Burnham 8HE Series Service manual

1111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Commercial Boilers
www.burnhamcommercial.com
Manual Contents Page
1. Pre-Installation.........................6
2. Boiler Assembly........................9
3. Water Trim and Piping ..................17
4. Gas Piping ...........................22
5. Venting ..............................24
6. Electrical ............................27
7. System Start-up .......................30
8. Service ..............................34
9. Service Parts .........................40
Series 8HE
Installation, Operating and Service Instructions for
WARNING
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.
!

2111828-01 - 1/23
8HE Installation, Operating & Service Instructions
IMPORTANT INFORMATION -
READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE
All boilers must be installed in accordance with National, State and Local Plumbing, Heating andAll 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 differElectrical 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 installationsfrom this instruction manual. Authorities having jurisdiction should be consulted before installations
are made. In all cases, reference should be made to the following Standards:are made. In all cases, reference should be made to the following Standards:
A. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.A. Current Edition of National Fuel Gas Code, NFPA 54/ANSI Z223.1.
B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, andB. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and
Solid Fuel Burning Appliances”, For Venting requirements.Solid Fuel Burning Appliances”, For Venting requirements.
C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and SafetyC. 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 safetyDevices for Automatically Fired Boilers”, for assembly and operations of controls and safety
devices.devices.
D. All wiring on boilers installed in the USA shall be made in accordance with the National ElectricalD. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical
Code, NFPA 70, and/or Local Regulations.Code, NFPA 70, and/or Local Regulations.
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.
Hazard Definitions
NOTICE: Indicates special instructions on
installation, operation, or service which are
important but not related to personal injury
hazards.
DANGER
Indicates a hazardous situation that, if not
avoided, will result in death or serious injury.
CAUTION
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate
injury.
WARNING
Indicates a hazardous situation that, if not
avoided, could result in death or serious injury.
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3111828-01 - 1/23
8HE Installation, Operating & Service Instructions
DANGER
•Explosion Hazard.
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, 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 supplier from a remotely located phone
•Burner/boiler systems produce steam or hot water in a pressurized vessel by mixing extremely flammable 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.
!
WARNING
•This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this
manual.
•Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury
or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.
Installation and service must be performed only by an knowledgeable, experienced, and skilled installer or service
agency.
• This boiler must be properly vented.
•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 system must be inspected and cleaned before the start of the heating season and should
be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed venting
system is 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.
•Installation is not complete unless a pressure relief valve is installed into the specified tapping on the supply top
of appliance - See Section 3, Paragraph C.
•This boiler is supplied with safety devices 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 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.
•Boiler 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.
•Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions,
including all those contained in component manufacturers manuals which are provided with the boiler before
installing, starting up, operating, maintaining or servicing.
• Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or liquids.
• Do not operate boiler with control which has been subject to water.
• All cover plates, enclosures and guards must be in place at all times.
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4111828-01 - 1/23
8HE Installation, Operating & Service Instructions
WARNING
• 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.
•Service boiler at least once a year - preferably at the start of the heating season. The inside of the combustion
chamber should also be inspected at the same time. Clean if necessary.
•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.
•
This boiler is designed to burn natural 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.
!
NOTICE:
1. 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.
2. Boilers built for installation at altitudes 2,000-5,000 ft. above sea level have been specially orificed to reduce
gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
3. All Series 8HE cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler and
Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each 8HE jacket,
which indicates the boiler Maximum Allowable working Pressure (MAWP). Each cast iron section is permanently
marked with the MAWP listed on the boiler’s ASME Data Label. The MAWP for all Series 8HE Boiler is 50 psi (Water
Only).
It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler MAWP.
Therefore, in addition to Safety Relief Valves set for 50 psi, Burnham Commercial also offers Safety Relief Valves set
for 30 psi (By Special Order Only).

