Burnham SERIES 2 User Manual

Price - $3.00

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

SERIES 2 (model B)

GAS BOILERS

For service or repairs to boiler, call your heating contractor. When seeking information on boiler,

provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

Boiler Serial Number

Installation Date

2 ____-_______

6_ _ _ _ _ _ _

Heating Contractor

Phone Number

Address

PartNo.81417032R10-11/99

Figure 1

Gas

Approx.

Shipping

Weight

(lb.)

Dimensions [inches]

Boiler

Model

Connection Water

Recommended

Vent Size

[1] [2]

For

Content

Number

Automatic [gallons]

Gas Valve

202

202X

203

204

205

206

207

208

209

210

18-3/4 10-3/4 6-3/8

45-5/8

47-1/8

48-1/2

8-1/2

9-1/8

9-3/4

10 [3]

4-3/4

5-1/4

1/2

3/4

2.5

3.2

3" dia. x 15 ft.

4" dia. x 15 ft.

5" dia. x 15 ft.

6" dia. x 15 ft.

7" dia. x 15 ft.

8" dia. x 15 ft.

212

262

306

354

414

458

514

550

608

23-1/4 15-1/4 7-5/8

26-1/2 18-1/2 9-1/4

29-3/4 21-3/4 10-7/8

4.7

5.5

6.2

12-1/2

50-1/8 10-3/8 6-5/8

36-1/4 28-1/4 14-1/8

39-1/2 31-1/2 15-3/4

42-3/4 34-3/4 17-3/8

7-1/4

7.7

8.5

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

[2] Refer to the National Fuel Gas Code, Apendix G for equivalent areas of circular and rectangular flue 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.

SECTION I - INSTALLATION INSTRUCTIONS

F. Slide the boiler forward or backward off the skid using

1. INSPECTSHIPMENT carefullyforanysignsofdamage.

the two wooden slats as runners.

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 filed immediately against the

carrier by the consignee. No claims for variances or short-

ages will be allowed by Boiler Manufacturer unless pre-

sented within sixty (60) days after receipt of equipment.

6. Move boiler to permanent position.

7. PROVIDE CLEARANCE and AIR for COMBUS-

TIONandVENTILATION.

2. BOILERINSTALLATIONmustconformtotherequire-

ments of the authority having jurisdiction, or in the absence

of such requirements, to:

U.S.A.-

National Fuel Gas Code, ANSI Z223.1,

obtainable from the American Gas Association,

1515 Wilson Blvd., Arlington (Rosslyn), VA

22209.

A. CLEARANCES

1.ALL INSTALLATIONS - Practical service clearances

must be considered (see Figure 1). A minimum of

24" 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" if right side clearance is increased to 9".

2.ALCOVE INSTALLATIONS - An alcove is consid-

ered a closet as shown in Figure 2 less front. Height

clearance may be reduced to 27".

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/

CGA-B149.1 or .2-latest edition obtainable

from the Canadian Gas Association, 55 Scars-

dale Road, Don Mills, Ontario, Canada M3B

2R3.

3. UNCONFINEDSPACE(seedefinition,Paragraph(B)

below) - Height clearance may be reduced to 27".

3. TheseGasBoilersareDESIGNCERTIFIEDFOR

INSTALLATIONONCOMBUSTIBLEFLOORING.DONOT

INSTALLTHESEBOILERSONCARPETING.

4. LOCATEBOILERinfrontoforbehindinstallation

position before removing Crate. Locate on a level floor as

close to chimney as possible. For basement installations,

provide a solid base such as concrete, if floor is not level or

if water may be encountered on floor 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.).

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.

Figure 2: Minimum Clearances

B. PROVIDECOMBUSTIONANDVENTILATIONAIRin

accordance with applicable provisions of local building

codes, or: U.S.A. - National Fuel Gas Code, NFPA 54/

ANSI Z223.1, Section5.3, Air for Combustionand

Ventilation; Canada - Natural Gas Installation Code,

CAN/CGA-B149.1, or Propane Installation Code,

CAN/CGA-B149.2,Part5,VentingSystemsandAir

Supply for Appliances.

1.CLOSET INSTALLATIONS (confined space) in a

building of other than unusually tight construction

(see definition below), provide combustion and

ventilation air as shown in Figure 2.

