow pressure drop is less than 1 psi. boilers, which may have a threaded pipe connection.
This is applicable to all flow rates, including the All low pressure steam boilers (15 psig) are supplied
highest flow rate corresponding with a 20ºF delta with a class 150 flanged steam connection. All high
T. pressure steam boilers (over 15 psig) are supplied
 with a class 300 flanged steam connection. B. If temperature differentials approach 40°F,
High Pressure Steam Piping to help prevent temperature fluctuations and
For boilers over 15 psig design (ASME Section I), insure proper circulation through the boiler, a
single boiler installations must have at least one recirculation loop as shown in Figure 3 should be
steam stop valve of the OS&Y type. For multiple considered. The recirculation flow should be at
boiler installations using a common steam header, least 1/2 GPM/BHP at all times when the boiler is
each boiler must have two steam stop valves. The online for operation.
preferred arrangement is to install a non-return 3. TANKLESS HEATER
stop type valve closest to the boiler, with an OS&Y
valve downstream. As an alternate, ASME B31.1
allows the use of two OS&Y valves. Dual OS&Y
Install an automatic mixing valve at the tankless heater
valves may be necessary on smaller boilers if the
outlet to avoid risk of burns or scalding due to
smallest available non-return stop valve (2-1/2") is excessively hot water at the fixtures. Adjust and
too large. maintain the mixing valve in accordance with the
Steam piping should not be reduced immediately manufacturer’s instructions.
at the boiler connection. A minimum straight run Installer une vanne mélangeuse automatique au chauffe-
of vertical pipe should be installed at the boiler eau sans réservoir pour éviter les risques de brûlure
steam outlet before reducing. Following this causés par une température excessive de l’eau dans la
guideline will improve the system steam quality. All plomberie. Ajuster la vanne mélangeuse conformément
Burnham Commercial steam boilers are capable aux instructions du fabricant, et la maintenir ainsi.
of providing a minimum steam quality of 98%.
Suggested minimum lengths are as follows: A. If boiler is ordered with tankless heater, connect
tankless heater piping as shown in Figure 2.
For pipe sizes 3 & 4" – Min pipe length is
30" For pipe sizes 6" – Min pipe length is B. The following guidelines should be followed
36" when piping the tankless heaters:
For pipe sizes 8, 10, & 12" – Min pipe length is 48"
For pipe sizes 16" – Min pipe length is 60" 4. FLOW REGULATION
See Fig 9 for details of recommended steam If flow through the heater is greater than its rating,
piping for a multiple boiler high pressure steam the supply of adequate hot water may not be able to
installation. keep up with the demand. For this reason a flow
regulator matching the heater rating should be installed
2. RECOMMENDED WATER BOILER in the cold water line to the heater. The flow regulator
RECIRCULATION LOOP should preferably be located below the inlet so it's not
The following guidelines relating to system water subjected to excess temperatures that may occur during
temperature fluctuation and flow through the boiler “off” periods when it is possible for the heat to be
must be observed. conducted back through the supply line. The flow
regulator also limits the flow of supply water regardless
A. It is important to operate your boiler in such a
of inlet pressure variations in the range of 20 to 120 psi.
manner as to prevent temperature fluctuation of
more then 40°F at any time. Rapid temperature
changes within the boiler can create stresses
in the boiler metal. These stresses can cause
damage to the boiler by loosening tubes, or
in more severe instances can crack tube sheet
ligaments,furnaces, or waterlegs.

FIGURE 2
SCHEMATIC TANKLESS HEATER PIPING
5. TEMPERING OF HOT WATER Installation of an automatic mixing valve will lengthen
the delivery of the available hot water by mixing some 10. BOTTOM BLOWDOWN PIPING
cold water with the hot. This prevents excessive and
possibly scalding hot water. Higher temperature hot See suggested piping schematics for bottom
water is possible by piping the hot water from the heater blowdown piping. The bottom blowdown connection on
the boiler has been properly sized according to ASME
prior to entering the mixing valve. The mixing valve
Code. DO NOT reduce the blowdown piping size from
should be “trapped” by installing it below the cold water
the boiler connection to the point of discharge. Do not
inlet to heater to prevent lime formation in the valve.
use galvanized pipe or fittings.
6. FLUSHING THE BOILER
Valve ratings:
All water contains some sediment which settles on
the inside of the coil. Consequently, the heater should For ASME Section IV low pressure steam (15 psig)
be periodically backwashed. This is accomplished by and water boilers, the valve pressure rating shall meet
installing hose bibs as illustrated and allowing water at or exceed the boiler MAWP rating, as stamped on the
city pressure to run into hosebib A, through the heater, boiler, but in no case less than 30 psig. The minimum
and out hosebib B until the discharge is clear. The tees temperature rating of the valves shall be 250F.
in which the hosebibs are located should be the same For ASME Section I, high pressure steam or high temp
size as heater connections to minimize pressure drop. water boilers, the minimum valve pressure rating shall
7. HARD WATER be 1.25 times the boiler MAWP or 225 psig, whichever
is less, but shall not be less than 100 psig. When the
May be applicable to some city and particularly well design pressure does not exceed 100 psig, non-ferrous
water. Have your water analyzed by a qualified water pipe may be used and the fittings may be bronze, cast
treatment specialist to determine if a water softener, iron, malleable iron, ductile iron, or steel. When the
conditioner or filtration is required. Treated water will design pressure exceeds 100 psig, fittings shall be steel
ensure longer tankless heater life and performance and the pipe shall be a minimum of schedule 80.
and is also beneficial to all the piping and fixtures in
the building.
8. FUEL SUPPLY PIPING
For information regarding gas supply line piping
schematic and sizing, drip leg, gas pressure regulator,
oil supply line piping schematic and sizing, oil pump,
and oil filter, please refer to the BURNER
INSTALLATION AND OPERATION MANUAL.

