Burnham Series 2B, 202, 202X, 203, 204 Installation & Service Instructions Manual

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NOTE: The equipment shall be installed in accordance with those installation regulations in force in the area where the
installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before
installations are made.

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.

The New York City Department of Buildings has approved the Series 2B boiler: Approval No. MEA 96-96-E
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Series 2B boiler. See the Massachusetts Board of

Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask
your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

Table of Contents

I. Installation Instructions ................... 4

II. Operating Instructions .....................18

III. Trouble Shooting..............................25

IV. Service ..............................................26

V. Repair Part .......................................

29

VI. Appendix

Low Water Cut Off ...........................51

The following dened 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.

DANGER

Indicates presence of a hazard which will cause
severe personal injury, death or substantial
property damage if ignored.

WARNING

Indicates presence of a hazard which can cause
severe personal injury, death or substantial
property damage if ignored.

Indicates presence of a hazard which will or can
cause minor personal injury or property damage
if ignored.

Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.

CAUTION

NOTICE

FAILURE TO FOLLOW ALL INSTRUCTIONS IN PROPER ORDER CAN CAUSE PERSONAL INJURY OR
DEATH. READ ALL INSTRUCTIONS BEFORE INSTALLING.

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.

2

WARNING

WARNING

WARNING

READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF BOILER.
POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE TECHNICIAN. MAINTAIN
INSTRUCTIONS IN LEGIBLE CONDITION.

Boiler

Model

Number

202 18-3/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10 [3] 1/2 2.5 3" dia. x 15 ft. 212

202X 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262

203 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262
204 23-1/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4 1/2 4 5" dia. x 15 ft. 306
205 26-1/2 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/4 1/2 4.7 6" dia. x 15 ft. 354
206 29-3/4 21-3/4 10-7/8 6 48-1/2 9-3/4 5-1/4 1/2 5.5 6" dia. x 15 ft. 414
207 33 25 12-1/2 7 50-1/8 10-3/8 6-5/8 3/4 6.2 7" dia. x 15 ft. 458
208 36-1/4 28-1/4 14-1/8 7 50-1/8 10-3/8 6-5/8 3/4 7 7" dia. x 15 ft. 514
209 39-1/2 31-1/2 15-3/4 8 52 11 7-1/4 3/4 7.7 8" dia. x 15 ft. 550
210 42-3/4 34-3/4 17-3/8 8 52 11 7-1/4 3/4 8.5 8" dia. x 15 ft. 608

[1] 15' chimney height is from bottom of draft hood opening to top of chimney.

[2] Refer to the National Fuel Gas Code for equivalent areas of circular and rectangular ue linings.

Maximum Allowable Working Pressure - 30 PSI (Water Only)
[3] 202 only. Dimension 'G' includes allowance for 4" x 3" reducer furnished with boiler. See Figure 8.

A B C D E F G

Dimensions [Inches] Gas

Connection

For Automatic

Gas Valve

Water

Content

[gallons]

Recommended

Vent Size

[1] [2]

Approx.

Shipping

Figure 1

Weight

[lb.]

3

I . Installation Instructions

1. INSPECT SHIPMENT carefully for any signs of

damage. All equipment is carefully manufactured,
inspected and packed. Our responsibility ceases upon
delivery of Boiler to the 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.

2. BOILER INSTALLATION must conform to the

requirements of the authority having jurisdiction, or in
the absence of such requirements, to:

U.S.A. - National Fuel Gas Code, ANSI Z223.1.
When required by the authority having juris-

diction, the installation must conform to
ANSI/ASME No. CSD-1.

CANADA - "Installation Codes for Natural and LP Gas

Burning Appliances and Equipment, CAN/
CSA-B149.1.

3. These Gas Boilers are DESIGN CERTIFIED FOR

INSTALLATION ON COMBUSTIBLE FLOORING.
DO NOT INSTALL THESE BOILERS ON
CARPETING.

NOTICE

Do not drop boiler. Do not bump boiler jacket

against oor.

4. LOCATE BOILER in front of or behind installation

position before removing Crate. Locate on a level oor

as close to chimney as possible. For basement
installations, provide a solid base such as concrete, if

oor is not level or if water may be encountered on
oor around Boiler.

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.).

DANGER

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.

5. REMOVE CRATE -

A. Remove all crate fasteners. Lift off outside

container.

B. Remove all screws and brackets securing boiler to

skid.

C. Save two of the wooden slats from the container

sleeve for use in Steps D & E.