5111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Important Product Safety Information:
Refractory Ceramic Fiber Product
WARNING
Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has
been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF
may change into crystalline silica, a known carcinogen. When disturbed as a result of servicing
or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
Avoid breathing RCF particulates and dust.
Precautionary Measures:
•Do not handle RCF parts or attempt any service or repair work involving RCF without wearing the following
protective gear:
1. A properly fitting National Institute for Occupational Safety and Health (NIOSH)-certified air-
purifying respirator with a filter efficiency of at least 95%. Respirator should also include a full
facepiece when handling used RCF. Other types of respirators may be required depending on site
conditions. Current NIOSH recommendations may be found on the NIOSH website
http://www.cdc.gov/niosh/homepage.html. NIOSH-approved manufacturers, respirators and
associated user instructions are listed on the NIOSH website.
2. Long sleeved, loose fitting clothing that is sufficiently tight around potential entry points for RCF
dust.
3. Gloves.
4. Eye protection, such as goggles, safety glasses with side shields, or full facepiece.
•Take steps to assure adequate ventilation.
•Handle RCF carefully to minimize airborne dust. Use hand tools whenever possible.
•Dampen used RCF with light water spray prior to removal to prevent airborne dust.
•Do not use compressed air or dry sweeping for clean-up. Frequently clean work area with a vacuum or by
wet sweeping to minimize debris accumulation.
•Vacuum work clothes before leaving work area. Wash work clothes separately from other laundry and
rinse washing machine after use to avoid contaminating other clothes.
•Wash all exposed body areas gently with soap and water after contact.
•Discard used RCF components by sealing in an airtight plastic bag or container.Refer to local, regional,
state or provincial regulations to identify applicable disposal requirements.
First Aid Procedures:
•Eye contact: Flush with water for at least 15 minutes. Do not rub eyes. Seek immediate medical attention
if irritation persists.
•Skin contact: Wash affected area gently with soap and water. Do not rub or scratch affected skin. Seek
immediate medical attention if irritation persists.
•Nose and throat contact: If these become irritated, leave the area and move to a location with clean fresh
air. Drink water and blow nose. Seek immediate medical attention if symptomspersist.
!
http://www.cdc.gov/niosh/homepage.html

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8HE Installation, Operating & Service Instructions
Table 1-2: Dimensional Data
1Pre-Installation
Figure 1-1: Dimensional Data

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8HE Installation, Operating & Service Instructions
A. 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 claim for damage or shortage
in shipment must be filed immediately against
carrier by consignee. No claims for variances or
shortages will be allowed by Boiler Manufacturer,
unless presented within sixty (60) days after
receipt of equipment.
B. Installation must conform to the requirements of
the authority having jurisdiction. In the absence
of such requirements, installation must conform
to the National Fuel Gas Code, NFPA 54/ANSI
Z223.1. Where required by the authority having
jurisdiction, the installation must conform to the
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME No CSD-
1.
C. Boiler is certified for alcove installation with
the following clearances from combustible
construction:
1. Front: 18 in.
2. Top: 36 in.
3. Draft hood, rear, sides and flue connector: 6
in.
D. Provide clearance for servicing and proper
operation (following clearances are recommended
and may be reduced to minimum clearances
shown above):
1. Single boiler, Front/Top: 24 in. (61.0 cm)
2. Multiple boiler, Sides: 1 in. (2.5 cm)
E. Install boiler on level floor as close to chimney as
possible. For basement installation provide a solid
base such as concrete or masonry construction
if floor is not level or if water may be encountered
on floor around boiler.
F. Protect gas ignition system components from
water (dripping, spraying, rain, etc.) during boiler
operation and service (circulator replacement,
control replacement, etc.).
G. Locate boiler to avoid water damage in case
there is a leak. If boiler must be located in an
area sensitive to water damage, install drain
pan underneath boiler and pipe to a suitable
drain location. Manufacturer will not be held
responsible for water damage resulting from
this appliance or any of its components.
H. Provide combustion and ventilation air in
accordance with applicable provisions of local
building codes, or the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, Air for Combustion and
Ventilation.
I. If replacing an existing boiler, check for and
correct common system problems including:
1. System leaks resulting in premature heat
exchanger failure from oxygen corrosion or
hardness deposits
2. Inadequate freeze protection resulting in
system freezing and leaking
3. Dirt or debris left in existing piping if it has not
been properly flushed or cleaned
WARNING
•Adequate combustion and ventilation air must be
provided to assure proper combustion.
•Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
NOTICE: Mis-sizing of the boiler with regard to
the heating system load will result in excessive
boiler cycling and accelerated component failure.
Burnham Commercial DOES NOT warrant failures
caused by mis-sized boiler applications. DO NOT
oversize the boiler to the system.
Boiler Model Special Base Part Number
805HE 61816055
806HE 61816065
Table 1-3: Special Base Required for Installation
on Combustible Flooring
1Pre-Installation (continued)
WARNING
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
!
WARNING
Appliance is design certified for installation on
noncombustible flooring only. For installation
on combustible flooring only when installed on
special base listed in Table 1-3. Boiler must not be
installed on carpeting. When boiler is installed on
concrete which is over a material that is subject
to melting (PVC, PEX radiant tubing, etc.), the
special base must be used. A concrete pad is not
sufficient to protect combustible flooring.
!
!

