Burnham 5B Series User manual

1
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8141302R15 - 12/12 PRice - $5.00
Commercial Boilers
www.burnhamcommercial.com
3050579

2
BOILER SIZE
5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B
(1)
LEH 1111111111111111111
(1)
REH 1111111111111111111
(1)
C 45678891011 12 13 14 15 16 16 17 18 19 21
(2)
CX --- --- --- --- --- --- --- --- --- 1 1 1 1 1 1 2 2 3 3
(3)
CXP --- --- --- --- --- 1 1 1 1 --- --- --- --- --- 1 --- --- --- ---
(1) Section Marking Cast on Section
(2) “C” Cast on Section - When supply and return connections are tapped, section is paint stencilled “CX”
(3) “C” Cast on Section - When supply and return connections are tapped and plugged, section is paint stencilled “CXP”
CARTONS, PACKAGES, OR BUNDLES
1Base-Burner-Manifold Assembly (By Gas and By Pilot System) - One Left & One Right Req’d on 5015B and Larger Boilers
COMPLETE 1
6
1
7
1
8
1
9
1
10
1
11
1
12
1
13
1
14 --- --- --- --- --- --- --- --- ---
L. SUB-BASE --- --- --- --- --- --- --- --- ---
L
1S
15
L
1S
16
L
1S
17
L
1S
18
L
1S
19
L
1S
20
L
1S
21
L
1S
22
L
1S
24
L
1S
26
R. SUB-BASE --- --- --- --- --- --- --- --- ---
R
1S
8
R
1S
9
R
1S
9
R
1S
10
R
1S
10
R
1S
10
R
1S
10
R
1S
10
R
1S
13
R
1S
13
2Tie Rod Bundle(s) 4 Sizes - One to Five Per Boiler
22” --- --- 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
27” --- --- 1 2 1 --- --- --- 2 1 --- --- --- --- 1 --- --- --- 2
37” 1 --- --- --- 1 2 1 --- 1 2 3 2 1 --- 3 4 3 1 ---
42” --- 1 --- --- --- --- 1 2 --- --- -- 1 2 3 --- --- 1 3 3
2 A Draw-up Rod Bundle(s) 3 Sizes - One to Three Per Boiler
37¾” --- --- --- --- --- 2 2 1 1 --- --- --- --- --- --- --- --- --- ---
49¼” 1 1 --- --- --- --- --- 1 1 2 2 1 1 1 --- --- --- 3 2
67¼” --- --- 1 1 1 --- --- --- --- --- --- 1 1 1 2 2 2 --- 1
3 A Boiler Assembly Carton(s) 6 Sizes - One to Five Per Boiler
3A6 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- ---
3A7 --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- ---
3A8 --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- --- 1
3A9 --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- 1 1
3A10 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- ---
3AM --- --- --- --- --- 1 1 1 1 1 2 2 2 2 2 3 3 3 3
4Boiler Sealing Carton(s) 5 Sizes - One to Three Per Boiler
06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 --- 1 --- ---
07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 2 --- --- ---
08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 ---
09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- 2 2 2
10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 --- --- 1
5Integral Drafhood Carton(s) 5 Sizes - One to Four Per Boiler (Natural & LP)
06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 1 --- 1 ---
07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 2 3 3
08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- --- 1
09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- --- --- ---
10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 1 --- ---
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.
  Byopeningcartonsinnumericalsequence,boilerassemblyissimplied.Ifthereisanexception,itwillbepointedoutintheboiler
assemblyprocedure.Whenitdoesoccur,youwillndthatassemblyoftheboilerisfurthersimplied.