9. RELIEF VALVES
Boiler relief valves are normally shipped loose and
have been properly sized for your boiler. The aggregate
capacity of the relief valves (as stamped on the valve
rating plates), must meet or exceed the minimum
required relieving capacity as stamped on the boiler
rating plate.
Install the valve(s) in the fittings supplied on the top
of the boiler using appropriate pipe dope. In some cases,
reducing bushings are required to adapt the relief valve
inlet to the boiler fitting. When required, the bushings are
supplied by Burnham. Using the bushings is NOT a code
violation. Always install the relief valves in the vertical
position with no intervening valve.
Pipe the relief valve to a safe point of discharge, with
same pipe size as the valve outlet connection – never
reduce. The discharge piping shall be arranged as short
as possible, and properly supported to prevent stresses
on the relief valve. Never install a valve or plug on the
relief valve outlet piping.
A method of gravity drain must be employed in the
discharge pipe at or near each relief valve and where
condensate may collect. Where a vertical discharge pipe
is used, a drip pan elbow is highly recommended.
 INSTALLATION INSTRUCTIONS

FIGURE 3TS-71-127-B

FIGURE 4 TS-71-124-D
 INSTALLATION INSTRUCTIONS

FIGURE 5 TS-71-174-D
15
16
INSTALLATION INSTRUCTIONS

FIGURE 6
TS-71-175-D
 SECTION III — OPERATING INSTRUCTIONS
1. ALWAYS INSPECT INSTALLATION BEFORE
STARTING BURNER. LOS SISTEMAS DE AGUA CALIENTE NO DEBEN ESTAR
SUJETO A UNA PRESIÓN SUPERIOR 30 LIBRAS, A
2. FILL HEATING SYSTEM WITH WATER. MENOS QUE LA CALDERA ES ESPECIALMENTE
DISEÑADO PARA PRESIÓN MAYOR OPERACIÓN SI LA
LA PRESIÓN INTERNA DE LA CALDERA EXCEDE LA
Any time that raw water is introduced to the boiler PRESIÓN DEL PARÁMETRO DE LA VÁLVULA DE
it must be heated to at least 180ºF immediately to SEGURO, ESTE ÚLTIMO LANZARÁ PRESIÓN
dissipate the dissolved gases which can otherwise INMEDIATA, PERO LA CAUSA DE ESTA
cause internal corrosion to the boiler. DESCOMPRESIÓN DEBE SER EXAMINADA Y corregido.
LA PRESIÓN EXCESIVA ES PELIGROSO. ADEMÁS,
Cada vez que se introduce agua no tratada en la caldera, PODRÍA DAÑAR EL SISTEMA DE CALEFACCIÓN O
debe calentarse inmediatamente hasta 100 ° C (180 ° F) CAUSA LESIONES O DAÑOS MATERIALES GRAVES. NO
para disipar gases disueltos que de otro modo causarían extraiga agua de la caldera cuando Este está encendido.
corrosión interna. Si la caldera funciona, no no agregue agua abriendo
completamente la válvula de potencia; agregue el agua
lentamente.
A. Steam Boilers Fill boiler to normal water line.
Water should be visible in the gauge glass.
After boiler is in operation, make up water
should be added slowly to maintain the water
level. 3. BURNER
B. Hot Water Boilers In a hot water heating A. Check wiring of all fuel valves. Verify that wiring
system, the boiler and the entire system (other is correct according to the factory supplied wiring
than the tank) must be full of water for diagram.
satisfactory operation. Water should be added B. Leave all manual fuel valves closed. This includes
to the system until the boiler pressure gauge manual shutoff valves supplied with the boiler
registers normal system design operating and facility installed valves at the boiler site.
pressure. To ensure that the system is full, water C. Perform all burner pre-startup checks according
should come out of all air vents when opened. to the burner manufacturer's specifications. Refer
to the burner manufacturer's installation manual
furnished with the boiler.
ON A HOT WATER SYSTEM THE PRESSURE MUST NOT D. Turn boiler on and verify that fuel valves are
EXCEED 30 POUNDS UNLESS THE BOILER IS
closed during the burner pre-purge cycle. Turn
ESPECIALLY DESIGNED FOR A HIGHER MAXIMUM
WORKING PRESSURE. IF A BOILER PRESSURE
boiler off and disconnect power.
EXCEEDS PRESSURE SETTING OF SAFETY RELIEF E. Adjust burner according to the burner
VALVE, VALVE WILL RELIEVE IMMEDIATELY, BUT manufacturer's specifications. Target CO2 level
CAUSE OF RELIEF MUST BE INVESTIGATED AND is 13% for optimum efficiency, but a range of
CORRECTED. EXCESS PRESSURE IS DANGEROUS, IN 12.5-13.0% is acceptable.
ADDITION, COULD CAUSE DAMAGE TO HEATING
SYSTEM, PERSONAL INJURY OR SERIOUS PROPERTY 4. TEST CONTROLS
DAMAGE.
DO NOT draw water from the boiler while in use. When
adding water while boiler is in operation, do not open
Beforethe
installation of the
supply valve boiler
fully, butisadd
considered complete
water slowly.
the operation of the boiler controls should be checked,
particularly the low water cutoff and the high limit
control.