8111828-01 - 1/23
8HE Installation, Operating & Service Instructions
1Pre-Installation (continued)
Table 1-4: Corrosive Combustion Contaminants
and Sources
Contaminants to avoid:
Spray cans containing chloro/fluorocarbons (CFC’s)
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms.
Adhesives used to fasten building products and
other similar products
Excessive dust and dirt
Areas likely to have contaminants:
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
J. For Multiple boiler installations see also Series
8HE Multiple Boiler Application Instructions,
111924-01, available on Burnham Commercial
website.
K. Check for and remove any potential combustion
air contaminants from area around boiler. See
Table 1-4.
NOTICE: Flue side corrosion caused by
contaminants is not covered by warranty.

9111828-01 - 1/23
8HE Installation, Operating & Service Instructions
A. Remove Crate
1. Remove all fasteners at crate skid.
2. Lift outside container and remove with all other
inside protective spacers and bracing.
B. Remove boiler from skid. See Figure 2-1. Exercise
care to avoid dropping boiler.
1. Place boiler in approximate location. Refer to
Section 1: Pre-Installation. Remove base hold
down bolts.
2. Using pry bar under rear corner of Base End
Panel, raise boiler and install 1½ in. wood
blocks under rear corners. Install ¾ in. pipe
roller between Base and skid.
3. Remove 1½ in. wood blocks. Place 3 in. pipe
roller on floor behind skid.
4. Roll boiler off skid. Move skid out of way.
5. Roll boiler until 3 in. roller is located as shown.
Use pry bar to install wood blocks under front
corners of base. Remove 3 in. roller.
6. Lift boiler with pry bar. Remove wood blocks.
Lower boiler.
C. For Packaged Boiler only, proceed to Paragraph
E.
D. Test Section Assembly for leaks before connecting
to system and installing controls, trim and jacket.
See Figure 2-3 and Table 2-2.
1. Attach pressure gauge capable of indicating
50 psi. Boiler Temperature-Pressure gauge
may be used and is located in Water Trim
Carton.
For testing gauge may be connected to
permanent location in 2 in. NPT supply pipe
as shown in Figures 3-4 and 3-5 or may be
connected to a tapping that is unused for
pressure testing, such as in Tapping C shown
in Figure 2-3.
2. Install purge valve with a hose that runs to a
drain in supply tapping or supply pipe.
3. Install fill valve and piping to Drain Tapping G.
4. Plug remaining open tappings.
5. Fill boiler completely with water by venting air
through purge valve. Close purge valve and
apply water pressure of at least 10 psi but less
than 50 psi gauge pressure.
Figure 2-1: Skid Removal
2Boiler Assembly
WARNING
Do not use air to leak test boiler.
!
WARNING
Use precautions and appropriate rigging
apparatus when moving heavy objects.
!6. Examine boiler for leaks or damage due to
shipment or handling.
7. Remove fill valve, purge valve and piping.
E. Install special base if installation is on
combustible flooring. See Figure 2-4. Floor shield
adds 4¾ in. to boiler height.
1. Place special base on combustible floor with
surface marked “FRONT” in upward position.
2. Locate special base with spacing to
combustible materials as shown in Figure 2-4.
3. Place boiler on special base. Boiler must rest
inside locating brackets. Boiler jacket panels
will overhang special base.
4. Do not enclose boiler (including special base)
on all four sides.
F. Move boiler to permanent location by sliding or
walking. Do not drop.
For Packaged Boiler, proceed to Paragraph L.
CAUTION
Sheet metal parts may have sharp edges
or burrs, use proper Personal Protective
Equipment (PPE) during assembly.
!