3
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
7 S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler
1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
2 --- --- --- 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---
3 --- --- --- --- --- --- 1 1 1 1 1 1 1 1 1 --- --- --- ---
4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1 1 1
67 BC-2 Low Water Cut-off Carton (Steam Boilers Only) One Per Boiler
1111111111111111111
7 W Water Trim Carton (Water Boilers Only - Includes L4006A Temp. Limit Control) 3 Sizes - One Per Boiler
2 1 1 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---
3 --- --- --- --- --- -- 1 1 1 1 1 1 1 1 1 1 1 --- ---
4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1
64 Low Water Cut-off Carton (Water Boilers Only) One Per Boiler
1111111111111111111
U
8 Complete Jacket Carton Assembly - One Per Boiler
9Gas Train Cartons (By Gas) 2 Sizes - One or Two Per Boiler
9
1 1* 1* 1* --- --- --- --- --- --- 2 1 --- --- --- --- --- --- --- ---
9
2 --- --- --- 1* 1 1 1 1 1 --- 1 2 2 2 2 2 2 2 2
9
3 EI 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
EI Controls Carton(s) (By Gas) (Intermittent Elec. Ign. - 100% Shutoff - 24V.) 1 Size - One or Two Per Boiler
EI
1 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
EI
2------------111112222222222
U
HCP
1
Plain Heater Cover Plate (Not furnished on Water Boiler Ordered With Two Tankless Heaters) One Per Boiler
1111111111111111111
U
HCP
2
Tapped (¾” NPT) Heater Cover Plate (Not Furnished on Water Boiler Ordered With Tankless Heater(s) One Per Boiler
1111111111111111111
U.S.A. EQUIPMENT CHECK LIST
INSPECT SHIPMENT carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed.
Our responsibility ceases upon delivery of Boiler to carrier in good condition. Any claims for damage or shortage in
shipmentmustbeledimmediatelyagainstthecarrierbytheconsignee.Noclaimsforvariancesorshortageswillbe
allowedbyBoilerManufacturer,unlesspresentedwithinsixty(60)daysafterreceiptofequipment.
*Carton 91, or 92onsizes5006Bthru5009BisstandardonallsystemsexceptEIandmaybeoptionalon5006Bthru
 5009BEI.
Carton 93isstandardonsizes5006Bthru5009BforEIsystems.
This Series 5B Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters:
 ApprovalNo.G1-0202-11A.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.
IMPORTANT INFORMATION
SERVICE ON THIS BOILER SHOULD BE UNDERTAKEN ONLY BY TRAINED AND SKILLED PERSONNEL.
KEEP BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER
FLAMMABLE VAPORS AND LIQUIDS.
DO NOT PLACE ANY OBSTRUCTION IN THE BOILER ROOM THAT WILL HINDER THE FLOW OF
COMBUSTION AND VENTILATING AIR.
READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF
BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICEMAN.
MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION.
SECTION I – EQUIPMENT CHECK LIST (continued)

4
BOILER SIZE
5006B 5007B 5008B 5009B 5010B 5011B 5012B 5013B 5014B 5015B 5016B 5017B 5018B 5019B 5020B 5021B 5022B 5024B 5026B
(1)
LEH 1111111111111111111
(1)
REH 1111111111111111111
(1)
C 45678891011 12 13 14 15 16 16 17 18 19 21
(2)
CX --- --- --- --- --- --- --- --- --- 1 1 1 1 1 1 2 2 3 3
(3)
CXP --- --- --- --- --- 1 1 1 1 --- --- --- --- --- 1 --- --- --- ---
(1) Section Marking Cast on Section
(2) “C” Cast on Section - When supply and return connections are tapped, section is paint stencilled “CX”
(3) “C” Cast on Section - When supply and return connections are tapped and plugged, section is paint stencilled “CXP”
CARTONS, PACKAGES, OR BUNDLES
1Base-Burner-Manifold Assembly (By Gas and By Pilot System) - One Left & One Right Req’d on 5015B and Larger Boilers
COMPLETE 1
6
1
7
1
8
1
9
1
10
1
11
1
12
1
13
1
14 --- --- --- --- --- --- --- --- --- ---
L. SUB-BASE --- --- --- --- --- --- --- --- ---
L
1S
15
L
1S
16
L
1S
17
L
1S
18
L
1S
19
L
1S
20
L
1S
21
L
1S
22
L
1S
24
L
1S
26
R. SUB-BASE --- --- --- --- --- --- --- --- ---
R
1S
8
R
1S
9
R
1S
9
R
1S
10
R
1S
10
R
1S
10
R
1S
10
R
1S
10
R
1S
13
R
1S
13
2Tie Rod Bundle(s) 4 Sizes - One to Five Per Boiler
22” --- --- 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
27” --- --- 1 2 1 --- --- --- 2 1 --- --- --- --- 1 --- --- --- 2
37” 1 --- --- --- 1 2 1 --- 1 2 3 2 1 --- 3 4 3 1 ---
42” --- 1 --- --- --- --- 1 2 --- --- -- 1 2 3 --- --- 1 3 3
2 A Draw-up Rod Bundle(s) 3 Sizes - One to Three Per Boiler
37¾” --- --- --- --- --- 2 2 1 1 --- --- --- --- --- --- --- --- --- ---
49¼” 1 1 --- --- --- --- --- 1 1 2 2 1 1 1 --- --- --- 3 2
67¼” --- --- 1 1 1 --- --- --- --- --- --- 1 1 1 2 2 2 --- 1
3 A Boiler Assembly Carton(s) 6 Sizes - One to Five Per Boiler
3A6 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- ---
3A7 --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- ---
3A8 --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- --- 1
3A9 --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- 1 1
3A10 --- --- --- --- 1 --- --- --- --- 1 --- --- --- --- 1 --- --- --- ---
3AM --- --- --- --- --- 1 1 1 1 1 2 2 2 2 2 3 3 3 3
4Boiler Sealing Carton(s) 5 Sizes - One to Three Per Boiler
06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 --- 1 --- ---
07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 2 --- --- ---
08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 2
09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- 2 2 1
10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 --- --- ---
5Integral Drafhood Carton(s) 5 Sizes - One to Four Per Boiler
06 1 --- --- --- --- 2 1 --- --- --- --- --- --- --- 2 1 --- 1 ---
07 --- 1 --- --- --- --- 1 2 1 --- --- --- --- --- --- 1 2 3 3
08 --- --- 1 --- --- --- --- --- 1 2 1 --- --- --- --- --- --- --- ---
09 --- --- --- 1 --- --- --- --- --- --- 1 2 1 --- --- --- --- --- ---
10 --- --- --- --- 1 --- --- --- --- --- --- --- 1 2 1 1 1 --- ---
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simplied.Ifthereisanexception,itwillbepointedoutinthe
boilerassemblyprocedure.Whenitdoesoccur,youwillndthatassemblyoftheboilerisfurthersimplied.
SECTION I – EQUIPMENT CHECK LIST (continued)