A. Check Operating Control Raise and lower Antes de que la instalación de la caldera se considere
operating control setting as required to start and completa, verifique el funcionamiento de sus
stop burner. dispositivos de control, en particular los interruptores
de bajo nivel de agua y el controlador de temperatura
B. Warning Check High Limit Control máxima.
Jumper Operating Control Terminals. Allow
level at normal waterline. Raise operating control
Burner to operate until shut down by limit.
setting to allow burner to operate. Open boiler drain to
Installation is not considered complete until this
allow water level to drop until burner operation is shut
check has been made. REMOVE JUMPER.
down by low water cutoff.
C. Check Low Water Cut-Off control with water
17
 A. Drain boiler until water is just visible in gauge
DO NOT ALLOW THE BOILER TO OPERATE BELOW glass. Run temporary pipe line from the surface
THE MINIMUM PERMISSIBLE WATER LEVEL AS blow-off to an open drain or some other
INDICATED ON THE BOILER. location where hot water may be discharged
safely.
NO DEJE FUNCIONAR LA CALDERA CUANDO EL NIVEL
Do not install valve in this line.
DE AGUA ES MENOR QUE EL UMBRAL INDICADO EN
LA CALDERA. Certain state and local codes may restrict
the use of some chemicals listed for cleaning
Close boiler drain and refill to normal water line. and maintaining the boiler. Check with local
Unless boiler is equipped with a manual reset low water authorities before proceeding with the use of
cutoff, burner should automatically restart during fill. any chemicals.
Reset operating control. B. Drain about 5 gallons of hot water from boiler into
a container and dissolve into it 1 pound o caustic
soda and one pound of trisodium phosphate
PROBE AND FLOAT TYPE LOW WATER CUT-OFF for each 50 gallons of boiler water. Additional
DEVICES REQUIRE ANNUAL INSPECTION AND containers may be required to dissolve sufficient
MAINTENANCE. Refer to Service Instructions, chemicals for large models. Remove safety valve
Section IV for proper cleaning instructions. and add solution to boiler water through exposed
LOS INTERRUPTORES DE TIPO DE SONDA Y FLOTADOR
tapping.
DE NIVEL BAJO DEBEN SER INSPECCIONADOS Y Use extreme care in handling these chemicals.
REPARADOS ANUALMENTE. sí mismo consulte las pautas Caustic soda is harmful to skin, clothing and
de mantenimiento en la sección IV para ver las pautas de
limpieza adecuadas.
eyes. Do not permit the dry material or the
concentrated solution to come into contact with
D. Check Operating Control on boiler equipped the skin or clothing.
with a tankless heater. With burner off, draw hot C. Close all valves leading to and from the
water until burner starts, then turn off hot water system to isolate the cleaning solution from
and check burner shut down. the system.
5. CLEANING A NEW STEAM BOILER D. Start Burner and operate sufficiently to boil the
Oil, grease & sediments which accumulate in a new water without producing steam pressure. Boil for
boiler and piping must be removed from the system in about 5 hours. Open boiler feed pipe sufficiently
order to prevent an unsteady water line and carryover of to permit a steady trickle of water from the
the water into the supply main above the boiler. Operate surface blowoff pipe. Continue this slow boiling
the boiler with steam in the entire system for a few days and trickle of overflow for several hours until the
allowing the condensate to return to the boiler. If the water coming from the overflow is clear.
condensate can temporarily be wasted, operate the E. Stop burner and drain boiler in a manner and
boiler only for the length of time it takes for condensate location that hot water can be discharged safety.
to run clear. If the latter cannot be achieved or if the F. When the boiler has cooled to 120°F or less refill
condensate is returned to the boiler, boil out the boiler boiler to normal water line. If water in gauge glass
using the SURFACE BLOWOFF connection on the does not appear to be clear, repeat steps A thru
boilers so equipped. E, boiling out the boiler for a longer time.
G. Remove temporary piping, plug tapping and/or
reinstall safety valve. Boil to bring water
temperature to 180ºF promptly in order to drive
off any dissolved gases in the fresh water.
6. CLEANING A WATER BOILER
The oil and grease which accumulate in a new hot
water boiler can be washed out in the following manner.
A. Remove safety relief valve using extreme care to
avoid damaging it.

