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 .......................................

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.

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.]

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.

Figure 2: Minimum Clearances

Volume [ft³](m

) = 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).

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

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.

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.

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.

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

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

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.

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.

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.

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.

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

2. Blocked Vent Switch: Automatically interrupts

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.

Figure 15: Wiring Schematic, Zone Valves

Figure 16: Wiring Schematic, Zone Circulators

II. Operating Instructions

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specied in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13b-1994.

1. MAIN BURNER CHECK - Check main burners to

see that they were not dislodged during shipment. Rear of burners should be in the slots in the rear of burner tray and the front of the burners should be seated

completely on the orices.

2. INITIAL START -

A. FILL ENTIRE HEATING SYSTEM WITH

WATER and vent air from system. Use the following procedure on a Series Loop System

equipped with zone valves. (See Figure 3).

1. Close isolation valve in boiler supply piping.

2. Isolate all circuits by closing zone valves or

balancing valves.

3. Attach a hose to hose bib located just below isolation valve in boiler supply piping. (Note -

Terminate hose in ve gallon bucket at a suitable oor drain or outdoor area).

4. Starting with one circuit, open zone valve.

5. Open hose bib.

6. Open ll valve (Make-up water line should be

located directly above isolation valve in boiler supply piping).

7. Allow water to overow from bucket until

discharge from hose is bubble free for 30 seconds.

8. Open zone valve to the second zone to be purged, then close the rst. Repeat this step until all zones have been purged, but always have one zone open. At completion, open all zone valves.

9. Close hose bib, continue lling the system until the pressure gauge reads 12 psi. Close ll valve.

(Note - If make-up water line is equipped with pressure reducing valve, system will

automatically ll to 12 psi. Leave globe valve

open).

10. Open isolation valve in boiler supply piping.

11. Remove hose from hose bib.

B. Turn ROOM THERMOSTAT to lowest setting. C. Be sure that gas to pilot and main burners has been

off for at least ve minutes and vent damper (if

used) has been in the open position. D. Turn "OFF" the electric switch serving boiler. E. Open valve on main gas line at meter. F. PURGE AIR FROM GAS PIPING. This

procedure will vary with equipment furnished but in

all cases adequate ventilation must be provided

and no smoking or open ame permitted. To

determine which of the procedures outlined in

succeeding paragraphs is applicable, match sufx of

Figure 17: Schematic Pilot and Gas Piping

Continuous Ignition (Standing Pilot)

Figure 18: Schematic Pilot and Gas Piping

Electronic Ignition (EI)

boiler model found on Rating Label with paragraph heading:

1. Standing Pilot Models (Sufx C):

a. Keep electric switch "OFF". b. Open Manual Shut-off Valve upstream of

Combination Gas Valve.

c. Disconnect Pilot Tubing at gas valve (Purge

must not be into combustion chamber).

d. Turn Main Gas Knob on Combination Gas

Valve to "Pilot" Position. Depress and hold in this position until purging is complete. Turn Main Gas Knob to "off" position.

Figure 19: Top View of VR Gas Valves

Figure 20: Operating Instructions, VR8204 and VR8304 Gas Valves

e. Reconnect pilot tubing and check pipe and

ttings from meter to combination Gas

Valve for leaks using soap solution or other approved method.

2. Electronic Ignition Models (Sufx I):

a. Turn "ON" electric switch serving boiler. b. Open Manual Shut-off Valve upstream of

Combination Gas Valve.

c. Loosen or remove Inlet Pressure Tap Plug in

Combination Gas Valve and when purging is complete, tighten or replace plug. See Figure

19.

d. Check pipe and ttings from meter to

Combination Gas Valve using soap solution or other approved methods.

CAUTION

Figure 21: LED Locations

e. Test gas piping and connections between

Combination Gas Valve and manifold,

orices, and pilot piping for leaks after

boiler is operating. Use soap solution or other approved method.

3. INSTRUCTIONS TO PUT THE BOILER IN

OPERATION. A. See Figure 20 for electronic ignition (EI).

Electronic Ignition Modules with LED indicators.

Table 5 cross-references the ignition module

terminal designations to the ignition terminal

Table 5: Ignition Module Terminal Cross Reference

Ignition Module

Terminal Designation

MV 1

MV/PV 2

PV 3

GND 4

24V (GND) 5

numbers in the wiring ladder diagrams. The yellow

LED indicates the status of the ame, see Table 6.

The green LED indicates the status of the system,

see Table 7. See Figure 21 for LED locations. See

24V 6

SPARK 9

Figure 28 for Troubleshooting Guide.

Table 6: Yellow LED Flame Codes

Yellow LED Flash

Code

Indicates Recommended Service Action

Heartbeat Normal Flame Signal N/A

Weak Flame Signal -

System will operate reliably but ame signal is less than

desired.

Note: This indication may ash temporarily during or

shortly after lightoff on some applications.

Marginal Flame Signal (less than 1.1 µA) System may not operate reliably over time. Service call recommended.

Note: This indication may ash temporarily during or

shortly after lightoff on some applications.

Perform routine maintenance to

assure optimum ame signal.

Check gas supply, pilot burner, ame sense wiring, contamination of ame rod, burner

ground connection.

Wiring Ladder Diagram

Terminal Number

No Flame or Flame Signal -

OFF

Flash Code Descriptions

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- The ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then repeats sequence.

below minimum threshold for system operation.

N/A

Table 7: Green LED Status Codes

Green LED Flash Code

(X + Y)

Flash Fast

Heartbeat Normal operation N/A None

Flash Code Descriptions:

OFF No “Call for Heat” N/A None

Startup - Flame sense calibration

5 minute Retry Delay-

Pilot ame not detected

during trial for ignition

Recycle- Flame failed during run

Flame sensed out of sequence

Flame sense leakage to ground

Low secondary voltage supply- (below 15.5 Vac)

5 minute Retry Delay-

6 + 2

On every third retry on same “Call for Heat”

On every 6th ame

6 + 3

failure during run on the same “Call for Heat”

Flame sensed out of

6 + 4

sequence- longer than 10 seconds

Soft lockout due to error

detected during self check sequences

- Flash Fast: rapid blinking

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then

repeats the sequence.

- X + Y ash codes signify that the LED ashes X times at 2Hz, remains off for two seconds, ashes Y times at 2

Hz, remains off for three seconds, and then repeats the sequence.