5
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
7 S Steam Trim Carton (Steam Boilers Only - Includes PA404 Pressure Limit Control) 4 Sizes - One Per Boiler
1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
2 --- --- --- 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---
3 --- --- --- --- --- --- 1 1 1 1 1 1 1 1 1 --- --- --- ---
4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1 1 1
67 BC-2 Low Water Cut-off Carton (Steam Boilers Only) One Per Boiler
1111111111111111111
7 W Water Trim Carton (Water Boilers Only - Includes L4006A Temp. Limit Control) 3 Sizes - One Per Boiler
2 1 1 1 1 1 1 --- --- --- --- --- --- --- --- --- --- --- --- ---
3 --- --- --- --- --- -- 1 1 1 1 1 1 1 1 1 1 1 1 1
4 --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- 1 1
64 Low Water Cut-off Carton (Water Boilers Only) One Per Boiler
1111111111111111111
U
8 Complete Jacket Carton Assembly - One Per Boiler
c
9
1
Gas Train Cartons (By Gas) 2 Sizes - One or Two Per Boiler
c
9
1
1 1 1 --- --- --- --- --- --- 2 1 --- --- --- --- --- --- --- ---
c
9
2
--- --- --- 1 1 1 1 1 1 --- 1 2 2 2 2 2 2 2 2
THERM. Controls Carton(s) (Manual Ignition. - 100% Shutoff - 24V.) 1 Size - One or Two Per Boiler
Natural 11111111---222222222---
OP Controls Carton(s) (By Gas) (Manual Ign. - 100% Shutoff - 24V. - Nat. - 120V. LP) 1 Size - One or Two Per Boiler
Natural --- --- --- --- --- --- --- --- 1 --- --- --- --- --- --- --- --- -- 2
Propane 1111111112222222222
U
HCP
1
Plain Heater Cover Plate (Not furnished on Water Boiler Ordered With Two Tankless Heaters) One Per Boiler
1111111111111111111
U
HCP
2
Tapped (¾” NPT) Heater Cover Plate (Not Furnished on Water Boiler Ordered With Tankless Heater(s) One Per Boiler
1111111111111111111
CANADIAN
EQUIPMENT CHECK LIST
INSPECT SHIPMENT carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed.
Our responsibility ceases upon delivery of Boiler to carrier in good condition. Any claims for damage or shortage in
shipmentmustbeledimmediatelyagainstthecarrierbytheconsignee.Noclaimsforvariancesorshortageswillbe
allowedbyBoilerManufacturer,unlesspresentedwithinsixty(60)daysafterreceiptofequipment.
SECTION I - EQUIPMENT CHECK LIST - Page 2
SECTION II - GENERAL INFORMATION - Page 7
SECTION III - INSTALLATION INSTRUCTIONS - Page 8
SECTION IV - OPERATION - Page 41
SECTIONV-SERVICE-Page65
SERVICE RECORDS - Page 72
SECTION VI - REPAIR PARTS - Page 73
APPENDIXA-FIGURES-Page105
APPENDIXB-TABLES-Page108
SECTION I – EQUIPMENT CHECK LIST (continued)