18
 The general objectives of boiler water
treatment are:
Certain state and local codes may restrict the use of A. Remove corrosive gases from feedwater and
some chemicals listed for cleaning and maintaining the
boiler water.
boiler. Check with local authorities before proceeding
with the use of any chemicals. B. Prevent sludge and scale deposits on the water
side heating surfaces.
El uso de algunos de los productos químicos enumerados C. Prevent foaming and carryover.
para la limpieza y el servicio de la caldera puede estar
restringido por los códigos municipales o provinciales.
Debe consultar con las autoridades locales antes de
usar cualquier producto químico. Consult with a local water treatment company regularly
engaged in the treatment of boiler water for advice in
maintaining the proper feedwater, boiler water, and
B. Drain about 5 gallons of hot water from boiler condensate chemistry.
into a container and dissolve into it 1 pound of
caustic soda and one pound of trisodium
phosphate for each 50 gallons of boiler water. Para obtener consejos sobre cómo mantener una
composición química adecuada para el agua de
C. Add solution through exposed tapping, and alimentación, el agua de la caldera y el condensado,
reinstall safety valve. consulte al personal de una planta local de tratamiento de
D. Fill the entire system with water. agua que trata regularmente el agua de la caldera.

E. Start firing the boiler.

Certain state and local codes may restrict the use of
F. Circulate the water though the entire system. some chemicals listed for cleaning and maintaining
G. Vent the system, including the radiation. the boiler. Check with local authorities before
proceeding with the use of any chemicals.
H. Allow boiler water to reach operating
temperature, if possible. 9. MAKE PH OR ALKALINITY TEST
I. Continue to circulate the water for a few hours.
After boiler and system have been cleaned and
J. Stop firing the boiler. refilled as previously described, test the pH of the water
K. Drain the system in a manner and to a location in the system. This can easily be done by drawing a
that hot water can be discharged safely. small sample of boiler water and testing with hydrion
paper which is used in the same manner as litmus
L. When the boiler has cooled down to 120°F or
paper, except it gives exact readings. A small color chart
less, remove plugs from all available returns and
on the side of the hydrion dispenser gives the reading
wash the water side of the boiler as thoroughly as
in pH. Hydrion paper is inexpensive and obtainable
possible, using a high-pressure water stream.
from any chemical supply house or through your local
M. Refill the system with fresh water, and bring druggist. The pH should be higher than 8.3 but lower
water temperature to 180°F promptly in order to than 10.5. Add some washout chemical (caustic soda), if
drive off any dissolved gases. necessary, to bring the pH within the specified range.
7. WATER BOILER OPERATION 10. FREQUENT WATER ADDITION
The following guidelines relating to system water
temperature fluctuation and flow through boiler must be
observed. If, during normal operation, it is necessary to add water
more frequently than once a month, consult a qualified
A. It is important to operate your boiler in such a service technician to check your system for leaks.
manner as to prevent temperature fluctuation of
more than 40°F at any time. Rapid temperature Si necesita agregar agua más de una vez al mes a una
changes within the boiler can create stresses in caldera normal, consulte a un técnico de servicio
the boiler metal. These stresses can cause calificado para verificar si hay fugas en su sistema.
damage to the boiler by loosening tubes, or in
more severe instances can crack tube sheet
A leaky system will increase the volume of make-up
ligaments, furnaces, or waterlegs.
water supplied to the boiler which can significantly
B. It is equally important to insure that there is shorten the life of the boiler. Entrained in make-up water
circulation through the boiler of at least 1/2 GPM/ are dissolved minerals and oxygen. When the fresh,
BHP at all times when the boiler is firing. cool make-up water is heated in the boiler the minerals
8. BOILER WATER TREATMENT
Boiler water treatment will help maximize the
effectiveness and prolong the life of pressure
vessels.
fall out as sediment and the oxygen escapes as a gas. In order to ensure long product life, oxygen sources
Both can result in reduced boiler life. The accumulation should be eliminated. This can be accomplished by
of sediment can eventually isolate the water from taking the following measures:
contacting the cast iron. When this happens the cast
A. Repairing system leaks to eliminate the need for
iron in that area gets extremely hot and eventually
addition of make-up water.
cracks. The presence of free oxygen in the boiler
creates a corrosive atmosphere which, if the B. Eliminating open tanks from the system.
concentration becomes high enough, can corrode the C. Eliminating and/or repairing fittings which allow
cast iron through from the waterside. Since neither of oxygen absorption.
these failure types are the result of a casting defect the D. Use of non-permeable materials in the
warranty does not apply. Clearly it is in everyone’s best distribution system.
interest to prevent this type of failure. The maintenance E. Isolating the boiler from the system water by
of system integrity is the best method to achieve less installing a heat exchanger.
makeup water.