D. Tilt the boiler to one side and slide a wooden slat

under the two raised feet.

E. Tilt the boiler to the other side and slide another

wooden slat under the two raised feet.

F. Slide the boiler forward or backward off the skid

using the two wooden slats as runners.

6. Move boiler to permanent position.

7. PROVIDE CLEARANCE and AIR for COMBUS-

TION and VENTILATION.

WARNING

Adequate combustion and ventilation air must be

provided to assure proper combustion.

A. CLEARANCES

1. ALL INSTALLATIONS - Practical service
clearances must be considered (see Figure 1). A
minimum of 24" (6.0cm) from the left side and
front jacket panels is recommended for servicing
but may be reduced to minimum shown in
Figure 2. Subject to boiler and system piping,
left side clearance may be reduced to 1" (2.5cm)
if right side clearance is increased to 9"
(22.9cm).

2. ALCOVE INSTALLATIONS - An alcove is
considered a closet as shown in Figure 2 less
front. Height clearance may be reduced to 27"
(68.6cm).

3. UNCONFINED SPACE (see denition,

paragraph (B) below) - Height clearance may be
reduced to 27" (68.6cm).

B. PROVIDE COMBUSTION AND VENTILATION

AIR in accordance with applicable provisions of
local building codes, or: U.S.A. - National Fuel

Gas Code, NFPA 54/ANSI Z223.1, Canada -
Natural and Propane Gas Installation Code, CAN/

CSA-B149.1.

1. CLOSET INSTALLATIONS (conned space) in

a building of other than unusually tight
construction (see denition below), provide

combustion and ventilation air as shown in
Figure 2.

2. Installations other than closet in paragraph (1) :
a. Determine volume of space (boiler room).

Rooms communicating directly with space
(through openings not furnished with doors)
are considered part of space.

4

Figure 2: Minimum Clearances

Volume [ft³](m

3

) = Length [ft](m) x Width

[ft](m) x Height [ft](m)

b. Determine Total Input of all appliances in

space. Round result to nearest 1,000 Btu per
hour (Btuh).

c. Determine type of space. Divide Volume by

Total Input.

i. If result is greater than or equal to 50 ft³

(1.4m3) per 1,000 Btuh, space is
considered an unconned space.

ii. If result is less than 50 ft³ (1.4m3) per

1,000 Btuh, space is considered a conned
space.

d. Determine building type. A building of

unusually tight construction has the
following characteristics:

i. Walls and ceiling exposed to outside

atmosphere have a continuous water vapor
retarder with a rating of 1 perm or less
with openings gasketed and sealed, and

ii. Weather-stripping has been added on

openable windows and doors, and

iii. Caulking or sealants applied in joints

around window and door frames, between

sole plates and oors, between wall-

ceiling joints, between wall panels, at
plumbing and electrical penetrations, and
at other openings.

e. For boiler located in a building of other than

unusually tight construction, adequate
combustion and ventilation air is normally

provided by fresh air inltration through

cracks around windows and doors.

f. For boiler located

in building of unusually

tight construction, provide outdoor air

through 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 (30.5cm) of
top of space. Locate remaining opening
within 12 inches (30.5cm) of bottom of
space. Minimum dimension of air opening is

3 inches (7.6cm). Size each opening per

following:

i. Direct communication with outdoors.

Minimum free area of 1 square inch
(6.5cm2) per 4,000 Btu per hour input of
all equipment in space.

ii. Vertical ducts. Minimum free area of 1

square inch (6.5cm2) per 4,000 Btu per
hour input of all equipment in space. Duct
cross-sectional area shall be same as
opening free area.

iii. Horizontal ducts. Minimum free area of 1

square inch (6.5cm2) per 2,000 Btu per
hour input of all equipment in space. Duct
cross-sectional area shall be same as
opening free area.

g. Ventilation Duct Louvers and Grilles. Equip

outside openings with louvers to prevent
entrance of rain and snow, and screens to
prevent entrance of insects and rodents.

Louvers and grilles must be xed in open

position or interlocked with equipment to
open automatically before burner operation.
Screens must not be smaller than ¼ inch
mesh.

Consider the blocking effect of louvers,

grilles and screens when calculating the

opening size to provide the required free

area. If free area of 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.

8. CONNECT GAS SERVICE from Meter to gas control

assembly in accordance with Local Piping Codes and
requirements of Gas Company, see Figure 1. They may

require piping of larger size than Control Assembly

Connection, especially if run from meter is long or

includes several elbows. (See Figure 1 for size of Gas

Connection to gas control assembly).