2.Installations other than Paragraph (1) above:

a. Determine volume of space (boiler room). Rooms

communicating directly with space (through

openings not furnished with doors) are considered

part of space.

Volume [ft³] = Length [ft] x Width [ft] x Height [ft]

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.

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 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

fixed 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.

i. If result is greater than or equal to 50 ft³ per 1,000

Btuh, space is considered an unconfined space.

ii.If result is less than 50 ft³ per 1,000 Btuh, space is

considered a confined 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

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).

This piping is to be supplied by the installer and must

include a trap, a ground joint union and a manual 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 liquefied 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.

The boiler must be isolated from the gas supply piping

system by closing its individual manual shutoff valve

during any pressure testing of the gas supply piping system

at pressures equal to or less than ½ psig.

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

floors, 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

infiltration 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 of top of space. Locate

remaining opening within 12 inches of bottom of

space. Minimum dimension of air opening is 3

inches. Size each opening per following:

i. Directcommunicationwithoutdoors. Minimumfree

area of 1 square inch per 4,000 Btu per hour input of

all equipment in space.

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:

A. Allowable loss of pressure to assure a burner manifold

pressure of 3½" water.

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

C. Length of piping and number of fittings.

D. Specific gravity of gas.

E. Correction factor for specific gravity.

ii. Vertical ducts. Minimum free area of 1 square inch

entering the boiler, see Figure 4. Also consult I=B=R

Installation and Piping Guides.

9. BOILERPIPING

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

with flow control valves to prevent gravity circulation

of boiler water during the operation of the cooling

system.

CAUTION

Failure to properly pipe boiler may result in

improper operation and damage to boiler or

building.

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

system which has a large volume or excessive radia-

tion where low boiler water temperatures may be

encountered (i.e. converted gravity circulation system,

etc.).

A. CLEARANCES - Hot water pipes do not require

clearance from combustible construction.

B. Install drain cock and safety relief valve as shown in

Figure 4. Note - Safety relief valve must be in vertical

position.

Remove the circulator and install a pipe tee between the

circulator and boiler return along with a second tee in

the supply piping as shown in Figure 5. 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 5 in order to regulate water flow

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.

C. Pipe safety relief valve discharge to floor.

WARNING

Safety relief valve discharge piping must

be piped near floor to eliminate potential

of severe burns. Do not pipe in any area

where freezing could occur. Do not install

any shut-off valves.

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 tempera-

ture.

D. Install circulator with flanges, 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

alsoI=B=RInstallationGuides.

F. Space heating and domestic water heating with Alliance

water heater (intermittent circulation only). Install

Alliance water heater as a separate heating zone. Refer

to Alliance Installation, Operating and Service Instruc-

tions for additional information.

I. A hot water boiler installed above radiation level must

be provided with a low water cutoff device as part of

the installation.

J. 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 first

place or prevent it from reaching the boiler. Problems

caused by oxygen contamination of boiler water are not

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

0.3 inch w.c. Pressure Drop

Length

0.5 inch w.c. Pressure Drop

[Feet]

1¼

100

132

278

190

152

130

115

105

520

350

285

245

215

195

180

170

160

150

1,050

730

590

500

440

400

370

350

320

305

175

120

360

250

200

170

151

138

125

118

110

103

680

465

375

320

285

260

240

220

205

195

1,400

950

770

660

580

530

490

460

430

400

Table 2: Equivalent Length of Fittings

Nominal Pipe Size

Fitting

Table 3: Specific Gravity Correction Factors

Specific

Gravity

Correction

Factor

Specific

Gravity

Correction

Factor

1¼

1.6

3.5

6.9

0.50

0.55

0.60

0.65

0.7

1.10

1.04

1.00

0.96

0.93

0.9

1.30

1.40

1.50

1.6

1.07

1.04

1.00

0.97

0.94

45° Ell

90° Ell

0.7

1.6

3.1

1.2

2.6

5.2

2.1

4.1

Tee (As Elbow)

covered by Burnham's standard warranty.

There are many possible causes of oxygen contamina-

tion such as:

1.Addition of excessive make-up water as a result of

system leaks.

1.7

0.75

0.8

0.87

2. Absorption through open tanks and fittings.

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:

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. SeeFig. 6.

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 fittings 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.