Indicates Next System Action Recommended Service Action

N/A None

If system fails to light on next trial

for ignition check gas supply, pilot Initiate new trial for ignition after retry delay completed.

Initiate new trial for ignition. Flash code will remain through the ignition

trial until ame is proved.

If situation self corrects within 10 seconds, control returns to normal sequence. If ame out of sequence remains longer than 10 seconds, control goes to Flash code 6+4 (see below)

Control remains in wait mode. When the fault corrects, control resumes normal operation after a one minute delay.

Control remains in wait mode. When the fault corrects, control resumes normal operation after one minute delay.

Initiate new trial for ignition after retry delay completed.

5 minute retry delay, then initiate new trial for ignition.

Control waits until ame is no longer

sensed and then goes to soft lockout. Flash code continues. Control auto resets from soft lockout after one hour.

Control auto resets from soft lockout after one hour.

burner, spark and ame sense wir-

ing, ame rod contamination or out

of position, burner ground connec-

tion.

If system fails to light on next trial

for ignition check gas supply, pilot

burner, ame sense wiring, ame

rod contamination, burner ground

connection.

Check for pilot ame. Replace gas

valve if pilot ame present. If no

pilot ame, cycle “Call for Heat.” If

error repeats, replace control.

Check ame sense lead wire for

damage or shorting. Check that

ame rod is in proper position.

Check ame rod ceramic for cracks,

damage or tracking.

Check transformer and AC line for

proper input voltage to the control.

Check with full system load on the

transformer.

Check gas supply, pilot burner, spark

and ame sense wiring, ame rod

contamination or out of position,

burner ground connection.

Check gas supply, pilot burner, ame

sense wiring, contamination of ame

rod, burner ground connection.

Check for pilot ame. Replace gas

valve if pilot ame present. If no

pilot ame, cycle “Call for Heat.” If

error repeats, replace control.

Reset by cycling “Call for Heat.” If

error repeats, replace the control

Figure 22: Lighting Instructions

B. See Figure 22 for continuous ignition system

(standing pilot).

4. CHECK GAS INPUT RATE TO BOILER

NOTICE

USA boilers built for installation at altitudes greater

than 2,000 feet above sea level have been specially

oriced 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, Section 8.1.2 and Appendix F.

Canadian boilers' orice sizing is indicated on the rating label. High altitude boiler models are identiable by

the fourth digit after the dash in the model number. 2: 0-2000', 4 or 5: above 2000'.

A. Input Rate and Maximum Inlet Pressure shown on

Rating Label must not be exceeded. Inlet pressure must not be lower than minimum inlet pressure shown on Rating Label.

B. All Rate checks and all adjustments are to be made

while boiler is ring - all other appliances connected

to the same meter as the boiler must be off.

C. With boiler off, water Manometer or water column

gauge should be connected to a shut-off valve installed in the 1/8" outlet pressure tap in the gas valve (see Figure 19). By installing gas valve upstream of manometer, gas pressure can be introduced gradually - without shut-off valve, surge of pressure when boiler is turned on, could blow liquid out of manometer. Replace plug in gas valve

when rate check is nished.

D. LP Gas Input: Adjust Regulator on Gas Valve so that manifold

pressure is 10 inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure. Counterclockwise rotation decreases pressure.

more accurate check on input is necessary see (2) below.

For minor input changes readjust Regulator Gas

Valve to increase or decrease manifold pressure to obtain corresponding increase or decrease in gas input. If it is necessary to increase manifold pressure more than 0.3" of water to obtain rated

input, remove orices and drill one size larger.

Reinstall and recheck input rate.

2. Additional Check on Input - Since input is a

function of heating value, specic gravity, and volume of gas ow contact your utility for the rst two items in order to utilize the formula

below. The gas meter should then be clocked for three (3) minutes with stop watch and substituting the appropriate values in the formula

below, determine what the gas ow should be in

this 3 minute period to give the input shown on the Rating Label:

Gas Input

(cu. ft.)

per 3 min. Value X from

Heating Multiplier

of Gas Table 3

(Btu / cu. ft.

Btuh Input

5. MAIN BURNER FLAMES should have a clearly

dened inner cone (see Figure 23 or 24) with no yellow

tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping.

Figure 23: 40mm Main Burner Flame

E. Natural Gas Input

1. Appx. Input - Adjust regulator on Gas Valve so that manifold pressure is three and a half (3½) inches water column. Turning Regulator Adjusting Screw Clockwise increases pressure, Counterclockwise rotation decreases pressure. If

Figure 24: 1 Inch Main Burner Flame

The main burners in this boiler will not operate cleanly

or efciently if they are contaminated with dirt and/or

construction dust. Burners should be cleaned and the combustion chamber vacuumed following instructions in Section IV. Service.

6. CHECK PILOT BURNER FLAME.

A. Continuous Ignition (Standing Pilot) LP gas Models 202 and 202X. See Figure 25. Natural gas Models 202 through 206 and 207 with

1" diameter burners. See Figure 25.

Figure 25: Typical Pilot Flame, Honeywell Q350

The pilot produces a single ame. The ame should

be steady, medium hard blue enveloping 3/8 to a 1/2 inch of thermocouple.

B. Continuous Ignition (Standing Pilot) Natural gas Models 207 with 40mm (1-9/16")

diameter burners and 208 through 210.

See Figure 26. LP gas Models 203 through 210. See Figure 26.

The pilot produces three (3) ames. The center

ame should be steady, medium hard blue

enveloping 3/8 to a 1/2 inch of thermocouple.

Figure 26: Typical Pilot Flame, Honeywell Q327

C. Electronic Ignition (EI), see Figure 27.

The pilot produces three (3) ames. The center

ame should be steady, medium hard blue

enveloping 3/8 to a ½ inch of sensing probe.

Figure 27: Typical Pilot Flame, Honeywell Q348A

7. CHECK THERMOSTAT OPERATION. Raise and

lower temperature setting as required to start and stop burners.

8. CHECK HIGH LIMIT CONTROL. Jumper

Thermostat Terminals or Thermostat connections in Limit Control. Allow burners to operate until shutdown by limit. REMOVE JUMPER.

9. CHECK DAMPER OPERATION. Vent Damper must

be open when boiler is running. Le registre doit être

ouvert lorsque le brûleur principal de l’appareil fonctionne. Start boiler, refer to instructions on damper to determine if damper is in the full open position.