5

Table 1: Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of ½ psig or Less

Length

[Feet]

10 132 278 520 1,050 175 360 680 1,400
20 92 190 350 730 120 250 465 950
30 73 152 285 590 97 200 375 770
40 63 130 245 500 82 170 320 660
50 56 115 215 440 73 151 285 580
60 50 105 195 400 66 138 260 530
70 46 96 180 370 61 125 240 490
80 43 90 170 350 57 118 220 460
90 40 84 160 320 53 110 205 430

100 38 79 150 305 50 103 195 400

Table 2: Equivalent Length of Fittings

0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop

½ ¾ 1 1¼ ½ ¾ 1 1¼

Table 3: Specic Gravity Correction Factors for

Natural Gas

Nominal Pipe Size

Fitting

½ ¾ 1 1¼

45° Ell 0.7 1 1.2 1.6
90° Ell 1.6 2.1 2.6 3.5

Tee (As Elbow) 3.1 4.1 5.2 6.9

This piping is to be supplied by the installer and must

include a trap, a ground joint union and a manual

Specic

Gravity

0.50 1.10 1.30 1.07

0.55 1.04 1.40 1.04

0.60 1.00 1.50 1.00

0.65 0.96 1.60 0.97

0.70 0.93 1.70 0.94

0.75 0.90 --- ---

0.80 0.87 --- ---

Correction

Factor

Specic

Gravity

shutoff valve upstream of the gas control assembly
outside of the jacket when codes require, see Figure 1.
A pipe thread compound resistant to the action of

liqueed petroleum gases should be applied to all

threaded joints in the gas piping. Pressure testing of the
Gas Supply Piping Boiler and its connections is
required before placing the boiler in operation.

The boiler and shutoff valve must be disconnected from

the gas supply piping system during any pressure
testing at pressures greater than ½ psig (3.5kPa).

A. Allowable loss of pressure to assure a burner

manifold pressure of 3½" (8.9cm) water for natural
gas.

B. Supply of gas to be provided in cubic feet.

C. Length of piping and number of ttings.
D. Specic gravity of gas.
E. Correction factor for specic gravity.

9. BOILER PIPING

The boiler must be isolated from the gas supply piping

system by closing its individual manual shutoff valve

CAUTION

during any pressure testing of the gas supply piping
system at pressures equal to or less than ½ psig
(3.5kPa).

RECOMMENDED SIZING OF GAS SUPPLY

PIPING TO BOILER FOR NATURAL GAS - shall
be such as to provide the required supply of gas without
undue loss of pressure between meter and the boiler.

Gas supply piping should be sized in accordance with

the Tables 1, 2 and 3. The following shall be taken into
account:

Failure to properly pipe boiler may result in
improper operation and damage to boiler or
building.

A. CLEARANCES - Hot water pipes do not require

clearance from combustible construction.

B. Install drain valve and safety relief valve as shown

in Figures 1 and 3. Note - Safety relief valve must
be in vertical position.

C. Pipe safety relief valve discharge to oor.

Correction

Factor

6

Figure 3: Recommended Water Piping for

Zone Valve Zoned Heating Systems

WARNING

Safety relief valve discharge piping must be

piped near oor to eliminate potential of severe

burns. Do not pipe in any area where freezing
could occur. Do not install any shut-off valves.

D. Install circulator with anges, gaskets and bolts

provided. Five foot long circulator harness allows
circulator to be mounted on supply or return.
Connect harness to circulator and secure any excess
conduit.

E. For heating only system piping, see Figure 3.

Consult also I=B=R Installation Guides.

F. For space heating and domestic water heating with

Alliance SL™ water heater (intermittent circulation
only); install Alliance SL™ water heater as a

separate heating zone. Refer to Alliance SL™

Installation, Operating and Service Instructions for
additional information.

G. If this boiler is used in connection with refrigeration

systems, the boiler must be installed so that the
chilled medium is piped in parallel with the heating
boiler using appropriate valves to prevent the chilled
medium from entering the boiler, see Figure 4. Also
consult I=B=R Installation and Piping Guides.

If this Boiler is connected to heating coils located in

air handling units where they may be exposed to
refrigerated air, the boiler piping must be equipped

Figure 4: Recommended Piping

for Combination Heating & Cooling

(Refrigeration) Systems

with ow control valves to prevent gravity

circulation of boiler water during the
operation of the cooling system.