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

10. INSTALLDRAFTHOODwithoutmodificationonoutlet

of flue collector (See Figure 1). Secure with sheet metal

screws.

11. INSTALLBLOCKEDVENTSWITCH

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.

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.

Figure 3: Boiler Piping

Figure 4: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

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.

WARNING

Failure to properly install and use this

Blocked Vent Switch may result in property

damage, personal injury or loss of life.

Figure 6

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

of the Draft Hood. (See Figure 1) Unpack the damper

carefully-DONOTFORCEITCLOSED!Forcingthe

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

intermittent ignition control systems.

12. TOMEETFEDERALLYMANDATEDEFFICIENCIES,

THISBOILERMUSTBEEQUIPPEDWITHAVENT

DAMPER.

OPENTHEVENTDAMPERCARTONandremovethe

InstallationInstructions.READTHEINSTALLATION

INSTRUCTIONSTHOROUGHLYbeforeproceeding.

The automatic gas control valve supplied on each

Series 2 boiler provides the reduncancy referenced in the

vent damper Installation Instructions.

B. Refer to Figure 7 in this manual.

C. Mount the vent damper assembly on the draft hood

without modification to either. (Refer to instructions

packed with the vent damper for specific instructions).

This is a must for the wiring harness to fit and the

damper position indicator to be visible to the users.

NOTICE

Please refer to the specifications,

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. Install the 90° BX connector attached to the flexible

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 flexible conduit and attach to the Jacket top

panel. (SeeFigure7).

Figure 5

installed above the bottom of chimney to prevent

blockage.

E. Continuous Ignition (Standing Pilot) Only. Remove

knockout from vent damper blade.

G. Vent pipe should slope upward from draft hood to

chimney not less than one inch in four feet. No portion

of vent pipe should run downward or have dips or

sags. Vent pipe must be securely supported.

H. Vent pipe must be inserted into but not beyond inside

wall of chimney liner. Seal tight between vent pipe

and chimney.

F. Size 202 Only. Install 4" x 3" reducing fitting on vent

damper outlet (or draft hood outlet for Canadian boiler

not equipped with vent damper).

13. INSTALL VENT CONNECTOR from reducing fitting

(202 Only), draft hood or damper to chimney, see Fig. 8.

I. Do not install non-listed (AGA, CGA, ETL or UL) vent

damper or other obstruction in vent pipe.

14. IFANEXISTINGBOILERISREMOVED-

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 follow-

ing 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 deficiencies

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 fireplace dampers.

A. Vent installation shall be in accordance with local

building codes; or the local authority having jurisdic-

tion; 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 fire 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 efficiency." 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 Installa-

tionCode,CAN/CGA-B149.1ortheLPGasInstallation

Code,CAN/CGA-B149.2-latestedition.

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

open fireplace.

C. Inspect chimney for obstructions or restrictions and

remove. Clean chimney if necessary.

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 flame of a

match or candle, or smoke from a cigarette, cigar or

pipe.

F. After it has been determined that each appliance remain-

ing connected to the common venting system properly

vents when tested as outlined above, return doors,

windows, exhaust fans, fireplace 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, NFPA 54/ANSI Z223.1. 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 appropriate

tables in Part 11 in the National Fuel Gas Code, NFPA

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

Figure 7: Plug-in Damper Installation

54/ANSIZ223.1.

16. INSTALLELECTRICWIRINGinaccordancewith

National Electric Code or the Canadian Electrical Code and

local regulations. See Figures 11 through 14 for applicable

wiring diagram. A separate Electrical Circuit should be run

from meter with a Fused Disconnect Switch in this Circuit.

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/ortheCSAC22.1ElectricalCode, ifanexternalelectrical

source is utilized.

15. INSTALLAROOMTHERMOSTATonaninsidewall

about four feet above floor. Never install thermostat on an

outside wall or where it will be influenced by drafts, hot or cold

water pipes, lighting fixtures, television, rays of the sun or near

a fireplace. Keep large furniture away from thermostat so there

will be free movement of room air around this control.

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.

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. VENTDAMPERSEQUENCEOFOPERATION

Effikal and Johnson Damper

Figure 8: Typical Vent Installation

Table 4: Wiring Diagrams and Heat Anticipator Settings

Wiring Diagram

Thermostat Heat

Ignition Type

Circulation Method

Anticipator Setting [Amps]

Figure Number

Page Number

Continuous

Intermittent

0.6

1.0

(Standing Pilot)

Constant/Gravity

Intermittent

0.6

1.0

Intermittent

Constant/Gravity

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.

is deenergized - 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.