10. CHECK IGNITION SYSTEM SAFETY SHUT-OFF

DEVICE. A. 24 volt-loosen thermocouple at gas valve.

B. Electronic Ignition - Remove pilot lead wires from

gas valve.

If burners do not shut down determine cause of

malfunction. Replace necessary items and check operation.

11. COMBUSTION CHAMBER BURN-OFF

A. The mineral wool combustion chamber panels may

contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation.

B. Ventilate the boiler room, set the high limit to its

maximum setting, set the thermostat to call for heat.

Allow the boiler to re for at least an hour or until

the odor from the cornstarch has dissipated.

C. Return the high limit and thermostat to their desired

settings.

III. Trouble Shooting

Honeywell Electronic Ignition Troubleshooting Guide

Figure 28: Troubleshooting Guide, Honeywell Electronic Ignition (EI)

IV. Service

1. Inspection should be conducted annually. Service as

frequently as specied in paragraphs below. While

service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be "off".

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

ATTENTION. Au moment de l’entretien des

commandes, étiquetez tous les ls avant

de les débrancher. Les erreurs de câblage peuvent nuire au bon fonctionnement et être dangereuses.

S’assurer que l’appareil fonctionne adéquatement une fois l’entretien terminé.

2. VENT SYSTEM. Vent system (see Figure 8 for typical

installation) should be checked annually for: A. Obstructions. B. Accumulations of soot. C. Deterioration of vent pipe or vent accessories due to

condensation or other reasons.

D. Proper support - no sags, particularly in horizontal

runs. E. Tightness of joints. F. Proper vent damper operation - see Section II

Operating Instructions, paragraph 9. G. Remove all accumulations of soot with wire brush

and vacuum, see Figure 29. Remove all

obstructions. Replace all deteriorated parts and

support properly. Seal all joints.

3. CLEANING BOILER FLUES, see Figure 29.

Flue passageways in the boiler sections should be

checked annually for any blockage or accumulation of

soot. To obtain access to ueways:

A. Remove vent pipe, damper (if boiler is so equipped),

blocked vent switch, and draft hood. B. Remove sheet metal screws securing Jacket Top

Panel, lift panel and rotate about relief valve piping

until top of boiler is exposed. C. Remove bolts securing Canopy to Boiler Sections.

Remove Canopy - ueways are now exposed. D. Models with ue gas bafes only: Remove bafes

by lifting out of ueways. Using ashlight, examine all ue passageways. If

passageways are free of soot and obstruction,

replace canopy (and ue gas bafes, if applicable),

and seal.

Reinstall Jacket Top Panel, draft hood, blocked vent

switch, damper (if boiler is so equipped), and vent pipe.

If the ue passageways need cleaning, remove

burners as described in paragraph 4 below. Using

long handle wire or bristle ue brush and vacuum, brush ueways thoroughly from top of boiler as

illustrated in Figure 29. Replace canopy and seal with boiler putty. Reinstall Jacket Top Panel, draft hood, blocked vent switch, damper (if boiler is so equipped), and vent pipe.

NOTICE

4. BURNERS AND FIREBOX SHOULD BE CLEANED

ANNUALLY, AND IF NECESSARY ADJUSTED ONCE A YEAR BY A QUALIFIED SERVICE AGENCY.

A. TO REMOVE BURNERS FOR CLEANING,

CHANGING ORIFICE PLUGS, OR REPAIRS.

1. Remove the jacket front panel.

2. Disconnect pilot tubing at the gas valve. See Figure 17.

3. Disconnect thermocouple (standing pilot) or pilot lead wires (electronic ignition) at the gas valve.

4. 40mm burners only. Remove injection shield assembly, where used. See Figure 30.

5. Remove wires to ame roll-out switch.

6. Remove the burner access panel.

7. Mark the location of the pilot main burner on the manifold if the marking on manifold is missing or obliterated.

Figure 29: Cleaning of Vent System

and Boiler Flues

8. Hold burner at throat. Lift front of burner to

clear orice. Burner which holds pilot can only

be removed by lifting the burner adjacent to its

right rst.

1" Burner

40mm Burner

Figure 30: Burner Cleaning and Installation

9. Brush top of burners with a soft bristle brush, see

Figure 30. Vacuum burners. Check orices to see

that drilled passageways are free of lint or dirt.

10. Vacuum tip of Pilot Burner.

B. CLEAN FIREBOX by vacuuming. Exercise care

not to disturb insulation inside the base.

C. INSTALL BURNERS by reversing procedure used

to remove burners. Make sure burner with pilot assembly is in same location as original installation

- see Table 8.

Check burners to see that they are located properly

in slot at rear of burner tray, see Figure 30. Reinstall injection shield assembly (40mm burners only, where used) and burner access panel.

Reconnect ame roll-out switch wires, pilot gas

supply, thermocouple lead or pilot lead.

D. CHECK MAIN BURNER and PILOT FLAMES,

see procedure Section II Operating Instructions, paragraphs 5 and 6.

5. CHECK ALL CONTROL AND DAMPER

OPERATION ANNUALLY see procedure in Section II Operating Instructions, paragraphs 7 through 10.

6. REMOVAL OR REPLACEMENT OF PILOT

ASSEMBLY OR PILOT ASSEMBLY PARTS

If pilot assembly, thermocouple or pilot orice need

replacing, remove main burner with pilot using procedure described in paragraph 4.

A. To replace orice:

1. Disconnect pilot tubing. The Honeywell Q350

pilot orices are insert type retained by the compression tting. The Honeywell Q327 and Q348A pilot orices are spud type screwed into pilot burner. Replace with desired orice. See

Key No. 5B.

2. Reconnect pilot tubing and check for leaks.

B. To replace Honeywell Q309A thermocouple in

Q327 or Q350 pilot:

1. Loosen attachment nut securing thermocouple to barrel of pilot burner. Disconnect other end at combination gas valve.

2. Remove thermocouple and replace with equal.

C. To replace complete pilot assembly.

1. Remove machine screws holding pilot burner to pilot bracket.

2. Disconnect pilot piping.

3. Disconnect all other leads to pilot.

4. Select pilot assembly with identical model number, reconnect leads and pilot tubing resecure to pilot bracket.

D. To adjust or check spark gap between electrode and

hood on Honeywell Q348A pilot.