6
FIG. 1
DIMENSIONAL DATA
Boiler
Size
Jacket
Overall
Length
‘A’
Drafthood Height, Size and Location
Top Supply
and Rear Return
Location
Supply
Conn.
Qty &
Size
Return Conn.
Qty. & Size
Gas Conn.
Size Nat. &
Propane
No. & Dia. of
Flue Outlets
Approx.
Shipping
Weight
(LB.)
‘B’
Dia.
‘C’
Dia.
‘D’
Dia.
‘E’
Dia. ‘F’ ‘G’ ‘H’ ‘J’ ‘K’ ‘M’ ‘N’
5006B 34 9 --- --- --- --- --- --- 17 19-3/4 --- --- (2) 3 (2) 3 1 (1) 9 1160
5007B 39-3/8 10 --- --- --- --- --- --- 19-3/4 32-1/4 --- --- (2) 3 (2) 3 1 (1) 10 1340
5008B 44-3/4 12 --- --- --- --- --- --- 22-3/8 38-3/8 --- --- (2) 3 (2) 3 1 (1) 12 1525
5009B 50-1/4 12 --- --- --- --- --- --- 25-1/8 43-3/4 --- --- (2) 3 (2) 3 1-1/4** (1) 12 1720
5010B 55-3/4 12 --- --- --- --- --- --- 27-7/8 49-1/4 --- --- (2) 3 (2) 3 1-1/4 (1) 12 1895
5011B 61-1/8 9 9 --- --- 27-1/4 --- --- 17 54-3/4 --- --- (2) 3 (2) 3 1-1/4 (2) 9 2085
5012B 66-1/2 9 10 --- --- 29-7/8 --- --- 19-3/4 60-1/8 --- --- (2) 3 (2) 3 1-1/4 (1) 9, (1) 10 2280
5013B 72 10 10 --- --- 32-5/8 --- --- 19-3/4 65-1/2 --- --- (2) 3 (2) 3 1-1/4 (2) 10 2460
5014B 77-1/2 10 12 --- --- 35-3/8 --- --- 22-3/8 71 --- --- (2) 3 (2) 3 1-1/4 (1) 10, (1) 12 2640
5015B 82-7/8 12 12 --- --- 38 --- --- 22-3/8 38-1/4 38-1/4 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1* (2) 12 2870
5016B 88-1/4 12 12 --- --- 40-3/4 --- --- 25-1/8 38-1/4 43-5/8 --- (3) 3 (2) 3, (1) 2-1/2 (1) 1, (1) 1-1/4* (2) 12 3070
5017B 93-3/4 12 12 --- --- 43-1/2 --- --- 25-1/8 43-5/8 43-5/8 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 12 3265
5018B 99-1/4 12 12 --- --- 46-1/4 --- --- 27-7/8 43-5/8 49-1/8 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 12 3445
5019B 104-5/8 12 12 --- --- 49 --- --- 27-7/8 49-1/8 49-1/8 (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 12 3620
5020B 110 9 9 12 --- 27-1/4 38 --- 27-7/8 54-1/2 49-1/8 --- (3) 3 (2) 3, (1) 2-1/2 (2) 1-1/4* (2) 9, (1) 12 3810 5021B 115-1/2 9 10 12 --- 29-7/8 40-3/4 --- 27-7/8 27-3/8 32-5/8 49-1/8 (4) 3 (2) 3, (2) 2-1/2 (2) 1-1/4* (1) 9, (1) 10, (1) 12 4005 5022B 121 10 10 12 --- 32-5/8 40-3/4 --- 27-7/8 32-3/4 32-5/8 49-1/8 (4) 3 (2) 3, (2) 2-1/2 (2) 1-1/4* (2) 10, (1) 12 4185
5024B 131-3/4 9 10 10 10 29-7/8 32-5/8 32-5/8 19-3/4 27-3/8 65-1/4 32-3/4 (5) 3 (2) 3, (3) 2-1/2 (2) 1-1/4* (1) 9, (3) 10 4530
5026B 142-3/4 10 12 10 10 35-3/8 35-3/8 32-5/8 19-3/4 32-3/4 70-3/4 32-3/4 (5) 3 (2) 3, (3) 2-1/2 (2) 1-1/4* (3) 10, (1) 12 4895
* Dual Manifolds - 5015B thru 5026B **1” - USA - EI
NOTE
1.5006BTHRU5014BBOILERSREQUIRE
SINGLE GAS TRAIN LOCATION ON LEFT END OF BOILER (STANDARD) GAS TRAIN MAY BE RELOCATED TO RIGHT END OF BOILER (EXCEPT 5012BAND5014BBOILERS).
2.5015BTHRU5026BBOILERSREQUIRE
DUAL GAS TRAINS.
3. GAS SUPPLY PRESSURE, IN W.C. NATURAL GAS MAXIMUM: 14” W.C. MINIMUM: 5.5” W.C.  (5009BAND5011BTHRU5014BAND
5020BTHRU5026B)
MINIMUM: 5” W.C.  (5006BTHRU5008BAND5010B,5015B
THRU5019B)
LP GAS: MAXIMUM: 14” W.C. MINIMUM: 11” W.C. 4. WATER BOILERS - MAXIMUM DESIGN
WORKINGPRESSURE:50PSI.
5. STEAM BOILER - MAXIMUM DESIGN
WORKING PRESSURE: 15 PSI.
6.DIMENSIONSININCHES

7
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.
CANADA – “Installation Codes for Natural and
Propane Gas Burning Appliances and Equipment,
CAN/CSA-B149 (.1 or .2)”.
DO NOT INSTALL THIS BOILER ON CARPETING.
2. BOILER LOCATION – locate on a level NON-
COMBUSTIBLE FLOOR as close as possible to
chimney so that vent connection is short and direct.
DANGER
Boilermustnotbeinstalleddirectlyoncombustible