A. The Vent Damper is continuously powered at Terminal

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 satisfied.

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 posi-

tion, 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 satisfied, the damper relay coil

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

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

SEQUENCE OF OPERATION

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing 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 qualified service agency before resetting

switch.

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 flow

and ignition of main burners.

2. Where condensation of flue gas is encountered in

boiler flues a reverse acting circulator control should

be installed to stop the circulator before the boiler

water temperature drops to that which flue gas

condensation may occur.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame 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 flame rollout switch is activated do

not attempt to place the boiler in operation. The source

of blockage must be corrected and the flame rollout

switch replaced by trained and skilled personnel from

a qualified service agency.

3. After the thermostat is satisfied the main valve will

close and main burner flames 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.

4. Pilot

The thermocouple proves pilot flame 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 flow.

Figure 12: Wiring Diagram, Intermittent Ignition and Intermittent Circulation

SEQUENCE OF OPERATION

NORMAL OPERATION

developed the blocked vent switch will open interrupt-

ing power to the VENT DAMPER and GAS VALVE.

Main burners and pilot burner will be extinguished

immediately, the VENT DAMPER will close and the

CIRCULATOR will continue to operate. The source

of blockage must be corrected by trained and skilled

personnel from a qualified service agency before

resetting switch.

1. When the THERMOSTAT calls for heat, the RELAY

is energized. The CIRCULATOR starts and the

VENT DAMPER is opened (see Paragraphs 17A

through 17D). When the damper blade reaches the

fully open position, the GAS VALVE powers the

igniter circuit and opens the pilot valve.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame rollout switch

will open interrupting power to the VENT DAMPER

and the GAS VALVE. Main burners and pilot burner

will be extinguished immediately. The VENT

DAMPER will close and the CIRCULATOR will

continue to operate. If the flame rollout switch is

activated do not attempt to place the boiler in opera-

tion. The source of blockage must be corrected and the

flame rollout switch replaced by trained and skilled

personnel from a qualified service agency.

2. The sensing circuit between the Q3450 or Q3480 pilot

and the GAS VALVE proves presence of pilot flame.*

3. The GAS VALVE de-energizes the igniter and opens

the main valve, allowing main gas to flow and

ignition of main burners.

4. Where condensation of flue gas is encountered in

boiler flues, a REVERSE ACTING CIRCULATOR

CONTROL should be installed to stop the CIRCULA-

TOR before the boiler water temperature drops to that

at which flue gas condensation may occur.

5. The burners and CIRCULATOR will operate simulta-

neously until the THERMOSTAT is satisfied.

4. Pilot

A. Any pilot failure on the Q3450 or Q3480 Pilot will

close the main gas valve and energize the igniter.

6. After the THERMOSTAT is satisfied the main valve,

pilot valve and the circulator will be de-energized and

main burner and pilot flames will be extinguished.

The VENT DAMPER will close (see Paragraph 17E).

B. If the igniter breaks or becomes disconnected, the pilot

valve coil loses power, closing the pilot valve.

5. For TROUBLE SHOOTING GUIDE, see Figure 28.

SAFETY SHUTDOWN

^*· SV9500 and SV9600 Gas Valves:

1. High Limit Switch

The igniter and pilot gas valve will stay energized

until either the pilot lights or the call for heat ends.

In the event excessive boiler water temperature is

developed the High Limit Switch will open, interrupt-

ing power to the VENT DAMPER and the GAS

VALVE. Main Burners and Pilot Burner will be

extinguished immediately. Normal operation will be

resumed when the boiler water temperature drops to a

point where the High Limit Switch closes.

SV9501 and SV9601 Gas Valves:

If the pilot fails to light after a 90 second trial for

ignition, the igniter will be de-energized and the pilot

gas valve will close. After a 5 minute delay, the

igniter will be re-energized and the pilot gas valve will

re-open. This continuous retry cycle will end either

when the pilot lights or the call for heat ends.