Oxygen contamination of the boiler water will cause

corrosion of iron and steel boiler components, and can
lead to boiler failure. Burnham’s standard warranty does
not cover problems caused by oxygen contamination of
boiler water or scale (lime) build-up caused by frequent
water addition or by improper water chemistry as shown
below.

La contaminación del agua de la caldera con oxígeno

provoca la corrosión de los componentes de hierro y
acero, y puede provocar fallas. La garantía estándar de
Burnham no cubre los problemas causados por la
contaminación del agua de la caldera con oxígeno o la
acumulación de incrustaciones (incrustaciones de cal)
que resultan de la adición frecuente de agua o una
composición química. inadecuado como se ilustra a
continuación.

Minimum Water Quality Requirements

pH - 8.3 - 10.5
TDS - 3500 ppm
Total alkalinity ppm as CaCO3 - 1200
Total copper ppm - .05
Oily matter ppm -1
total harness ppm -3 Chlorides - < 50 ppm

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.
D. Suction at pump and valve seals.
 SECTION IV — SERVICE INSTRUCTIONS
G. When boiler and water are below 120°F, shut off
power to the unit and lock out the circuit
See item 10 under Operating Instruction if it becomes breakers.
necessary to add water to the boiler more frequently
H. If required, open front and rear doors for
than once a month.
observation of fireside surfaces.
Consulte la sección 10 en la sección de I. Drain boiler down as far as required. (Usually
Instrucciones de funcionamiento si es necesario completely.) Make sure the vent valve on the top
rellenar la caldera más de una vez al mes. of the boiler remains open. Open and lock the
float control low water cutoff drain valves. These
1. GENERAL will serve as additional vents.
Inspection should be conducted annually. Service J. Shut and lock the boiler feed valves, and any
as frequently as specified in paragraphs below. Before blowdown valves that can be affected by other
service or maintenance is performed complete boiler boilers in the same facility (i.e., bottom blow down
shutdown/cooldown procedure. valves can tie into a common blowdown
separator in a multiple boiler installation).
2. BOILER SHUT DOWN AND K. If necessary to remove handhole and/or manhole
COOLDOWN PROCEDURE plates for water side inspection or maintenance,
NOTE: This procedure is generally required in use extreme caution. Loosen the nuts securing
preparation for corrective or preventative maintenance the arch enough to allow the plate to drop
in the unit. This procedure must be supervised by an approximately 1/8 inch when tapped loose with
individual who is thoroughly qualified in operation and a mallet. Once again, ensure the pressure in the
maintenance of the equipment at hand. This is written boiler is “0” before loosening the plate. Remove
with Steam Boilers in mind, but the principles are the plate the remainder of the way. Wear gloves
applicable to Hot Water Boilers as well. and eye protection at all times.
A. Decrease plant load as much as possible.
3. CLEAN THE BOILER HEATING
B. Turn boiler switch off. If control power from SURFACES AND FLUE
burner is used to support accessories, leave on
until boiler system has cooled down. At least once each year, preferably at the end of the
heating season.
C. Shut and lock manual gas and oil valves as
applicable. A. Clean the Vent System
D. In single boiler installations, some small steam loads Vent system should be checked annually for:
can remain on to assist in a controlled cooldown of the 1. Obstructions.
boiler (i.e., deaerator). In multiple boiler installations,
2. Accumulations of soot.
shut down the non-return valve and the back up valve.
Lock them shut. 3. Deterioration of vent pipe or vent accessories
due to condensation or other reasons.
E. Allow the boiler feed pump to remain active. As the
boiler cools down, the water level is reduced by 4. Proper support no sags, particularly in
demand or shrinkage. It is best to be aware of the horizontal runs.
boiler level at all times. 5. Tightness of joints.
F. When boiler pressure has decreased to 5 to 10 psi
Remove all accumulations of soot with a wire
on the pressure gauge, open the boiler manual
brush and vacuum. Remove all obstructions. Replace
vent valve on the top of the boiler. This is to act as
deteriorated parts and support properly. Seal all joints.
a sentinel against the increase in
pressure and to prevent the boiler from going into B. Clean the Boiler Heating Surfaces
a vacuum. Lock the valve open. At the end of the heating season, clean boiler
NOTE: Depending on the size of the boiler, the large heating surfaces thoroughly. Access to boiler
mass of heating surfaces that are still hot can cause the firetubes may be gained by removing the front
boiler water temperature to increase, even if the gauge and rear smokeboxes or smokebox doors.
pressure is “0”. It is better to allow the entire system to Where applicable, remove the turbulators, paying
cool gradually, never force cool the boiler as damage close attention to which tubes have turbulators.
can also be inflicted due to “thermal shock.”
Clean firetubes with flue brush and reinstall turbulators. If turbulators are corroded or deteriorated,
 replacing them will ensure a high level of boiler 5. MAINTENANCE OF LOW WATER CUTOFF
efficiency. Remove soot and rust and reseal the DEVICES
boiler.
Turbulator location and quantities are shown
below. Access to turbulator replacement is
from the front smokebox. Turbulators should Los interruptores de bajo nivel de tipo sonda o flotador
be installed and removed from the front of the deben inspeccionarse y mantenerse anualmente.
boiler only.
Probe and float type low water cutoff devices require
Series 3: Turbulators are only used in sizes 40, 50, annual inspection and maintenance.
and 60hp. There are (24) in the second pass and
(26) in the third pass. See diagram below. A. Probe Type Low Water Cut Off Although these
devices are solid state in design, the probe is
exposed to possible contamination in the boiler
water.
It is important to physically remove the probe
from the boiler tapping annually and inspect it for
accumulation of scale or sediment.
Following these steps inspect, clean and/or
replace the probe:
1. Turn off electric service to the boiler.
2. Drain boiler water to a level below the tapping
for the probe.
3. Disconnect the wiring connections between
the low water cutoff and the probe.
4. Dismount the low water cutoff control from the
probe.
TURBULATOR LOCATIONS 5. Unscrew the probe from the boiler tapping.
Tubes with asterisks require turbulators 6. Inspect that portion of the probe that is
4. BOTTOM BLOWDOWN PROCEDURE exposed to the boiler water for scale or
Burnham high pressure steam boilers are equipped sediment buildup.
with two bottom blowdown connections. Bottom 7. Light deposits may be removed by wiping the
blowdown should be done while the boilers are under probe with a damp cloth. Wiping the probe
pressure, with the burner off or at low fire. There should with a cloth soaked in vinegar will remove
be two quick-opening valves and one downstream more tenacious lime deposits. The most
slow-opening valve. Open the slow-opening valve first. stubborn deposits may be removed from the
Slowly open the front quick-opening valve to warm up probe by using diluted amount (3 part of water
the piping and blowdown separator. Open the valve for to 1 part) of phosphoric acid (H2PO4).
a few seconds with a quick blast to flush out sludge and
sediment from the bottom of the boiler. Do not lower the
boiler water level by more than ½". Close the valve, then
repeat for the rear quick-opening valve. Close the slow- Tenga cuidado al manipular ácido fosfórico y siga
opening valve. Make sure all valves are closed. A water las instrucciones en la etiqueta del envase.
treatment consultant can recommend an appropriate
manual blowdown schedule, but is generally done once Exercise caution when handling phosphoric acid and
per shift. follow the instruction label on its container.