H. Use a boiler bypass if the boiler is to be

operated in a system which has a large
volume or excessive radiation where low
boiler water temperatures may be
encountered (i.e. converted gravity
circulation system, etc.).

Install a pipe tee at the boiler return along

with a second tee in the supply piping as shown in

Figure 3. The bypass should be the same size as the

supply and return lines with valves located in the
bypass and supply outlet as illustrated in Figure 3 in

order to regulate water ow to maintain higher

boiler water temperatures.

Set the by-pass and boiler supply valves to a half

throttle position to start. Operate boiler until the
system water temperature is at a normal operating
range.

Adjust the valves to provide 180° to 200°F supply

water temperature. Opening the boiler supply valve
will raise the system temperature, while opening the
by-pass valve will lower the system supply
temperature.

I. A hot water boiler installed above radiation level

must be provided with a low water cutoff device as
part of the installation.

If a low water cut-off is required, it must be

mounted in the system piping above the boiler.

The minimum safe water level of a hot water boiler

is just above the highest water containing cavity of
the boiler; that is, a hot water boiler must be full of
water to operate safely.

Refer to Section VI for low water cut-off piping and

wiring instructions.

J. If it is required to perform a long term pressure test

of the hydronic system, the boiler should rst be

isolated to avoid a pressure loss due to the escape of
air trapped in the boiler.

7

To perform a long term pressure test including the

boiler, ALL trapped air must rst be removed from

the boiler.

A loss of pressure during such a test, with no visible

water leakage, is an indication that the boiler

contained trapped air.
K. 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.
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:

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.

10. INSTALL DRAFT HOOD without modication on

outlet of ue collector (See Figure 1). Secure with sheet

metal screws.

WARNING

Do not alter boiler draft hood or place any
obstruction or non-approved damper in the
breeching or vent system. Flue gas spillage can

occur. ETL certication will become void.

11. INSTALL BLOCKED VENT SWITCH

The blocked vent switch assembly shipped taped to the

top of the boiler includes a power cord and a switch
attached to a mounting bracket. The mounting bracket
has a three tooth staggered comb stamping at one end
with a #10 sheet metal screw in the center tooth.

A. Untape the blocked vent switch assembly from the

top of the boiler and uncoil the power cord.

Figure 6

B. Pinch the black strain relief bushing installed in the

jacket right side panel to dislodge it from the jacket
and pull just enough of the black power cord out so
the blocked vent switch will reach the near side of
the draft hood skirt. Do not pull out more power
cord than necessary.

C. Position the mounting bracket (with switch attached)

onto the lower edge of the draft hood skirt by
locating the center tooth (with the #10 sheet metal
screw) on the outside and the other two teeth inside
the draft hood skirt. See Figure 6.

D. Slide the mounting bracket up tight against the

lower edge of the draft hood skirt, so that the #10
sheet metal screw is above the skirt's stiffening rib.

E. Secure the bracket in this position by tightening the

#10 sheet metal screw against the outer surface of
the draft hood skirt.

F. Reinsert the excess power cord through the jacket

side panel hole to take the slack out of the power
cord running up to the blocked vent switch.

G. Reposition the strain relief bushing around the

power cord at the jacket side panel, pinch the two
halves of the bushing together, and snap it back into
the hole in the jacket side panel to secure the power
cord to the jacket.

H. Be sure the power cord, mounting bracket, and

switch are secure and located as shown in Figure 6.

8

Figure 7: Plug-in Damper Installation

WARNING

Failure to properly install and use this Blocked
Vent Switch may result in property damage,
personal injury or loss of life.

12. TO MEET FEDERALLY MANDATED

EFFICIENCIES, THIS BOILER MUST BE
EQUIPPED WITH A VENT DAMPER.

OPEN THE VENT DAMPER CARTON and remove

the Installation Instructions. READ THE INSTALLA­TION INSTRUCTIONS THOROUGHLY
proceeding.

The automatic gas control valve supplied on each Series

2™ boiler provides the redundancy referenced in the
vent damper Installation Instructions.

before

CAUTION

Do not use one vent damper to control two heating
appliances.

A. The vent damper should be the same size as the

outlet of the Draft Hood. (See Figure 1) Unpack the
damper carefully - DO NOT FORCE IT CLOSED!
Forcing the damper may damage the gear train and
void the warranty. The damper assembly includes a
prewired connection harness for use on all 24V
Standing Pilot or electronic ignition control systems.