10 111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Figure 2-4: Installation of Special Base for
Combustible Flooring
G. Confirm that one (1) Flue Baffle is properly
positioned in each Boiler Flueway. Tabs at the top
of each Flue Baffle should be resting on top row of
Flue Pins on each adjoining section.
H. Install Canopy on section assembly. See Figure
2-5. Canopy and hardware are located in
Combination Boiler Parts and Control Carton.
1. Place ceramic fiber blanket on top of block
assembly perimeter.
2. Position Canopy on top of Section Assembly.
Locate between end sections and sealing
ledge on front and back of each section.
3. Fasten each end with ¼ in. - 20 x 1 in. carriage
bolts, washers and nuts.
I. Inspect joints between sections. They were
factory sealed. If any openings resulted during
shipment or handling, reseal with furnace cement.
Confirm tie rods are only hand tight to allow for
thermal expansion.
2Boiler Assembly (continued)
Tapping Size Purpose
A 2 in. Supply
B 2 in. Return
C 3/4 in. Relief Valve
D 3/4 in. HydroStat ® Limit
E 3/4 in. Opt. Auxiliary
L4006E Limit
F 3/4 in. Washout
G 3/4 in. Drain
Table 2-2: Purpose of Tappings
Figure 2-3: Tapping Locations
J. Install Base Front Panel. See Figure 2-5. Panel
and hardware located in Combination Boiler Parts
and Control Carton.
1. Attach Base Front Panel to Section Assembly
using ¼ in. - 20 x 1¼ in. carriage bolts,
washers and nuts.
2. Seal between top of Base Front Panel and
Section Assembly with furnace cement
(shipped in Combination Boiler Parts and
Control Carton).
3. Seal between top of Base Rear Panel and
Section Assembly with furnace cement.

11111828-01 - 1/23
8HE Installation, Operating & Service Instructions
K. Install Pilot/Main Burner Assembly. See Figure 2-7.
Assembly is located in Combination Boiler Parts
and Control Carton. Verify assembly is properly
located on support bracket in Base Rear Panel,
seated on Main Burner Orifice, and secured with
hitch pin clip.
L. Burner Air Shutters. See Figure 2-7. (On
Packaged Boilers, Front Door and Burner Access
Panel(s) must be removed to make adjustments.)
Initial setting of burner air shutters should be
between fully open and approximately 11/16 in.
between front edge of Burner Air Shutter and
burner mounting ring should be approximately
11/16 in. To adjust this distance, loosen screw at
top of air shutter and slide into correct position.
Then tighten screw. (Replace Burner Access
Panel(s) and Front Door on Packaged Boilers.)
For Packaged Boiler, proceed to Section 3: Water
Trim and Piping.
M. Attach Flame Roll-out Switch to Burner Access
Panel. See Figure 2-6. Flame Roll-out Switch and
hardware are located in Combination Boiler Parts
and Control Carton. Flame Roll-out Switch is a
single use device - do not test with heat - switch
cannot be reset.
1. Cut insulation from semicircular notch at right
end of the burner access panel.
2. Attach Flame Roll-out Switch Mounting Bracket
to burner access panel with (1) #8 x ½ in. lg.
sheet metal screw.
3. Attach Flame Roll-out Switch to mounting
bracket with (1) #8 x ¾ in. lg. sheet metal
screw.
N. Install Burner Access Panel(s). Locate Burner
Access Panel(s) in Combination Boiler Parts and
Control Carton. Engage Burner Access Panel
holes with projections on Base Front Panel. See
Figure 5.
O. Install Electro-Well and Immersion Well.
1. Remove 3/4 NPT x 1 in. Electro-Well (black
plastic) from Combination Boiler Parts and
Control Carton.
2. Insert Electro-Well in Tapping D. See Figure
2-3.
3. Insert 3/4 NPT x 3 in. Immersion-Well
(brass) in Tapping E. If vertical gas piping
is to be installed inside of boiler jacket, it is
recommended that second limit be installed in
system piping.
Figure 2-5: General Assembly (Knockdown Boilers)
2Boiler Assembly (continued)