Water columns should be blown down once per shift to

keep the internal parts of the pump control and low water 8. Wire brushing of the probe is not
cutoff free from sediment. If the boiler is equipped with a recommended.
“water column bypass” switch, depress the switch while 9. Clean the pipe threads of the probe to remove
performing the blowdown. Close the valve and release old, hardened pipe dope and other foreign
the switch. matter.
10. Apply a moderate amount of good quality pipe
dope to the pipe threads on the probe, leaving
the first two threads bare. Do not use PTFE
(Teflon) tape.
11. Screw the probe into the boiler tapping. 12. Mount the low water cutoff control on
 the probe. The following Surface Blowoff connections are
13. Reconnect the control to probe wiring. provided as standard:
14. Fill the boiler to its normal waterline. A. Series 3: (1) fitting each, right and left sides of
15. Add boiler water treatment compound as the boiler.
needed (see Section III Item 8).
B. The amount and frequency of surface blowoff is
16. Restore electric service to boiler. based on the amount of TDS you are targeting,
17. Fire burner to raise water temperature to the amount of make-up water, and the amount
above 180°F to drive off free oxygen. of TDS in the make-up water. The following is an
example for a 250hp steam boiler:
1. Approximate evaporating rate at full capacity:
BEFORE RETURNING BOILER TO SERVICE: Follow the 250 bhp x 34.5 = 8625 lb/hr
low water cutoff check out procedure in Section III Item
4 Part C. 2. Make-up water (i.e. 20%): 1725 lb/hr
3. TDS of make-up water (i.e.): 400 ppm
ANTES DE DEVOLVER LA CALDERA POR UN
MANTENIMIENTO: Siga el procedimiento para 4. Max TDS recommended in the boiler water:
verificar el dispositivo de corte de combustible en 3500 ppm
caso de poca agua en la sección III, artículo 4, parte
C. 5. Reduction factor: 3500/400 = 8.75
6. Surface blowoff rate: 1725 / 8.75 = 197 lb/hr x
B. Float Type Low Water Cut-Off During the hr/60 min x gal/8.34 lb = .4 gpm
heating season, if external low water cutoff is
on the boiler, the blow off valve should be In this example .4 gpm would be the continuous
opened once a month (use greater frequency blowdown rate to keep the boiler water TDS at 3500
where conditions warrant), to flush out the ppm. This is a good starting point and may need fine
sediment chamber so the device will be free to adjustment during actual operation.
function properly.
7. CHECK BURNER AND CONTROLS at
Low water cutoffs and water feeders should be least once a year. See Item 4 under
dismantled annually by qualified personnel, to the Operating
extent necessary to insure freedom from obstructions Instructions for control checks. See Burner Manual for
and proper functioning of the working parts. Inspect burner tests and adjustments.
connecting lines to boiler for accumulation of mud,
scale, etc., and clean as required. Examine all visible 8. LUBRICATE BOILER COMPONENTS
wiring according to manufacturer’s instructions.
for brittle or worn insulation and make sure electrical Generally, this
contacts are clean and that they function properly. Give involves burner and circulator.
special attention to solder joints on bellows and float
9. CHECK SAFETY VALVE at the start of each
when this type of control is used. Check the float for
heating season and once or twice during the season
evidence of collapse and check mercury bulb (where
to be sure it is in working condition. To do this, fasten
applicable) for mercury separation or discoloration.
wire or cord to the lever of the valve and pull the lever
DO NOT ATTEMPT TO REPAIR MECHANISM IN THE
standing a safe distance away from the valve.
FIELD. Complete replacement mechanisms, including
necessary gaskets and installation instructions, are 10. ATTENTION TO THE BOILER WHILE NOT
available from the manufacturer. IN OPERATION.
6 SURFACE BLOWDOWN PROCEDURE
The purpose of the Surface Blowoff connection is to
provide a means to remove impurities that collect near If a boiler is not used during the winter months, and it is in a
the surface of the water level on steam boilers, and to place subject to freezing, it must be fully drained to prevent
freezing damage.
bleed off a small portion of the boiler water to lower the
level of TDS (total dissolved solids). This will decrease
Si una caldera se apaga durante el invierno en un lugar
boiler foaming and improve steam quality.
donde es probable que la temperatura caiga por debajo
del punto de congelación, debe ventilarse por completo
para evitar daños por congelación.
 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. Water Boilers Since a water boiler is a
closed system, no draining/refilling should be
necessary.
C. Note any time raw water is introduced into the
boiler it must be immediately heated to 180°F
to drive off dissolved gases. If water treatment
is used, sufficient water treatment compound
should be added to condition the make-up
water.
11. REPAIR PARTS
Give boilers series and model number when
ordering repair parts. All repair parts can be ordered
through your local representative or call us at
888-791-3790.
 PERIODIC TESTING RECOMMENDED CHECK LIST