1. Use round wire gauge to check spark gap.

2. Spark gap should be 1/8 inch for optimum performance.

E. Reinstall main burner following procedure described

in paragraph 4.

7. LUBRICATION

There are no parts requiring lubrication on the part of

the service technician or the User. Circulator bearings are water lubricated.

Table 8: Pilot Burner Location

Boiler

Model

202 1 1 1 & 2 ---

202X 1 1 1 & 2 1 & 2

203 1 1 1 & 2 1 & 2 204 2 2 2 & 3 2 & 3 205 3 2 3 & 4 2 & 3 206 4 3 4 & 5 3 & 4 207 6 3 6 & 7 3 & 4 208 7 4 7 & 8 4 & 5 209 8 4 8 & 9 4 & 5 210 9 5 9 & 10 5 & 6

* Main burners numbered left to right as viewed from front of boiler.

Main Burner with

Pilot Bracket *

1 Inch 40mm 1 Inch 40mm

Pilot Burner Located

Between Main

Burners *

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures: Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

V. Repair Parts

Section Assembly and Canopy Group ............................30

Base Assembly ..................................................................32

Manifold and Main Burners

1 Inch Main Burners ..................................................

40mm Main Burners ..................................................36

Pilot Burner and Gas Valve

Continuous Ignition (Standing Pilot) .......................38

Electronic Ignition .....................................................40

Jacket Assembly ...............................................................41

Water Trim .......................................................................44

Controls .............................................................................46

Draft Hood and Vent Damper .........................................47

Key

Description Part No.

No.

1. Section Assembly (Intermittent and Continuous Circulation Only)

617170221 1 --- --- --- --- --- --- --- --- --617170321 --- 1 1 --- --- --- --- --- --- --617170421 --- --- --- 1 --- --- --- --- --- --617170521 --- --- --- --- 1 --- --- --- --- ---

1 Section Assembly, Complete

1. Section Assembly (Gravity Circulation Only)

1 Section Assembly, Complete

617170621 --- --- --- --- --- 1 --- --- --- --617170721 --- --- --- --- --- --- 1 --- --- --617170821 --- --- --- --- --- --- --- 1 --- --617170921 --- --- --- --- --- --- --- --- 1 --617171021 --- --- --- --- --- --- --- --- --- 1

617170231 1 --- --- --- --- --- --- --- --- --617170331 --- 1 1 --- --- --- --- --- --- --617170431 --- --- --- 1 --- --- --- --- --- --617170531 --- --- --- --- 1 --- --- --- --- --617170631 --- --- --- --- --- 1 --- --- --- --617170731 --- --- --- --- --- --- 1 --- --- --617170831 --- --- --- --- --- --- --- 1 --- --617170931 --- --- --- --- --- --- --- --- 1 --617171031 --- --- --- --- --- --- --- --- --- 1

202 202X 203 204 205 206 207 208 209 210

Quantity

Key

Description Part No.

No.

2. Canopy Group

Quantity

202 202X 203 204 205 206 207 208 209 210

61117022 1 --- --- --- --- --- --- --- --- --611170300 --- 1 --- --- --- --- --- --- --- --611170302 --- --- 1 --- --- --- --- --- --- --611170402 --- --- --- 1 --- --- --- --- --- ---

Canopy Assembly (except for 206H)

Canopy Assembly 206H 6111706010 --- --- --- --- --- 1 --- --- --- --2B Carriage Bolt, 1/4-20 x 1" 80860115 2 2 2 2 2 2 2 2 2 2 2C Flat Washer, 1/4" 80860603 2 2 2 2 2 2 2 2 2 2 2D Nut, Hex, 1/4-20 80860407 2 2 2 2 2 2 2 2 2 2 2E Cerafelt Sealing Strip, 1/2" x 1" x 10' 6206001 1 1 1 1 1 1 1 1 1 1

Flue Gas Bafe (*Standing Pilot 1"

Burners Only) 2F

(** LP Standing Pilot 1" Burners Only)

(*** Standing Pilot Models Only)

611170502 --- --- --- --- 1 --- --- --- --- --611170602 --- --- --- --- --- 1 --- --- --- --611170702 --- --- --- --- --- --- 1 --- --- --611170802 --- --- --- --- --- --- --- 1 --- ---

611170902 --- --- --- --- --- --- --- --- 1 ---

611171002 --- --- --- --- --- --- --- --- --- 1

71106001 1*** --- 2** 3** 4** 5** 6** 7* 8* 9*

Section Assembly and Canopy Group

THIS PAGE LEFT INTENTIONALLY BLANK

Base Assembly

Key

Description

No.

3. Base Assembly

Base Assembly

(Complete)

Available for 1 Inch

Burners Only

3A Base Tray

Boiler

Size

202 618600291 1

202X 618600391 1

203 618600391 1 204 618600491 1 205 618600591 1 206 618600691 1 207 618600791 1 208 618600891 1 209 618600991 1 210 618601091 1 202 718600291 1

202X 718600391 1

203 718600391 1 204 718600491 1 205 718600591 1 206 718600691 1 207 718600791 1 208 718600891 1 209 718600991 1 210 718601091 1

Part No. Qty.

Key

No.

Description

Boiler

Size

Part No. Qty.

3. Base Assembly Continued

202 718600211 1

202X 718600311 1

203 718600311 1 204 718600411 1

3B Base Wrapper

3B1 Base End Insulation All 720601 2

3B2 Base Rear Insulation

205 718600511 1 206 718600611 1 207 718600711 1 208 718600811 1 209 718600911 1 210 718601011 1

202 72060025 1

202X 72060035 1

203 72060035 1 204 72060045 1 205 72060055 1 206 72060065 1 207 72060075 1 208 72060085 1 209 72060095 1 210 72060105 1

Key

No.

Description

Boiler

Size

Part No. Qty.

Key No.

Description

Boiler

Size

Part No. Qty.