B. Mount the vent damper assembly after the draft

hood, as close to the draft hood as practicable

without modication to the draft hood or vent

damper. (Refer to Figure 7 and to instructions

packed with the vent damper for specic

instructions). This is a must for the wiring harness to

t and the damper position indicator to be visible to

the users.

NOTICE

Provide adequate clearance for servicing.

WARNING

Provide 6" (15.2cm) minimum clearance between
damper and combustible construction.

C. Install the 90° BX connector attached to the exible

conduit in the 7/8" knockout on the left side of the
jacket. Plug the factory wired Vent Damper Harness

into the polarized receptacle. Install a cable clamp
around the exible conduit and attach to the Jacket

top panel. (See Figure 7).

NOTICE

Please refer to the specications, installation

instructions and troubleshooting guide packed
in the vent damper carton for complete detailed
installation instructions. Also refer to Figure 7 in
this manual.

D Continuous Ignition (Standing Pilot) Only. Remove

knockout from vent damper blade.

E. Size 202 Only. Install 4" x 3" reducing tting on

vent damper outlet.

13. INSTALL VENT CONNECTOR from reducing

tting (202 Only), draft hood or damper to chimney, see

Figure 8.

9

Figure 8: Typical Vent Installation

DANGER

Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.

A. Vent installation shall be in accordance with local

building codes; or the local authority having
jurisdiction; or the National Fuel Gas Code, ANSI
Z223.1/NFPA 54; or the Standard for Chimneys,
Fireplaces, Vents, and Solid Fuel Burning
Appliances, ANSI/NFPA 211. Both of the
aforementioned standards, ANSI Z223.1 and ANSI/
NFPA 211, specify Type B and Type L double wall

metal vents and re clay tile lined masonry

chimneys as suitable chimney constructions for
Category I, draft hood equipped appliances, such as
this Series 2™ boiler. Both standards prohibit the
use of unlined masonry construction as a chimney,
with the exception in ANSI Z223.1/NFPA 54 that
"Where permitted by the authority having
jurisdiction, existing chimneys shall be permitted to
have their use continued when an appliance is
replaced by an appliance of similar type, input

rating, and efciency." ANSI/NFPA 211 prohibits

the use of single wall metal vent as a chimney, while
ANSI Z223.1 allows it under very restrictive
conditions. In Canada refer to the Natural Gas and
LP Installation Code, CAN/CSA-B149.1.

B. Do not connect into same leg of chimney serving an

open replace.

C. Inspect chimney for obstructions or restrictions and

remove. Clean chimney if necessary.

D. Vent pipe to chimney must not be smaller than outlet

on draft hood or damper. Although single wall vent
pipe may be used, Type B is recommended. The
venting system must be arranged so that only the

boiler is served by the damper device. Installation
per paragraph 12 complies with this provision.

E. Where two or more appliances vent into a common

vent, the area of the common vent should at least
equal the area of the largest vent plus 50% of the
area in the additional vents. Do not connect the vent
of this appliance into any portion of mechanical
draft system operating under positive pressure.

F. Vent pipe should have the greatest possible initial

rise above the draft hood consistent with the head
room available and the required clearance from
adjacent combustible building structure. Vent Pipe
should be installed above the bottom of chimney to
prevent blockage.

G. Vent pipe should slope upward from draft hood to

chimney not less than one inch in four feet. Doivent

présenter des tronçons horizontaux dont la pente

montante est d’au moins ¼ po par pied (21 mm/m)
entre la chaudière et l’évent. No portion of vent
pipe should run downward or have dips or sags.
Vent pipe must be securely supported. Les sections

horizontales doivent être supportées pour prévenir le
échissement.

H. Vent pipe must be inserted into but not beyond

inside wall of chimney liner. Seal tight between vent
pipe and chimney.

I. Do not install non-listed (AGA, CGA, CSA, ETL or

UL) vent damper or other obstruction in vent pipe.

WARNING

14. IF AN EXISTING BOILER IS REMOVED -

When an existing boiler is removed from a common

venting system, the common venting system is likely to
be too large for proper venting of the appliances
remaining to it.

At the time of removal of an existing boiler, the

following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the other
appliances remaining connected to the common
venting system are not in operation:

A. Seal any unused openings in the common venting

system.

B. Visually inspect the venting system for proper size

and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion, and other

deciencies which could cause an unsafe condition.

C. Insofar as is practical, close all building doors and

windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum

10

speed. Do not operate a summer exhaust fan. Close

replace dampers.

D. Place in operation the appliance being inspected.

Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.