ITEM FREQUENCY ACCOMPLISHED BY REMARKS

Gauges, monitors, Daily Operator Make visual inspection
and indicators and record readings in
log
Instrument and Daily Operator Make visual check against
equipment settings recommended
specifications
Firing rate control Weekly Operator Verify factory settings
Semi- Service Technician Verify factory settings
annually Service Technician Check with combustion
Annually test
Igniter Weekly Operator Make visual inspection,
check flame signal strength,
if on display (see
"combustion safety controls)

Fuel Valves
Pilot and Weekly Operator Open limit switch - make
Main aural
and visual check - check
valve position indicators
and check fuel meters if so
fitted
Pilot and Annually Service Technician Perform leakage tests - refer
Main Gas or to burner instructions
Oil
Combustion Safety
Controls Flame Failure Weekly Operator If flame display installed, read
and log; for both pilot and
main flames, notify service
organization if readings are
very high, very low or
fluctuating; refer to burner
instructions.

Flame Signal Strength Weekly Operator If flame display installed, read

and log; for both pilot and
main flames, notify service
organization if readings are
very high, very low, or
fluctuating; refer to burner
instructions.
Pilot Turndown Tests As Service Technician Required after any
required/ adjustments to flame
Annually scanner mount or pilot
burner; verify annually - refer
to burner instructions
Low Water Fuel Daily/Weekly Operator Refer to control instructions
Cutoff and Alarm Semi-annually Operator Perform a slow drain test in
accordance with ASME Boiler
and Pressure Vessel Code
Section VI

High Limit Safety Control Annually Service Technician Refer to control instructions

Operating Control Annually Service Technician Refer to control instructions

Air Proving Switch Monthly Operator Refer to burner instructions
PERIODIC TESTING RECOMMENDED CHECK LIST

ITEM FREQUENCY ACCOMPLISHED BY REMARKS

Atomizing Air/Steam Annually Service Technician Refer to burner instructions

High and Low Monthly Operator Refer to burner instructions

Gas Pressure
Interlocks
High and Low Oil Monthly Operator Refer to burner instructions
Pressure
Interlocks
High and Low Oil Monthly Operator Refer to burner instructions
Temperature Interlocks

Fuel Valve Interlock Annually Service Technician Refer to burner instruction

Switch

Purge Switch Annually Service Technician Refer to burner instructions

Burner Position Interlock Annually Service Technician Refer to burner instructions

Low Fire Start Interlock Annually Service Technician Refer to burner instructions

Automatic At Least Service Technician Under supervision of gas

Changeover Control Annually utility
(dual fuel)
Safety Valves As required Operator In accordance with procedure
in Section VI, ASME Boiler
and Pressure Vessel Code,
Recommended Rules for
Care and Operation of
Heating Boilers or Section VII
for power boilers.