The boiler shall be installed such that the gas ignition
system components are protected from water (dripping,
spraying, rain, etc.) during boiler operation and service
(circulator replacement, control replacement, etc.).
 Donotinstallboilerwheregasolineorotherammable
vapors or liquids, or sources of hydrocarbons (i.e.
bleachers, cleaners, chemicals, sprays, paint removers,
fabric softeners, etc. ) are used or stored.
Refer to table below for minimum clearances, service
clearances, and clearances for removal of Tankless
Heaters.
3. PROVIDE COMBUSTION AND VENTILATION
AIR.
In the USA refer to National Fuel Gas Code, NFPA
54/ANSI Z223. Section 5.3, Air for Combustion and
Ventilation. In Canada refer to Natural Gas Installation
Code, CAN/CSA-B149.1 – latest edition or Propane
Installation Code, CAN/CSA-B149.2 – latest edition.
Local code provisions may apply and should be
referenced.
WARNING
Adequate combustion and ventilation air must

a. Determine volume of space (boiler room). Rooms
communicating directly with the space, in which
the appliances are installed, through openings not
furnished with doors, are considered a part of the
space.
 Volume(ft³)=Length(ft)xWidth(ft)xHeight(ft)
b. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round
theresulttothenearest1000Btuperhour.
c. Determine type of space.
Divide Volume by Total Input of all appliances
in space. If the result is greater than or equal to
50ft³/1000Btuperhour,thenitisconsideredan
unconned space.
 Iftheresultislessthan50ft³/1000Btuperhour,
then the space is considered a conned space.
d. For boiler located in an unconned space of a
conventionally constructed building, the fresh
airinltrationthroughcracksaroundwindows
and doors normally provides adequate air for
combustion and ventilation.
e.Forboilerlocatedinaconnedspaceoran
unconnedspaceinabuildingofunusuallytight
construction, provide outdoor air with the use
of two permanent openings which communicate
directly or by duct with the outdoors or spaces
(crawl or attic) freely communicating with the
outdoors. Locate one opening within 12 inches of
top of space. Locate remaining opening within 12
inches of bottom of space. Minimum dimension
of air opening is 3 inches. Size each opening per
following:
1. Direct communication with outdoors. Minimum
freeareaof1squareinchper4,000Btuperhour
input of all equipment in space.
2. Vertical ducts. Minimum free are of 1 square
inchper4,000Btuperhourinputofall
CLEARANCES - From Table below and from dimensional data in Fig. 1, determine BOILER ROOM space necessary for appropriate access
to and servicing of Boiler. Consideration should be given to other appliances installed in the same area. Consult with local Building and
Safety Codes for compliance.
MINIMUM CLEARANCE - JACKET TO
COMBUSTIBLE CONSTRUCTION
RECOMMENDED
SERVICE CLEARANCE TO
NON-COMBUSTIBLE CONSTRUCTION
CLEARANCES REQ’D FOR REMOVAL
OF TANKLESS HEATER
AT-2 AT-3 AT-4
Left Side 24” (61 cm) 18” (Controls) 27” 32” 42”
Right Side 24” (61 cm) 18” (Controls) 27” 32” 42”
Front 24” (61 cm) 36” (Cleaning-Burner Removal) --- --- ---
Rear 24” (61 cm) 36” (Cleaning) --- --- ---
Top 24” (61 cm) ---------------------------------------- --- --- ---