3. Base Assembly Continued

202X 618600341 1

Base Front Panel

Assembly

202X 718600305 1

Burner Tray (1" Main Burners)

202X 71806037 1

Burner Tray (40mm Main Burners)

202 618600241 1

203 618600341 1 204 618600441 1 205 618600541 1 206 618600641 1 207 618600741 1 208 618600841 1 209 618600941 1 210 618601041 1 202 718600205 1

203 718600305 1 204 718600405 1 205 718600505 1 206 718600605 1 207 718600705 1 208 718600805 1 209 718600905 1 210 718601005 1

202 718600206 1

203 71806037 1 204 71806047 1 205 71806057 1 206 71806067 1

3. Base Assembly Continued

3E Base Leg Assembly All 6186001 4

3E1 Base Leg All 71860021 4 3E2 Nylon Glide All 8186006 4

202 718600261 1

202X 718600361 1

203 718600361 1 204 718600461 1

3F Burner Access Panel

Cerafelt Sealing Strip,

1" x 2" x 10' (Section Assembly to Base)

Self-Tapping Screw,

1/4" -20 x 1/2"

Self-Tapping Screw,

5/16" -18 x 1-1/4" Flat Washer, 5/16",

USS

Hex Lock Nut,

5/16 -18

205 718600561 1 206 718600661 1 207 718600761 1 208 718600861 1 209 718600961 1 210 718601061 1

All 6206002 1

202 thru 206

207 thru 210

80860700 20

80860700 21

All 80860717 4

All 80860601 4

All 80860464 4

207 71806077 1 208 718600806 1 209 718600906 1 210 718601006 1

Manifold and Main Burners

(1 Inch Main Burners)

Key

Description Part No.

No.

202 202X 203 204 205 206 207 208 209 210

Quantity

4. Manifold and Main Burners (1 Inch Main Burners Only)

4A Main Burner 8236099 1 2 2 4 6 8 11 13 15 17 4B Main Burner with Pilot Bracket ----- See Table Below

82260023 1 --- --- --- --- --- --- --- --- --82260033 --- 1 1 --- --- --- --- --- --- --82260043 --- --- --- 1 --- --- --- --- --- --82260053 --- --- --- --- 1 --- --- --- --- ---

4C Manifold

4D Main Burner Orice ----- See Table Below

Screw, Machine, Slotted Round Head, #10 -32 x 3/16" (Standing Pilot)

Screw, Machine, Philips Head w/Captive Lockwasher, #10 -32 x 1/4" (Electronic Ignition)

Screw, Self Tapping, Philips Pan

Head, 1/4 - 20 x 1/2"

82260063 --- --- --- --- --- 1 --- --- --- --82260073 --- --- --- --- --- --- 1 --- --- --82260083 --- --- --- --- --- --- --- 1 --- --82260093 --- --- --- --- --- --- --- --- 1 --82260103 --- --- --- --- --- --- --- --- --- 1

80860800 2 2 2 2 2 2 2 2 2 2

80860874 1 1 1 1 1 1 1 1 1 1

80860700 4 4 4 4 4 4 4 4 4 4

4B. 1 Inch Main Burner with Pilot Bracket, 24-volt Continuous Ignition (Standing Pilot) Natural Gas Only

Main Burner with 70° Q350 Pilot Bracket and Offset Lancings

Main Burner with 60° Pilot Bracket 8236098 --- --- --- --- --- --- --- 1 1 1

8236097 1 1 1 1 1 1 1 --- --- ---

4B. 1 Inch Main Burner with Pilot Bracket, 24-volt Continuous Ignition (Standing Pilot) LP Gas Only

4B Main Burner with 45° Pilot Bracket 8236111 --- --- 1 1 1 1 1 1 1 1

4B. 8 Inch Main Burner with Pilot Bracket, Electronic Ignition Only

4B Main Burner with 60° Pilot Bracket 8236098 1 1 1 1 1 1 1 1 1 1

4D. 1 Inch Main Burner Orices, Natural Gas, Normal Altitude, U.S.A. and Canada

Main Burner Orice, #47 (White) 822710 2 3 --- --- --- --- 12 14 16 18

Main Burner Orice, #45 (Pink) 822711 --- --- 3 5 7 9 --- --- --- ---

4D. 1 Inch Main Burner Orices, LP/Propane, Normal Altitude, U.S.A. and Canada

Main Burner Orice, 1.25 mm (Purple) 822705 2 --- --- 5 7 9 --- --- --- ---

Main Burner Orice, #55 (Green) 822708 --- --- 3 --- --- --- --- --- --- --- Main Burner Orice, 3/64" (Blue) 822704 --- 3 --- --- --- --- 12 14 16 18

Manifold and Main Burners

(40mm Main Burners)

Key

Description Part No.

No.

202X 203 204 205 206 207 208 209 210

Quantity

4. 40 MM Main Burners Only

4A Main Burner 8236135 1 1 2 3 4 5 6 7 8

4B. 40 MM Main Burner, Electronic Ignition Only

Main Burner with 48° Pilot Bracket 8236143 --- --- --- --- --- --- --- --- ---

Main Burner with 41° Pilot Bracket 8236136 1 1 1 1 1 1 1 1 1

4B. 40 MM Main Burner, 24-volt Continuous Ignition (Standing Pilot) Natural Gas Only

Main Burner with 48° Pilot Bracket 8236143 1 1 1 1 1 1 1 1 1

Main Burner with 41° Pilot Bracket 8236136 --- --- --- --- --- --- --- --- ---

4B. 40 MM Main Burner, 24-volt Continuous Ignition (Standing Pilot) LP Gas Only

Main Burner with 48° Pilot Bracket 8236143 1 --- --- --- --- --- --- --- ---

Main Burner with 41° Pilot Bracket 8236136 --- 1 1 1 1 1 1 1 1

Key

Description Part No.

No.

4. 40 MM Main Burners Only (Continued)

4C. 40MM Main Burner Manifold

Quantity

202X 203 204 205 206 207 208 209 210

82260028 --- --- --- --- --- --- --- --- --82260038 1 1 --- --- --- --- --- --- --82260048 --- --- 1 --- --- --- --- --- --82260058 --- --- --- 1 --- --- --- --- ---

4C Manifold

82260068 --- --- --- --- 1 --- --- --- --82260078 --- --- --- --- --- 1 --- --- --82260088 --- --- --- --- --- --- 1 --- --82260098 --- --- --- --- --- --- --- 1 --82260108 --- --- --- --- --- --- --- --- 1