Inspect Burner Semi-annually Service Technician Refer to burner instructions

Components
Boiler Hydro-Test Annually Service Technician Performed as required, in
accordance with NBIC Part
2, not to exceed 90% of
relief valve setting.
 Commercial Boilers

LIMITED WARRANTY
LIMITED WARRANTY
Subject to the terms and conditions herein, Seller warrants
E. The suitability of any Product for any particular
to the original owner at the original installation site that
application.
products manufactured by Seller (“Products”) comply,
at the time of manufacture, with recognized hydronics
F. Any failure resulting from misuse, modification, not
industry regulatory agency standards and requirements
authorized by Seller in writing, improper installation
therein effect and will be free from defects in materials and
or lack of proper maintenance.
workmanship for a period of 12 months after the date of
start-up or 18 months after the date of shipment,
G. Equipment furnished by the owner, either mounted or
whichever shall be less (the “Warranty Period”)
unmounted, or when contracted for by owner to be
installed or handled.
REMEDY
A. The sole remedy for breach of this warranty is
Seller’s liability under this warranty shall not in any case
expressly limited to the repair or replacement of any
exceed the amount paid for the Product found defective.
part found to be defective under conditions of normal
use within the Warranty Period. Installation is not
THIRD-PARTY WARRANTIES
included.
For goods or components not manufactured by Seller, the
warranty obligations of Seller shall, in all respects, conform
B. Warranty The owner must notify the original installer
and be limited to the warranty actually extended to Seller by
of the Product and Seller (Attention: Burnham
its vendors.
Commercial, PO Box 3939, Lancaster, PA 17604) in
writing, within the Warranty Period, providing a
SEVERABILITY
detailed description of all claimed defects.
To the extent that any provisions of this warranty would be
Transportation to a factory or other designated facility
void or prohibited under applicable law, such provisions
for repairs of any products or items alleged defective
shall be limited in effect to the minimum extent necessary to
shall, in all events, be the responsibility and at the
render the remaining provisions hereof enforceable.
cost of the owner.

NO OTHER WARRANTIES
EXCLUSIONS
Seller makes no implied warranty of merchantability or
Seller shall have no liability for:
fitness for a particular purpose, or other warranties with
A. Incidental, special or consequential damages, such as
respect to any products or services except as expressly set
loss of the use of products, facilities or production,
forth in this limited warranty.
inconvenience, loss of time or labor expense involved
in the repairing or replacing of the alleged defective
Product.

B. The performance of any Product under conditions

varying materially from those under such Products is
usually tested under industry standards as of the
shipment time.

C. Any damage to the Product due to abrasion, erosion,

corrosion, deterioration, abnormal temperatures or the
influence of foreign matter or energy. Form No. 81460433 - 3/19
Printed in the U.S.A.
D. The design or operation of owner’s plant or equipment Lancaster, PA 17601
or of any facility or system of which any Product may Phone: 888-791-3790
be made a part. www.burnhamcommercial.com

28
 provide flame stability will be less efficient.
Combustion efficiency does not
take into account heat loss to the surrounding air
through the boiler
jacket and piping

Fuel-to-Steam Efficiency
Sometimes referred to as overall efficiency. This is a
ratio of heat output to heat input. This includes
boiler jacket and piping losses to the surrounding
environment. It is the percent of usable heat in the
steam (or hot water) compared to the heat input
supplied by the burner. It is also defined as the
combustion efficiency less boiler jacket and piping
loss (radiation and convection losses). Since fuel-to-
steam
efficiency reflects the portion of actual usable heat
supplied to the system, it is most useful when
Highlights comparing performance of similar equipment, or
 Low or High Pressure Steam or Water when doing fuel savings analysis.
 Highly Efficient Three-Pass Design
 Fully Waterbacked Primary Heating Surfaces
 Separate Rear Tube Sheets for Longer Service Life
 Wetback Design Allows Easy Front and Rear Access
 Made in the USA
 No Expensive Refractory or Door Replacement as with
Some Drybacks

Benefits
 Forced-Draft Firing with Oil (No. 2,4,5, or 6), Gas, or
Combination Gas/Oil
 Low or High Pressure Steam or Water
 High Efficiency Three-Pass Design
 Fully Water-Backed Primary Heating Surfaces for
Increased Efficiency
 Separate Rear-Tube Sheets for Longer Service Life
 Easy Front and Rear Access for Ease of Maintenance
 ASME Code Construction

Thermal Efficiency
The effectiveness of the boiler as a heat
exchanger. It is the ability of the boiler to
exchange heat through tubes and furnace, by
radiation, conduction and convection, to the
transfer medium (water). A few of the factors
affecting thermal efficiency are heating
surface, tuve number and diameter, furnace
tube length and diameter.

Combustion Efficiency
This is a measure of the ability of the burner
to effectively and
completely burn the fuel, coupled with the
thermal efficiency of the boiler. Burners
requiring high amounts of excess air to