8
SECTION III – INSTALLATION INSTRUCTIONS
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
conned space. Use indoor air if two permanent
openings communicate directly with additional
space(s)ofsufcientvolumesuchthatcombined
volumeofallspacesmeetcriteriaforunconned
space. Size each opening for minimum free area
of1squareinchper1,000Btuperhourinputof
allequipmentinspaces,butnotlessthan100
square inches.
4. LOUVERS AND GRILLES of Ventilation Ducts
All outside openings should be screened and louvered.
Screens used should not be smaller than ¼ inch mesh.
Louvers will prevent the entrance of rain and snow.
a. Free area requirements need to consider the blocking
effect of louvers, grilles, or screens protecting the
openings. If the free area of the louver or grille
isnotknown,assumewoodlouvershave20-25
percent free area and metal louvers and grilles have
60-75percentfreearea.
b.Louversandgrillesmustbexedintheopen
position or interlocked with the equipment to open
automatically during equipment operation.
FIG. 2
SINGLE MANIFOLD BASE 5006B
THRU 5014B SECTION BOILERS
1. BASE-BURNER-MANIFOLD ASSEMBLY(S).
a.5006Bsectionthru5014Bsectionboilersrequire
single base assembly, see Fig. 2.
b.5015Bsectionthru5026Bsectionboilersrequirea
left and a right base subassembly, see Fig. 3.
Remove Base Assembly(s) From Skid(s)
c. Remove bolts securing Base Assembly(s) to
shipping skid(s) and place Base(s) in location where
Boiler is to be installed.
d. Join Base Sub-assemblies together (15 section &
largerboilers)byrstremovinguppershipping
strip and lower shipping angles from subassemblies.
Use(4)¼”-20x¾”MS,nutsandwasherstoattach
subassemblies, see Fig. 3.
e. Attach Front Intermediate Jacket Panel Support
Bracket and Lower Rear Intermediate Panel Support
Bracket to lower channel on Front Base Frame and
RearBaseFrame,respectively,using(4)¼”-20x
¾”MS,nutsandwashers.
f. Base must be level in both directions and secure on
theoor.ShimandgroutunderBaseifnecessary.
g. Place cardboard covering over the top of the burner
assembly to protect them during the assembly of the
boiler sections.
2. CLEAN BOILER SECTIONS inside and out to remove
dirt due to shipment and handling.
Open Tie Rod Bundle(s). Open Draw-up Rod
Bundle(s).
Open Boiler Assembly Carton(s).
3. SET LEFT END SECTION ON BASE so that locating
lugs on bottom of section go inside Front and Rear Base
Frames. Slide section on base until these lugs strike
High Base End Panel at left end of Base, see Fig. 4.
(Note – if High Base End Panel is at right end of Base,
section assembly must start with Right End Section).
Leftendsectionsareidentiedby“LEH”caston
section;RightEndSectionsareidentiedby“REH”
cast on section.
4. CLEAN NIPPLES AND NIPPLE PORTS thoroughly
with a de-greasing solvent. Use the Loctite® #592
supplied to lubricate the nipples and nipple ports.
Apply the lubricant to the nipples and nipple ports, then
use a brush to disperse it evenly around the nipples and
thenippleports.Useapproximately25mlofLoctite®
#592perueway[(1)7”and(2)3”nipplesandtheir
(6)correspondingnippleports].UseNippleGauge
furnished – follow instructions included with gauge to
set nipples. USE ALL PRECAUTIONS TO AVOID
COCKED NIPPLES.
5. PAINT ALL GROUND SURFACES of each section
with the Sealer Compound furnished.
6. ASSEMBLECENTERSECTIONS.RefertoFig.6
for proper location of Tapped, and sometimes plugged,
SECTION II – GENERAL INFORMATION (continued)

9
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atwasher
against nut.
FIG. 3
DUAL MANIFOLD BASES - 5015B THRU 5026B SECTION BOILERS
FIG. 4
LEH SECTION ON BASE FIG. 5
ASSEMBLY OF CENTER SECTIONS
SECTION III – INSTALLATION INSTRUCTIONS (continued)

10
FIG. 6
ARRANGEMENT OF SECTIONS AND CANOPY(S)
SECTION III – INSTALLATION INSTRUCTIONS (continued)

11
c. Insert short end of draw-up rod through front & rear
nipple ports on both sections, see Fig. 5.
d.Placetwo(2)atwashers,draw-upchannelanda
nutoneachendofdraw-uprodsandnger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. If
necessary, tap Nipples lightly with a blunt tool or
rod to keep Nipples from cocking while Sections are
being drawn up. DO NOT DRAW UP SECTION(S)
WHEN NIPPLES ARE COCKED. Continue
tightening Draw-Up Rods equally until Sections
meet iron-to-iron on the ground surface. BUMPING
OUTER EDGES OF SECTION WITH WOODEN
BLOCK WILL EASE DRAW-UP OPERATION.
f. KEEP DRAW-UP ROD THREADS, NUTS AND
WASHERS LUBRICATED with grease or heavy oil
to prevent damage to rods and threads and to make
assembling easier.
g. USING A PINCH BAR, insert WOOD WEDGES
under last Center Section assembled so as to raise
itjustaboveBoilerBase.Thiswillkeepthenext
section to be assembled above the base, thus making
it easier to join and draw-up. MOVE WOOD
WEDGES FORWARD EACH time a Section has
been drawn up.
7. ASSEMBLE REMAINING END SECTION WITH
DRAW-UP RODS in a manner similar to that for
assembling Center Sections. Remove wedges from
under Boiler. Be sure Boiler is aligned and seated on
Base.
a. After section assembly is completed install 5/8” tie
rods from tie rod bundle through the upper lug holes
in the front of Boiler and Lower lug holes in the rear
ofBoilersectionsandtightenuntiltheyarenger
tightonly,toallowforexpansion.Thisisnecessary
in order to allow clearance for installation of Flue
coverplates.Finally,remove¾”draw-uprodsfrom
nipple ports.
FIG. 7
PURPOSE OF TAPPINGS AND THEIR LOCATIONS
PURPOSE OF TAPPINGS 1
Location Tapping Per
End Section Size Steam Boilers Water Boilers
A 1 3” Supply Supply
B 1 3” Return Return
C21 1-1/2” Pressure Operating Control
(Bushed to 1/4”)
Temperature Operating Control (less heater)
Bushed to 3/4”; Plug (with heater)
D 1 1/2” Pressure Gauge Theraltimeter
E 2 1/2” Water Gauge, LWCO & Pressure Limit Plug
F 1 3/8” Try-Cock (Special Order) ----
G31 ---- Cover Plate Cover Plate or Tankless Heater
H 1 1” See Note 4 See Note 4
J 1 1-1/2” Indirect Water Heater
Supply or Return ----
K 1 3/4” Indirect Water Heater Limit ----
1Tappings on both end sections are identical - Recommend trim be installed in left end section or on same end as gas train.
2This tapping is used for safety valve and surface blowoff (steam boilers) and safety relief valve (water boilers) on end not equipped with trim.
3Temperature operating control location on tankless heater equipped boilers. Also alternate operating control location, tapped cover plate.
4 If using a oat type LWCO, feeder or pump controller on a steam boiler that does not use quick connect hook up ttings, install between
tappings H and return B. Use opposite return B for system return connection. Water boilers using a probe LWCO must mount probe in
supply pipe above boiler without any stop valves.
SECTION III – INSTALLATION INSTRUCTIONS (continued)