4D. 40 MM Main Burner, Natural Gas, 2001-5000 Ft. USA Only

#43 822713 2 --- --- --- --- --- --- --- ---

#39 822727 --- 2 3 --- --- --- --- --- --#38 822720 --- --- --- 4 5 6 7 8 9

4D. 40 MM Main Burner, LP Gas, 2001-5000 Ft. USA Only

#54 822734 2 --- --- --- --- --- --- --- ---

#53 822722 --- 2 3 4 5 6 7 8 9

4D. 40 MM Main Burner, Natural Gas, 5001-9000 Ft. USA Only

#41 822729 N/A 2 3 --- --- --- --- --- ---

#40 822728 --- --- --- 4 5 6 7 8 9

4D. 40 MM Main Burner, LP Gas, 5001-9000 Ft. USA Only

#54 822734 N/A 2 --- --- --- --- --- --- ---

#53 822722 --- --- 3 4 5 6 7 8 9

4D. 40 MM Main Burner, Natural Gas, 2001-4500 Ft. Canada Only

#37 822719 N/A 2 3 4 --- --- --- --- ---

#36 822771 --- --- --- --- 5 6 7 8 9

4D. 40 MM Main Burner, LP Gas, 2001-4500 Ft. Canada Only

4D #52 822721 N/A 2 3 4 5 6 7 8 9

Screw, Machine, Slotted Round Head, #10-32 x 3/16" (Standing Pilot)

Screw, Machine, Philips Head w/Captive Lockwasher, #10-32 x 1/4" (Electronic Ignition)

Screw, Self Tapping, Philips Pan Head,

1/4 -20 x 1/2"

4G Injection Shield Assembly 71860_ _62 A/R A/R A/R A/R A/R A/R A/R A/R A/R

_ _: number of cast iron sections

80860800 2 2 2 2 2 2 2 2 2

80860874 1 1 1 1 1 1 1 1 1

80860700 4 4 4 4 4 4 4 4 4

* 1" Burner Only

** 40mm Burner Only

Key

Description Part No.

No.

5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, Natural Gas (1 Inch and 40mm Main Burners)

Pilot Burner, Honeywell Q350A1321 8236065 1 1 1 1 1 1 *1 --- --- ---

Pilot Burner, Honeywell Q327A1006 8236022 --- --- --- --- --- --- **1 1 1 1

Pilot Orice, Honeywell 390686-22 .012"

Pilot Orice, Honeywell 388146AG .026" --- --- --- --- --- --- 1 1 1 1

5C Adptr, 1/4"OD x 1/4" NPT Included w/5A & 5E 8236109 2 2 2 2 2 2 2 2 2 2

Pilot Tubing, 1/4" OD x 30" LG 8236122 1 1 1 1 1 1 1 --- --- ---

Pilot Tubing, 1/4" OD x 40" LG 8236123 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell VR8200C3005 81660143 1* 1* 1* 1* 1* 1* --- --- --- --Gas Valve, Honeywell VR8300C4027 81660154 --- --- --- --- --- --- 1* 1* 1* 1*

Gas Valve, Honeywell VR8200C6065 100333-01 1** 1** 1** 1** 1** 1** --- --- --- --Gas Valve, Honeywell VR8300C4266 100334-01 --- --- --- --- --- --- 1** 1** 1** 1**

5F Thermocouple, 30", Honeywell Q309A 8236024 1 1 1 1 1 1 1 1 1 1

Included

with 5A

Quantity

202 202X 203 204 205 206 207 208 209 210

1 1 1 1 1 1 --- --- --- ---

Key

Description Part No.

No.

202 202X 203 204 205 206 207 208 209 210

Quantity

5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, LP/Propane (1 Inch and 40mm Main Burners)

Pilot Burner, Honeywell Q327A1147 8236023 --- --- 1 1 1 1 1 1 1 1

Pilot Burner Assembly, Honeywell Q350A (Includes 5B & 5F)

Pilot Orice, Honeywell 388146KR (.014")

Pilot Orice, Honeywell 390686-23 (.008") 1 1 --- --- --- --- --- --- --- ---

5C Adptr, 1/4"OD x 1/4" NPT Included w/5A & 5E 8236109 2 2 2 2 2 2 2 2 2 2

Pilot Tubing, 1/4" OD x 30" LG 8236122 1 1 1 1 1 1 1 --- --- ---

Pilot Tubing, 1/4" OD x 40" LG 8236123 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell VR8200C3013 81660144 1 1 1 1 1 1 --- --- --- ---

Gas Valve, Honeywell VR8300C4035 81660163 --- --- --- --- --- --- 1 1 1 1

5F Thermocouple, 30", Honeywell Q309A 8236024 1 1 1 1 1 1 1 1 1 1

8236105 1 1 --- --- --- --- --- --- --- ---

Included

with 5A

--- --- 1 1 1 1 1 1 1 1

Key

No.

Description Part No.

202 202X 203 204 205 206 207 208 209 210

Quantity

5. Pilot Burner and Gas Valve, Electronic Ignition (EI), Natural Gas

5A Pilot Burner, Honeywell Q348A1002 8236072 1 1 1 1 1 1 1 1 1 1

5B Pilot Orice, Honeywell 388146NE

Compression Nut/Fitting, 1/4" OD x 1/4 C.C.

(Included with 5A and 5E) Pilot Tubing, 1/4" OD x 30" 8236122 1 1 1 1 1 1 1 --- --- ---

Pilot Tubing, 1/4" OD x 40" 8236123 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell VR8204C3007 81660145 1 1 1 1 1 1 --- --- --- ---

Gas Valve, Honeywell VR8304P4306 81660161 --- --- --- --- --- --- 1 1 1 1

5F Igniter/Sensor Cable, 36", Honeywell 394800 8236084 1 1 1 1 1 1 1 1 1 1

5G Ground Wire Assembly 6136054 1 1 1 1 1 1 1 1 1 1

Included

with 5A

8236109 2 2 2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1 1 1

5. Pilot Burner and Gas Valve, Electronic Ignition (EI), LP/Propane

5A Pilot Burner, Honeywell Q348A1010 8236081 1 1 1 1 1 1 1 1 1 1

5B Pilot Orice, Honeywell 388146KP

Compression Nut/Fitting, 1/4" OD x 1/4 C.C.