E. Test for spillage at the draft hood relief opening

after 5 minutes of main burner operation. Use the

ame of a match or candle, or smoke from a

cigarette, cigar or pipe.

F. After it has been determined that each appliance

remaining connected to the common venting system
properly vents when tested as outlined above, return

doors, windows, exhaust fans, replace dampers and

any other gas burning appliance to their previous
conditions of use.

G. Any improper operation of the common venting

system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1 and/or CAN/CSA B149.1, Installation

Codes. When resizing any portion of the common

venting system, the common venting system should

be resized to approach the minimum size as

determined using the National Fuel Gas Code,
ANSI Z223.1 and/or CAN/CSA B149.1, Installation

Codes.

Au moment du retrait d’une chaudière existante, les

mesures suivantes doivent être prises pour chaque

appareil toujours raccordé au système d’evacuation
commun et qui fonctionne alors que d’autres
appareils toujours raccordés au système
d’évacuation ne fonctionnent pas:

A. Sceller toutes les ouvertures non utilisées du

système d’évacuation.

B. Inspecter de facon visuelle le système d’évcuation

pour déterminer la grosseur et l’inclinaison

horizontale qui conviennent et s’assurer que le

système est exempt d’obstruction, d’étranglement,
de fuite, de corrosion et autres défaillances qui
pourraient présenter des risques.

C. Dans la mesure du possible, fermer toutes les portes

et les fenêtres du bâtiment et toutes les portes entre

l’espace où les appareils toujours raccordés au
système d’évacuation sont installés et les autres

espaces du bâtiment. Mettre en marche les

sécheuses, tous les appareils non raccordés au
système d’évacuation commun et tous les
ventilateurs d’extraction comme les hottes de
cuisinière et les ventilateurs des salles de bain.
S’assurer que ces ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner les
ventilateurs d’été. Fermer les registres des
cheminées.

D. Mettre l’appareil inspecté en marche. Suivre les

instructions d’allumage. Régler le thermostat de
facon que l’appareil fonctionne de facon continue.

E. Faire fonctionner le brùleur principal pendant 5 min

ensuite, déterminer si le coupe-tirage déborde à

l’ouverture de décharge. Utiliser la amme d’une

allumette ou d’une chandelle ou la fumée d’une
cigarette, d’un cigare ou d’une pipe.

F. Une fois qu’il a été déterminé, selon la méthode

indiquée ci-dessus, que chaque appareil raccordé au
système d’évacuation est mis à l’air libre de facon

adéquate. Remettre les portes et les fenêtres, les

ventilateurs, les registres de cheminées et les

appareils au gaz à leur position originale.

G. Tout mauvais fonctionnement du système

d’évacuation commun devrat être corrigé de facon

que l’installation soit conforme au National Fuel
Gas Code, ANSI Z223.1 et (ou) aux codes
d’installation CAN/CSA-B149.1. Si la grosseur

d’une section du système d’évacuation doit être
modiée, le système devrait être modié pour

respecter les valeurs minimales des tableaux
pertinents de l’appendice F du National Fuel Gas

Code, ANSI Z223.1 et (ou) des codes d’installation
CAN/CSA-B149.1.

15. INSTALL A ROOM THERMOSTAT on an inside

wall about four feet above oor. Never install

thermostat on an outside wall or where it will be

inuenced by drafts, hot or cold water pipes, lighting
xtures, television, rays of the sun or near a replace.

Keep large furniture away from thermostat so there will
be free movement of room air around this control.

Table 4: Wiring Diagrams and Heat Anticipator Settings

Ignition Type Circulation Method

Continuous

(Standing Pilot)

Electronic

If system tends to overheat above thermostat's temperature setting, reduce heat anticipator setting by

0.1 or 0.2 amps. If system tends to shortcycle without reaching desired room temperature, increase heat
anticipator setting by 0.1 or 0.2 amps.

Intermittent 0.6 11

Constant/Gravity 1.0 14

Intermittent 0.6 12

Constant/Gravity 1.0 15

Thermostat Heat Anticipator

Setting [Amps]

Wiring

Diagram Figure

11

Heat Anticipator in Thermostat should be set to match

the requirements of the control to which it is connected.
See Table 4. If system tends to overheat above the
thermostat's temperature setting, reduce heat anticipator
setting by .1 or .2 amps. If system tends to short cycle
without reaching desired room temperature, increase
heat anticipator setting by .1 or .2 amps.