12
FIG. 8
INSTALLATION OF BUILT-IN HEATER FIG. 9
TESTING BOILER ASSEMBLY FOR LEAKS
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nal
installation, see Fig. 7.
Open Tankless Heater Carton(s) If Supplied.
Open Heater Opening Cover Plate Carton(s).
9. INSTALL BUILT-IN WATER HEATER(S) OR
HEATER OPENING COVER PLATE(S), See Fig.
8. Heater may be installed in either End Section or,
in some cases, in both End Sections. Heater Opening
Cover Plates are used to cover any unused heater
openings.
a. Place rubber gasket against surface of plate and
align holes.
b. Place washer on each of 3/8” Cap Screws furnished
and insert cap screws through plate and gasket.
Startallscrewsintapsbeforenaltightening.
10. HYDROSTATIC TEST, see Fig. 9: After the boiler
sections have been assembled, it is essential that the
boilerbehydrostaticallytestedbeforethecanopy,ue
cover plates, jacket, or piping is installed.
a.Plugallboilertappingsandllboilercompletely
with cold water.
CAUTION
      

b. All completed boilers must satisfactorily pass the
prescribed hydrostatic test.
(1) STEAM BOILERS: The assembled boiler must
be subjected to a hydrostatic test of 45 psig to 55
psig.
(2) HOT WATER BOILERS: The assembled boiler
must be subjected to a hydrostatic test of 75 psig
to 85 psig.
WARNING
       


11. EXAMINE BOILER CAREFULLY, INSIDE AND
OUTSIDE, to insure against leaks from cocked nipples
or through concealed breakage caused in shipping and
handling. This precaution is for your protection and
will simplify handling of necessary replacements and
adjustment claims. After making certain that there are
no leaks, drain boiler and remove plugs for boiler trim
and other connections.
Open Boiler Sealing Carton.
12. SEAL BETWEEN BOILER SECTIONS AND BASE,
seeFig.10.
a.Push¾”braidedceramicbreRope(furnished)into
gap between bottom of End Section and Low Base
End Panel until rope touches Front and Rear Base
Frames.Placethe1-1/2”x2”x5/8”steelspacers
between low base panel and section and in front of
rope – align holes. Secure section to low base end
panelwith3/8”-16x2”CapScrews,washersand
nuts.
b. Secure opposite end section to high base end panel
with3/8”-16x2”CapScrews,washersandnuts.
c. Apply Furnace Cement to gaps between section
assembly and base to make gas tight seal.
d. Check all joints between Boiler sections and use
remaining Furnace Cement or Sealer Compound to
make joints gas tight.
SECTION III – INSTALLATION INSTRUCTIONS (continued)

13
13. INSTALL FLUE COVER PLATES over cleanout
openings on Front and Rear of Boiler. Use ¼” Carriage
Boltsinstalledattopandbottomofueopeningsand
securewithwasherandjamnuttoprovideaxed
stud.Installue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.
CLEARANCES – Steam and Hot water pipes shall
have clearances of at least ½” from all combustible
construction.
NOTICE
      

       

       


       


        

       


       

a. With Steam Heating System, refer to Fig. 12, 13, 14
or 15.
b. With Forced Circulation HOT WATER HEATING
SYSTEMS,seeFig.16Aand16B.Foradditional
reference, consult I=B=R Installation and Piping
GuideNo.250.
NOTE: When Hot Water Heating Boilers are
connected to Heating Coils located in Air Handling
Unitswheretheymaybeexposedtorefrigerated
air circulation, the Boiler Piping System must
be equipped with Flow Control Valves or other
automatic means to prevent gravity circulation of
the Boiler Water during the cooling cycle.
c. With COMBINATION HEATING AND COOLING
(REFRIGERATION) SYSTEMS having the same
Distributing Units, Piping and Circulator, See Fig.
17. For additional reference, consult ASHRAE
SystemsHandbook2008Edition.
d. NOTE: Valves must be installed in the supply and
return branches to the Heating Boiler and Water
Chiller so as to prevent circulation of Chilled Water
through the Boiler or Heated Water through the
Chiller.
OXYGEN CORROSION:
 Oxygencontaminationoftheboilerwaterwillcause
corrosion of the iron and steel boiler components,
which can lead to failure. As such, any system must
bedesignedtopreventoxygenabsorptionintherst
place or prevent it from reaching the boiler. Problems
causedbyoxygencontaminationofboilerwaterarenot
covered by Burnham’s standard warranty.
FIG. 10
SEALING OF BASE, INSTALLATION OF
FLUE COVERS AND CANOPIES
FIG. 11
ATTACHMENT OF FLUE COVERS
SECTION III – INSTALLATION INSTRUCTIONS (continued)