(Included with 5A and 5E) Pilot Tubing, 1/4" OD x 30" 8236122 1 1 1 1 1 1 1 --- --- ---

Pilot Tubing, 1/4" OD x 40" 8236123 --- --- --- --- --- --- --- 1 1 1

Included

with 5A

8236109 2 2 2 2 2 2 2 2 2 2

1 1 1 1 1 1 1 1 1 1

Gas Valve, Honeywell VR8204C3015 81660146 1 1 1 1 1 1 --- --- --- ---

Gas Valve, Honeywell VR8304P4314 81660160 --- --- --- --- --- --- 1 1 1 1

5F Igniter/Sensor Cable, 36", Honeywell 394800 8236084 1 1 1 1 1 1 1 1 1 1

5G Ground Wire Assembly 6136054 1 1 1 1 1 1 1 1 1 1

Key

No.

Description Part No.

6. Jacket Assembly, Complete

Quantity

202 202X 203 204 205 206 207 208 209 210

604170254 1 --- --- --- --- --- --- --- --- --604170354 --- 1 1 --- --- --- --- --- --- --604170454 --- --- --- 1 --- --- --- --- --- --604170554 --- --- --- --- 1 --- --- --- --- ---

6 Jacket Assembly, Complete

6. Jacket Assembly

6A Jacket Wrap-Around Panel

604170654 --- --- --- --- --- 1 --- --- --- --604170754 --- --- --- --- --- --- 1 --- --- --604170854 --- --- --- --- --- --- --- 1 --- --604170954 --- --- --- --- --- --- --- --- 1 --604171054 --- --- --- --- --- --- --- --- --- 1

604170215 1 --- --- --- --- --- --- --- --- --604170315 --- 1 1 --- --- --- --- --- --- --604170415 --- --- --- 1 --- --- --- --- --- --604170515 --- --- --- --- 1 --- --- --- --- --604170615 --- --- --- --- --- 1 --- --- --- --604170715 --- --- --- --- --- --- 1 --- --- --604170815 --- --- --- --- --- --- --- 1 --- --604170915 --- --- --- --- --- --- --- --- 1 --604171015 --- --- --- --- --- --- --- --- --- 1

Key

Description Part No.

No.

202 202X 203 204 205 206 207 208 209 210

Quantity

6. Jacket Assembly (Continued)

604170223 1 --- --- --- --- --- --- --- --- --604170323 --- 1 1 --- --- --- --- --- --- --604170423 --- --- --- 1 --- --- --- --- --- --604170523 --- --- --- --- 1 --- --- --- --- ---

6B Jacket Vestibule Panel

6C Jacket Top Panel

6D Jacket Front Removable Door

6E Jacket Lower Front Panel

Sheet Metal Screw, Type AB, Phillips

Truss Head, #8 x 1/2"

6G Snap Bushing, Heyco SB-1093-15 8136257 2 2 2 2 2 2 2 2 2 2

6H Snap Bushing, Heyco SB-437-5 8136048 1 1 1 1 1 1 1 1 1 1

604170623 --- --- --- --- --- 1 --- --- --- --604170723 --- --- --- --- --- --- 1 --- --- --604170823 --- --- --- --- --- --- --- 1 --- --604170923 --- --- --- --- --- --- --- --- 1 --604171023 --- --- --- --- --- --- --- --- --- 1 604170233 1 --- --- --- --- --- --- --- --- --604170333 --- 1 1 --- --- --- --- --- --- --604170433 --- --- --- 1 --- --- --- --- --- --604170533 --- --- --- --- 1 --- --- --- --- --604170633 --- --- --- --- --- 1 --- --- --- --604170733 --- --- --- --- --- --- 1 --- --- --604170833 --- --- --- --- --- --- --- 1 --- --604170933 --- --- --- --- --- --- --- --- 1 --604171033 --- --- --- --- --- --- --- --- --- 1 604170242 1 --- --- --- --- --- --- --- --- --604170342 --- 1 1 --- --- --- --- --- --- --604170442 --- --- --- 1 --- --- --- --- --- --604170542 --- --- --- --- 1 --- --- --- --- --604170642 --- --- --- --- --- 1 --- --- --- --604170742 --- --- --- --- --- --- 1 --- --- --604170842 --- --- --- --- --- --- --- 1 --- --604170942 --- --- --- --- --- --- --- --- 1 --604171042 --- --- --- --- --- --- --- --- --- 1 604170216 1 --- --- --- --- --- --- --- --- --604170316 --- 1 1 --- --- --- --- --- --- --604170416 --- --- --- 1 --- --- --- --- --- --604170516 --- --- --- --- 1 --- --- --- --- --604170616 --- --- --- --- --- 1 --- --- --- --604170716 --- --- --- --- --- --- 1 --- --- --604170816 --- --- --- --- --- --- --- 1 --- --604170916 --- --- --- --- --- --- --- --- 1 --604171016 --- --- --- --- --- --- --- --- --- 1

80860000 26 26 26 26 26 26 26 26 26 26

Water Trim

Key

No.

Description Part No. Quantity

Safety Relief Valve, 30 psi, 3/4 NPT, Conbraco 10-408-05 81660319 1

Safety Relief Valve, 50 psi, 3/4 NPT, Conbraco 10-303-10 101662-01 1

8. Circulator, Bell & Gossett SLC-30 Option (Intermittent and Continuous Circulation Only)

8A Circulator with Gaskets, Bell & Gossett NRF-22 8056174 1

8B Gasket, Bell & Gossett NRF-22 806602029 2

8. Circulator, Grundfos Option (Intermittent and Continuous Circulation Only)

8A Circulator with Gaskets, Grundfos UP 15-42F 8056173 1

8B Gasket, Grundfos 510179 806602016 2

8. Circulator, Taco 007 Option (Intermittent and Continuous Circulation Only)

8A Circulator with Gaskets, Taco 007F 8056170 1

8B Gasket, Taco '00' Series 806602006 2

8. Circulator, Taco 0010 Option (Intermittent and Continuous Circulation Only)

8A Circulator with Gaskets, Taco 0010 8056176 1

8B Gasket, Taco '00' Series 806602006 2

9. Miscellaneous Circulator Hardware (Intermittent and Continuous Circulation Only)

9A Flange, 1-1/4 NPT 806602013 2 9B Screw, Cap Hex Head, 7/16 -14 x 1-1/2" 80861301 4 9C Nut, Hex, 7/16 -14 80860406 4

10. Limit Control

10A Limit, Honeywell L4080D1234 100189-01 1

10B Well, 1/2 NPT (Included w/10A) ---- 1 10C Limit, Honeywell L4080B1212 (Dual Limit Only) 80160474 1 10D Well, 3/4 NPT, Honeywell 123870A (Dual Limit Only) 80160426 1

11. Miscellaneous Trim

11A Drain Valve, Conbraco 35-302-03 806603061 1

11B Temperature - Pressure Gauge 8056164U 1

11C Nipple, 1-1/4 NPT x 3" 806600005 1 or 2

11D Tee, 1-1/4 x 3/4 x 1-1/4 NPT 806601002 1 or 2

11E Nipple, 1-1/4 NPT x 4" 806600028 1

Key

Description Part No. Quantity

No.