12 111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Figure 2-6: Flame Roll-out Switch Installation
Figure 2-7: Burner/Burner Access Panel Installation
2Boiler Assembly (continued)

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8HE Installation, Operating & Service Instructions
P. Install Jacket. See Figure 2-9.
1. Locate four (4) Jacket Attachment Brackets in
Combination Boiler Parts and Control Carton.
Attach to Front Base Panel and Rear Base
Panels with #8 sheet metal screws. See Figure
2-5.
2. Hang Left Side Panel and Right Side Panel
onto Jacket Attachment Brackets.
3. Attach Lower Rear Panel to Left and Right Side
Panels. Do not tighten sheet metal screws.
4. Attach Upper Rear Panel to Lower Rear Panel.
Do not install three (3) upper screws.
5. Remove Rating Label from envelope
marked “RATING LABEL ENCLOSED”.
Remove Combustible Clearance Label from
Combination Boiler Parts and Controls Carton.
Attach to Vestibule Panel in locations shown.
6. Attach Vestibule Panel to Left Side and Right
Side Panels.
7. Attach Lower Front Tie Bar to Left Side and
Right Side Panels.
8. Engage Upper Front Panel in slots on Left
Side and Right Side Panels. Place Top Panel
in position. Attach Top Panel to Left Side, Right
Side and Upper Rear Panels.
9. Tighten all jacket screws.
10. Affix Lighting/Operating Instructions Label and
Wiring Diagram Label to inside of Front
Removable Door. Labels are located in
Combination Boiler Parts and Control Carton.
Q. Install Hydrostat 3200 Limit Control.
Locate limit in Combination Boiler Parts and
Control Carton, as well as the Hydrostat Remote
Mounting Brackets. See Figure 2-8 for location of
screw holes on Jacket Vestibule Panel for remote
mounting brackets.
1. Attach bottom mounting bracket to Vestibule
Panel with two (2) standard truss head jacket
screws.
2. Insert the top mounting bracket into the slots
on the back of the limit control and rotate the
bracket upward.
3. Place the limit control box on to the bottom
mounting bracket and attach the top bracket
with two (2) more standard truss head jacket
screws.
4. Insert limit probe into left immersion well as far
as possible and secure with spring clip. (See
also HydroStat 3200 manual provided with
boiler).
Figure 2-8: Hydrostat 3200 Remote Mounting
Screw Holes on Jacket Vestibule Panel
R. Install Auxiliary Limit or operating control (if used).
Insert control probe into right immersion well as
far as possible. Tighten screws.
S. Install Gas Control System. All components are
located in Combination Boiler Parts and Control
Carton.
1. Install Gas Control Assembly on Manifold. See
Figure 2-10. Use thread (joint) compound (pipe
dope) resistant to action of liquefied petroleum
gas.
2. Install pilot burner piping and controls. See
Figure 2-11.
T. Install Ignition Module.
1. Attach Ignition Control Mounting Bracket to
Jacket Vestibule Panel using two (2) #8 x ½
in. sheet metal screws.
2. Attach Honeywell Ignition Module to
Mounting Bracket using two (2) #8 x ½ in.
sheet metal screws.
3. Connect pilot ground wire and ignitor/sensor
lead(s) to ignition module. Refer to “Section 6:
Electrical” for connection details.
2Boiler Assembly (continued)