16. INSTALL ELECTRIC WIRING in accordance with

National Electric Code or the Canadian Electrical Code
and local regulations. See Figures 11 through 16 for
applicable wiring diagram. A separate electrical circuit
must be run from the main electrical service with an
over-current device/disconnect in the circuit. A service
switch is recommended and may be required by some
local jurisdictions. When installed, the boiler must be
electrically grounded in accordance with local codes or,
in the absence of local codes, with the National
Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1
Electrical Code, if an external electrical source is

utilized.

For zone valve wiring, a separate 24V transformer is

required rather than attempting to use the boiler

mounted control. Consult zone valve manufacturer for

assistance.

17. VENT DAMPER SEQUENCE OF OPERATION.

See Figure 9.
A. The Vent Damper is continuously powered at

Terminal 1.

B. When there is a call for heat, the damper relay coil is

energized through Terminal 5 if all limits ahead of
the damper are satised.

C. The relay coil closes contacts which energize the

damper motor, causing the damper to open.

D. When the damper blade reaches the fully open

position, power is sent back to the ignition circuit
through Terminal 2 and the damper motor is de-

energized.

E. When the call for heat is satised, the damper relay

coil is de-energized - closing contacts which
energize the damper motor. This causes the damper

to close. When the damper blade reaches the fully

closed position, the damper motor is de-energized.

POWER FAILURE - The damper blade will stop in

the position it was in when power failed.
(Combustion can never take place unless the damper
blade is in the fully open position.)

Figure 9: Vent Damper Schematic Wiring Diagram

This boiler contains controls which may cause the boiler to shut down and not restart 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.

Avoid operating this boiler in an environment where saw dust, loose insulation bers, dry wall dust, etc.

are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and
inspected daily to insure proper operation.

12

CAUTION

CAUTION

Figure 11: Wiring Diagram, 24 Volt Standing Pilot and Intermittent Circulation

SEQUENCE OF OPERATION
Normal Operation

1. When the thermostat call for heat, the vent damper
will open (see paragraphs 17A through 17D). The
circulator is started through a relay and at the same

time the gas valve is energized allowing main gas
ow and ignition of main burners.

2. Where condensation of ue gas is encountered in
boiler ues a reverse acting circulator control should

be installed to stop the circulator before the boiler

water temperature drops to that which ue gas

condensation may occur.

3. After the thermostat is satised the main valve will
close and main burner ames will be extinguished.

The vent damper will close (see paragraph 17E).

SAFETY SHUTDOWN

1. High Limit Switch

In the event excessive boiler water temperature is

developed the high limit switch will open
interrupting power to the gas valve. The main
burners will be extinguished immediately, and the
vent damper will close at the same time, but the
circulator will continue to operated. Normal
operation will be resumed when the boiler water
temperature drops to a point where the high limit
switch closes.

2. Blocked Vent Switch
In the event excessive blockage in the vent system is

developed the blocked vent switch will open
interrupting power to the gas valve. The main
burners will be extinguished immediately, the
circulator will continue to operate, and the vent
damper will remain open until the thermostat is
turned off. The source of blockage must be
corrected by trained and skilled personnel from a

qualied service agency before resetting switch.

3. Flame Rollout Switch
In the event excessive blockage in the boiler section

ue passageways is developed the ame rollout

switch will open interrupting power to the gas valve.
The main burners will be extinguished immediately,
the circulator will continue to operate and the vent
damper will remain open until the thermostat is

turned off. If the ame rollout switch is activated do

not attempt to place the boiler in operation. The

source of blockage must be corrected and the ame

rollout switch replaced by trained and skilled

personnel from a qualied service agency.

4. Pilot

The thermocouple proves pilot ame and in the

absence of such within 45-90 seconds causes the
combination gas valve, which is equipped with a

100% shut-off provision, to be de-energized, thus,
preventing main gas or pilot gas ow.

13

Figure 12: Wiring Diagram, Electronic Ignition (EI), Intermittent Circulation

SEQUENCE OF OPERATION
NORMAL OPERATION

1. When the thermostat calls for heat, the relay is

energized. The circulator starts and the vent damper

opens (see Paragraphs 17A through 17D). When the
damper blade reaches the fully open position, the

ignition module is energized opening the pilot valve
and energizing the igniter to ignite the pilot burner.

2. Sensor proves presence of pilot ame. Main valve

opens to ignite main burners.

3. The burners and circulator will operate

simultaneously until the thermostat is satised.

4. After thermostat is satised, ignition module is de­energized, extinguishing pilot and main ame. Vent

damper closes (see paragraph 17E).