14
FIG. 12
RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN
I OR 2 SUPPLY CONNECTIONS - 5006B THRU 5014B
SECTION III – INSTALLATION INSTRUCTIONS (continued)

15
FIG. 13
RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN
3 SUPPLY CONNECTIONS - 5015B THRU 5020B
SECTION III – INSTALLATION INSTRUCTIONS (continued)

16
FIG. 14
RECOMMENDED STEAM BOILER PIPING, GRAVITY RETURN
4 OR 5 SUPPLY CONNECTIONS - 5021B THRU 5026B
SECTION III – INSTALLATION INSTRUCTIONS (continued)

17
FIG. 15
TYPICAL STEAM PIPING ARRANGEMENT FOR BOILERS WITH PUMPED CONDENSATE RETURN AND BOILER FEED UNIT
SECTION III – INSTALLATION INSTRUCTIONS (continued)

18
FIG. 16A
RECOMMENDED WATER BOILER PIPING
1 SUPPLY CONNECTION & 1 RETURN CONNECTION
SIZES 5006B THRU 5019B
FIG. 16B
RECOMMENDED WATER BOILER PIPING
3 SUPPLY CONNECTIONS & 2 RETURN CONNECTIONS
SIZES 5020B THRU 5026B
SECTION III – INSTALLATION INSTRUCTIONS (continued)

19
 Therearemanypossiblecausesofoxygen
contamination such as:
1.Additionofexcessivemake-upwaterasaresultof
system leaks.
2.Absorptionthroughopentanksandttings.
3.Oxygenpermeablematerialsinthedistribution
system.
 Inordertoinsurelongproductlife,oxygensources
should be eliminated. This can be accomplished by
taking the following measures:
FIG. 17
RECOMMENDED BOILER PIPING FOR
COMBINATION HEATING & COOLING SYSTEMS
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ttings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
1. Attach Lower Jacket End Panel Support Bracket to
BaseEndPanel(Bothends)using¼”-20x½”self-
tapping screws, see Fig. 2 and 18.
2. Attach Lower Left and Lower Right Jacket End
Panelstotheirrespectivebracketsusing#10-32x
½” self-tapping screws, see Fig. 19.
3. See Fig. 7 “Purpose of Tappings and Their
Location” and remove necessary knockouts from
Upper Left and from Upper Right Jacket End
Panels.
4. Place Upper Right End Panel on top of Lower
Right End Panel with lip on bottom of Upper Panel
positioned behind Lower Panel. Secure to section
using#10-32x½”self-tappingscrews.Attach
Upper Left End Panel in a similar manner, see Fig.
19.
NOTE: FOR INSTALLATION OF THE
FRAMEWORK FOR THE LOWER UNCOMMON
JACKET PARTS REFER TO THE FOLLOWING:
a.5006Bthru5010Bsectionboilers–Paragraph
16,Fig.21
b.5011Bthru5026Bsectionboilers–Paragraph
30,Fig.25
COMPLETION OF JACKET INSTALLATION –
5006BTHRU5010BSECTIONBOILERS
NOTE: Do not tighten any screws until Jacket
installation is complete.
INSTALLATION OF LOWER FRAMEWORK
16. With “U” channel facing down, slip upper front channel
behind joints formed by End Panels and secure to End
Panels using #8 SMS. Position Lower Front Channel
so that “U” of channel faces boiler. Slip Lower Front
Channel behind Lower End Panels and secure with
#8 SMS. Repeat similar procedure for installation of
Upper Rear and Lower Rear Channels.
17. INSTALLATION OF VESTIBULE PANEL refer to
Fig.20.
FIG. 18
INSTALLATION OF JACKET SUPPORT
BRACKETS TO BASE END PANELS
SECTION III – INSTALLATION INSTRUCTIONS (continued)

20
FIG. 19
INSTALLATION OF JACKET END PANELS
FIG. 20
VESTIBULE ATTACHMENT DIAGRAM
 AttachHexCouplingstoendof
CarriageBoltswhichsecureue
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-
DRAFTHOOD5006Bthru5010B
Section Boilers, see Fig. 22. Place
Cerafelt strips on top of section
assemblynexttoledgesformedby
centersectionsandnexttoledgeon
end sections. Overlap at corners.
21. SECURE CANOPY-DRAFTHOOD
with5/16”-18x5/8”MSdriveninto
the tapped lugs provided for this
purpose on top of the sections. Two
screws are required at each end.
Refer to Fig. 23.
SECTION III – INSTALLATION INSTRUCTIONS (continued)