12. Transformer/Relay Assembly (Intermittent Circulation Only)

12A Junction Box, 4" x 4" x 1-1/2" 8136259 1 12B Transformer/Relay, Honeywell R8285D5001 80160155U 1 12C Relay, Honeywell R8222U1006 80160096U 1

12. Transformer (Continuous and Gravity Circulation Only)

12A Junction Box, 4" x 4" x 1-1/2" 8136259 1 12D Transformer, 40VA, Honeywell AT140D1012 or AT72D1188 80160039 1

13. Flame Rollout Switch

13A Flame Rollout Switch 80160044 1 13B Flame Rollout Switch Mounting Bracket 7186018 1

14. Blocked Vent Switch

14 Blocked Vent Switch Replacement Assembly 6016058 1

15. Ignition Module (EI Only)

15A Ignition Module, Honeywell S8610M3009 100958-01 1 15B Ignition Module Support Bracket 7016001 1

Key

Description Part No.

No.

16. Draft Hood Carton

Quantity

202 202X 203 204 205 206 207 208 209 210

8116067 1 1 1 --- --- --- --- --- --- --8111702 --- --- --- 1 --- --- --- --- --- ---

16 Draft Hood

17. Vent Damper

4" 8116321 1 1 1 --- --- --- --- --- --- --5" 8116322 --- --- --- 1 --- --- --- --- --- ---

6" 8116323 --- --- --- --- 1 1 --- --- --- --7" 8116324 --- --- --- --- --- --- 1 1 --- --8" 8116325 --- --- --- --- --- --- --- --- 1 1

18. Vent Reducer

18 Reducer, 4" x 3" 1 --- --- --- --- --- --- --- --- --- ---

8111703 --- --- --- --- 1 1 --- --- --- --8111704 --- --- --- --- --- --- 1 1 --- --8111705 --- --- --- --- --- --- --- --- 1 1

SERVICE RECORD

DATE SERVICE PERFORMED

SERVICE RECORD

DATE SERVICE PERFORMED

SERVICE RECORD

DATE SERVICE PERFORMED

VI. Low Water Cut Off (LWCO)

WARNING

DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use

connections specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.

baseboard on the same oor level as the boiler). In

addition, some jurisdictions require the use of a LWCO with a hot water boiler.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

What Kind

Typically, in residential applications, a probe type

LWCO is used instead of a oat type, due to their

relative costs and the simplicity of piping for a probe LWCO.

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

manufacturers recommend an annual inspection of the probe.

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration can be

universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown below.

LWCO Location

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch connection must have a minimum diameter to

prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located above

the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without draining the heating system. Many probe LWCO

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas red boilers

where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.

How to Test

Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by lling the system.

The boiler should attempt to operate once the water level is above the LWCO.

Limited Warranty

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FOR RESIDENTIAL CAST IRON WATER BOILERS

Subject to the terms and conditions set forth below, U.S. Boiler Co., Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1,1991:

ONE YEAR LIMITED WARRANTY

ON RESIDENTIAL GRADE WATER BOILERS

U.S. Boiler Co., Inc. warrants to the original owner that its residential grade water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a water boiler is found to be defective in material or workmanship during this one year period, U.S. Boiler Co., Inc. will, at its option, repair or replace the defective part.

LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER

U.S. Boiler Co., Inc. warrants to the original owner that the heat exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation. If a

claim is made under this warranty during the rst ten years from the

date of original installation, U.S. Boiler Co., Inc. will, at its option, repair or replace the heat exchanger. If a claim is made under this warranty after the expiration of ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option and upon payment of the pro-rated service charge set forth below, repair or replace the heat exchanger. The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows:

NOTE: If the heat exchanger model involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the Burnham Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These warranties are applicable only to water boilers designated as residential grade by U.S. Boiler Co., Inc. and installed in a single or two-family residence and do not apply to steam boilers of any kind or to commercial grade boilers.

2. Components Manufactured by Others: Upon expiration of the one year limited warranty on residential grade water boilers, all boiler components manufactured by others but furnished by U.S. Boiler Co., Inc. (such as oil burner, circulator and controls) will be subject only to the

manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc. are conditioned upon the installation of the residential grade water boiler in strict compliance with U.S. Boiler Co., Inc. installation instructions. U.

S. Boiler Co., Inc. specically disclaims liability of any kind caused by or

relating to improper installation.

4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Co., Inc. conditioned upon the use of the residential grade water

boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthorized

modication, or is damaged as a result of being otherwise improperly

operated or serviced including, but not limited to, damage from any of the

following: operation with insufcient water, allowing the boiler to freeze, subjecting the boiler to ood conditions, and operation with unapproved

water or fuel additives which cause deposits or corrosion.

5. Removal and Installation: These warranties do not cover expenses of removal or reinstallation. The owner is responsible for the cost of removing and reinstalling any defective part and its replacements and all labor and material connected therewith.

6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties.

7. Limitation of Damages: Under no circumstances shall U.S. Boiler Co., Inc. be liable for incidental, indirect, special or consequential damages of any kind whatsoever under these warranties, including, but not limited to, injury or damage to persons or property and damages for loss of use, inconvenience or loss of time. U.S. Boiler Co., Inc. liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade water boiler involved. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entire obligation of U.S. Boiler Co., Inc. with respect to any defect in a residential grade water boiler and U.S. Boiler Co., Inc. shall have no express obligations, responsibilities or liabilities of any kind whatsoever other than those set forth herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will

not void the owner’s rights under these warranties.

Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the owner should write to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079, Lancaster, PA 17604, giving full particulars in support of the claim.

The owner is required to make available for inspection by U.S. Boiler Co., Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S. Boiler Co., Inc. at the above address for inspection or repair. In addition, the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

03/03

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

Specifications and Main Features

Frequently Asked Questions

User Manual