SAFETY SHUTDOWN

1. Limit: Automatically interrupts main burner
operation when water temperature exceeds set point.
Maximum allowable temperature is 250°F. Normal
operation resumes when water temperature falls
below set point.

2. Blocked Vent Switch: Automatically interrupts

main burner operation when excessive vent system
blockage occurs. Control is a multiple use device. If
blocked vent switch is activated do not attempt to
place boiler in operation. Correct source of blockage
and reset blocked vent switch.

3. Flame Roll-out Switch: Automatically interrupts

boiler operation when ames or excessive heat are

present in vestibule. Control is single use device. If

ame roll-out switch is activated do not attempt to

place boiler in operation. Correct source of blockage

and replace ame roll-out switch.

4. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown,
ignition module restarts ignition sequence.

5. For Electronic Ignition Trouble Shooting Guide, see
Page 25 of this manual.

14

Figure 13: Wiring Diagram, 24 Volt Standing Pilot with Continuous or Gravity Circulation

SEQUENCE OF OPERATION
NORMAL OPERATION

1. When the thermostat call for heat, the vent damper
will open (see paragraphs 17A through 17D). The

gas valve is energized allowing main gas to ow and

operation of the main burners.

2. Where condensation of ue gas is encountered in
boiler ues a reverse acting circulator control should

be installed to stop the circulator before the boiler

water temperature drops to that which ue gas

condensation may occur.

3. After the thermostat is satised the main valve will
close and main burner ames will be extinguished.

The vent damper will close (see paragraph 17E). If
the boiler is so equipped, circulator will continue to
run.

SAFETY SHUTDOWN

1. High Limit Switch: In the event excessive boiler
water temperature is developed the high limit switch
will open interrupting power to the gas valve. The
main burners will be extinguished immediately.
Normal operation will be resumed when the boiler
water temperature drops to a point where the high
limit switch closes.

2. Blocked Vent Switch: In the event excessive
blockage in the vent system is developed the
blocked vent switch will open interrupting power to
the gas valve. The main burners will be extinguished
immediately and the vent damper will remain open
until the thermostat is turned off. The source of
blockage must be corrected by trained and skilled

personnel from a qualied service agency before

resetting switch.

3. Flame Rollout Switch: In the event excessive

blockage in the boiler section ue passageways is
developed the ame rollout switch will open

interrupting power to the gas valve. The main
burners will be extinguished immediately and the
vent damper will remain open until the thermostat is

turned off. If the ame rollout switch is activated do

not attempt to place the boiler in operation. The
source of the blockage must be corrected and the

ame rollout switch replaced by trained and skilled
personnel from a qualied service agency.

4. Pilot: The thermocouple proves pilot ame and in

the absence of such within 45-90 seconds causes the
combination gas valve, which is equipped with a

100% shut-off provision, to be de-energized, thus,
preventing main gas or pilot gas ow.

15

Figure 14: Wiring Diagram, Electronic Ignition (EI), Continuous or Gravity Circulation

SEQUENCE OF OPERATION
NORMAL OPERATION

1. When the thermostat calls for heat the vent damper
opens (see Paragraphs 17A through 17D). When the
damper blade reaches the fully open position, the

ignition module is energized opening the pilot valve
and energizing the igniter to ignite the pilot burner.

2. Sensor proves presence of pilot ame. Main valve

opens to ignite main burners.

3. The burners will operate until the thermostat is

satised.

4. When thermostat is satised, ignition module is de­energized, extinguishing pilot and main ame. If

boiler is equipped with circulator, circulator will
continue to run. Vent damper closes (see Para-graph
17E).

SAFETY SHUTDOWN

1. Limit: Automatically interrupts main burner
operation when water temperature exceeds set point.
Maximum allowable temperature is 250°F. Normal
operation resumes when water temperature falls
below set point.

2. Blocked Vent Switch: Automatically interrupts

main burner operation when excessive vent system
blockage occurs. Control is a multiple use device. If
blocked vent switch is activated do not attempt to
place boiler in operation. Correct source of blockage
and reset blocked vent switch.

3. Flame Roll-out Switch: Automatically interrupts

boiler operation when ames or excessive heat are

present in vestibule. Control is single use device. If

ame roll-out switch is activated do not attempt to

place boiler in operation. Correct source of blockage

and replace ame roll-out switch.

4. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown,
ignition module restarts ignition sequence.

5. For Electronic Ignition Trouble Shooting Guide, see
Page 25 of this manual.

16