14 111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Figure 2-9: Jacket Assembly
2Boiler Assembly (continued)
Figure 2-10: Main Gas Piping, Intermittent Ignition

15111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Figure 2-10: Main Gas Piping, Intermittent Ignition
2Boiler Assembly (continued)

16 111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Figure 2-11: Schematic Pilot Piping
2Boiler Assembly (continued)

17111828-01 - 1/23
8HE Installation, Operating & Service Instructions
A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
1. 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.
2. In order to insure long product life, oxygen
sources must be eliminated. This can
be accomplished by taking the following
measures:
a. Repairing system leaks to eliminate the
need for addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which
allow oxygen absorption.
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
f. Use properly designed and operating air
elimination devices in water piping.
B. Design boiler piping and flow rate to obtain
proper temperature rise though the boiler. (See
Table 3-1)
C. Install Safety Relief Valve. See Figure 3-2.
Components are located in Water Trim Carton.
Safety Relief Valve must be installed with spindle
in vertical position.
1. Install ¾ in. NPT x 3½ in. lg. nipple in tapping
“C”. See Figure 2-3.
2. Install safety relief valve on ¾ in. NPT nipple.
Table 3-1: Flow Rate, Temperature Rise, and
Pressure Drop
Boiler
Model
Flow Rate
(GPM)
Temp. Rise
Thru Boiler
Min. Boiler
Piping NPT
Boiler
Pressure
Drop
805HE
20
13
10
20° F
30° F
40° F
1½ in.
1¼ in.
1¼ in.
3 ft.
2 ft.
1 ft.
806HE
25
17
13
20° F
30° F
40° F
1½ in.
1½ in.
1¼ in.
3 ft.
2 ft.
1 ft.
3Water Trim and Piping
WARNING
• Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
•Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to
boiler failure. Burnham Commercial’s Warranty does not cover problems caused by oxygen contamination of boiler
water or scale (lime) build-up caused by frequent addition of water.
!
WARNING
• Pipe discharge of relief valve to a location
where water or steam will not create a hazard
or cause property damage if the relief valve
opens.
• End of discharge pipe must terminate in an
unthreaded pipe.
• If relief valve discharge is not piped to a
drain, it must terminate at least 6 inches above
floor.
• Termination of the relief valve discharge
piping must be in an area where it is not likely
to become plugged by debris or subjected to
freezing.
!
DANGER
• Do not install any valves between boiler and
relief valve.
• Do not install any valves between relief valve
and discharge.
• Do not move relief valve from factory location.
• Do not plug relief valve discharge.
• Do not install a relief valve with a setting
greater than 15 psi.
!

18 111828-01 - 1/23
8HE Installation, Operating & Service Instructions
D. Install Drain Valve in rear of Left End Section,
Tapping “G”. See Figure 3-3. Components are
located in Water Trim Carton.
E. Install Temperature-Pressure Gauge. Components
are located in Water Trim Carton.
1. Standard Temperature - Pressure Gauge
Piping. See Figure 3-4.
a. Install 2 in. NPT x 10 in. lg. nipple with
gauge tapping into Supply Tapping “A”.
See Figure 2-3. Gauge tapping should face
forward.
b. Insert Temperature-Pressure Gauge.
Tighten by applying pressure to square
shank on back of gauge. DO NOT APPLY
PRESSURE ON GAUGE CASE since this
may ruin gauge calibration.
2. Alternate Temperature-Pressure Gauge Piping.
See Figure 3-5.
a. Install 2 NPT x 10 in. Nipple into Supply
Tapping “A”. See Figure 2-3.
b. Install 2 NPT x ¾ NPT x 2 NPT Tee
(provided) or 2 NPT x 2 NPT x ¾ NPT Tee
(installer furnished). ¾ NPT leg should face
forward.
c. Install ¾ NPT x ¼ NPT Bushing.
d. Insert Temperature-Pressure Gauge.
Tighten by applying pressure to square
shank on back of gauge. DO NOT APPLY
PRESSURE ON GAUGE CASE since this
may ruin gauge calibration.
3Water Trim and Piping (continued)
Figure 3-3: Drain Piping Installation
F. Connect system supply and return piping to
boiler.
1. Maintain minimum ½ in. clearance from hot
water piping to combustible materials.
2. Pump flow rates and minimum boiler supply
and return pipe sizes are shown in Table 3-1.
3. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled
medium piped in parallel with heating boiler
using appropriate valves to prevent chilled
medium from entering boiler. See Figure 3-6.
4. If boiler is connected to heating coils located
in air handling units where they may be
exposed to refrigerated air, boiler piping
must be equipped with flow control valves
to prevent gravity circulation of boiler water
during cooling system operation. A hot water
boiler installed above radiation level must be
provided with a low water cutoff device as part
of installation. The HydroStat control provided
with the boiler includes a low water cut-off
function.
5. Continued boiler operation for prolonged
periods of time under conditions when
temperature differential across the system
exceeds 40°F and/or return water temperature
stays below 135°F, may result in premature
boiler failure due to flue gas condensation and/
or thermal shock.
Figure 3-2: Safety Relief Valve Installation
WARNING
•
Burnham Commercial recommends maintaining
temperature differential (drop) across the system
at 40°F or less and return water temperature at
minimum of 135°F.
• Continued boiler operation for prolonged periods of
time under conditions when temperature differential
across the system exceeds 40°F and/or return water
temperature stays below 135°F, may result in premature
boiler failure due to flue gas condensation and/or
thermal shock.
!

19111828-01 - 1/23
8HE Installation, Operating & Service Instructions
Figure 3-4: Temperature-Pressure Gauge
Installation
Figure 3-5: Alternate Temperature-Pressure Gauge
Installation
Methods to provide boiler water protection
are listed below. See also Tekmar Essay #021
“Mixing Methods and Sizing of Variable Speed
Injection Pumps”, Taco #102-143 Variable
Speed Circulator Instruction Sheet, and
information from mixing valve manufacturer.
a. Bypass Piping – Bypass piping is
recommended for any installation for
improved system temperature balance,
while serving to protect the boiler from
sustained condensing operation. The
bypass also provides some measure of
low return water temperature protection by
reducing flow through the boiler. See upper
part of Figure 3-7.
b. Bypass Circulator - A bypass circulator
is recommended to divert hot supply
water into the return when system return
temperatures can periodically dip below
135°F. A variable speed circulator is
recommended for increased protection. See
Figure 3-7 Detail A.
c. Primary/secondary Piping with Bypass –
Primary/Secondary piping is recommended
to provide two points of mixing when
dual temperature systems are used (i.e.
baseboard and radiant heat, outdoor reset
and domestic hot water production, systems
incorporating night setback or multiple zone
pumps on clock schedules). See Figure 3-7,
Detail B.
d. Primary/secondary Piping with 3-way Valve
– A 3-way valve with return temperature
sensor is recommended to protect the
boiler or sensing element from sustained
condensing operation, particularly if the
system will continuously run below 135°F for
extended periods (due to low temperature
applications like snow melt, heat pump
systems or others). See Figure 3-7, Detail C,
and information from mixing valve vendor.
3Water Trim and Piping (continued)

20 111828-01 - 1/23
8HE Installation, Operating & Service Instructions
6. A hot water boiler installed above radiation
level must be provided with a low water cutoff
device as part of installation. The HydroStat
control provided with the boiler includes a low
water cutoff function.
7. A start-up strainer is recommended for all
installations (new and replacement alike) to
prevent system debris and sediment from
ending up in the boilers where it will inhibit heat
transfer and may eventually cause a cast iron
section to crack from overheating.
G. Indirect Water Heater (if used). Refer to Indirect
Installation, Operating and Service Instructions for
additional information. Install in same manner as
space heating zone.
Water Quality Requirements
pH: 6.0 - 9.5
Total hardness grains / gal: < 7
Chlorides: < 50 ppm
3Water Trim and Piping (continued)
Figure 3-6: Recommended Piping for Combination
Heating & Cooling (Refrigeration) System