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

Figure 13: Wiring Diagram, Intermittent Ignition and Continuous or Gravity Circulation

SEQUENCE OF OPERATION

NORMAL OPERATION

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing power to the ignition module and dual combina-

tion gas valve. Main burners and pilot burner will be

extinguished immediately and the vent damper will

close. The source of blockage must be corrected by

trained and skilled personnel from a qualified service

agency before resetting switch.

1. When THERMOSTAT calls for heat, the VENT

DAMPER is opened (see Paragraphs 17A through

17D). When the damper blade reaches the fully open

position, the GAS VALVE powers the igniter circuit

and opens the pilot valve.

2. The sensing circuit between the Q3450 or Q3480 pilot

and the GAS VALVE proves presence of pilot flame.*

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame rollout switch

will open interrupting power to the ignition module

and the dual combination gas valve. Main burners and

pilot burner will be extinguished immediately and the

vent damper will close. If the flame rollout switch is

activated do not attempt to place the boiler in opera-

tion. The source of blockage must be corrected and the

flame rollout switch replaced by trained and skilled

personnel from a qualified service agency.

3. The GAS VALVE de-energizes the igniter and opens

the main valve, allowing main gas to flow and

ignition of main burners.

4. On Boilers equipped with Circulators that are wired to

run continuously and, where condensation of flue gas

is encountered in boiler flues, a REVERSE ACTING

CIRCULATOR CONTROL should be installed to stop

the Circulator before the Boiler Water Temperature

drops to that at which flue gas condensation may

occur.

4. Pilot

5. The Burners will operate until the THERMOSTAT is

satisfied.

A. Any pilot failure on the Q3450 or Q3480 pilot will

close the main gas valve and energize the igniter.

6. After the THERMOSTAT is satisfied the GAS

VALVE will be de-energized. The Main Burners and

Pilot Burner will be extinguished. If Boiler is

equipped with circulator, Circulator will continue to

run. The VENT DAMPER will close (see Paragraph

17E).

B. If the igniter breaks or becomes disconnected, the pilot

valve coil loses power, closing the pilot valve.

5. For TROUBLE SHOOTING GUIDE, see Figure 28.

* · SV9500 and SV9600 Gas Valves:

SAFETY SHUTDOWN

1. High Limit Switch

The igniter and pilot gas valve will stay energized

until either the pilot lights or the call for heat ends.

SV9501 and SV9601 Gas Valves:

In the event excessive boiler water temperature is

developed, the High Limit will open, interrupting

power to the IGNITION MODULE and the DUAL

COMBINATION GAS VALVE. Main Burners and

Pilot Burner will be extinguished immediately and the

vent damper will close. Normal operation will be

resumed when the Boiler Water Temperature drops to

a point where the High Limit Switch closes.

If the pilot fails to light after a 90 second trial for

ignition, the igniter will be de-energized and the pilot

gas valve will close. After a 5 minute delay, the

igniter will be re-energized and the pilot gas valve will

re-open. This continuous retry cycle will end either

when the pilot lights or the call for heat ends.

Figure 14: Wiring Diagram, 24 Volt Standing Pilot with Continuous or Gravity Circulation

SEQUENCE OF OPERATION

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing 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 qualified service agency

before resetting switch.

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 flow and

operation of the main burners.

2. Where condensation of flue gas is encountered in

boiler flues a reverse acting circulator control should

be installed to stop the circulator before the boiler

water temperature drops to that which flue gas

condensation may occur.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame 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 flame rollout switch is activated do

not attempt to place the boiler in operation. The source

of the blockage must be corrected and the flame

rollout switch replaced by trained and skilled person-

nel from a qualified service agency.

3. After the thermostat is satisfied the main valve will

close and main burner flames 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.

4. Pilot

The thermocouple proves pilot flame 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 flow.

Figure 15: Wiring Schematic, Zone Valves

Figure 16: Wiring Schematic, Zone Circulators

SECTION 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 specified 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 orifices.

2. INITIAL START -

A. FILL ENTIRE HEATING SYSTEM WITH WATER

and vent air from system. Use the following procedure

onaSeriesLoopSystemequippedwithzonevalves. (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 bib cock located just below isolation

valve in boiler supply piping. (Note - Terminate hose in

five gallon bucket at a suitable floor drain or outdoor

area).

4. Starting with one circuit, open zone valve.

5.Open bib cock.

6.Open fill valve (Make-up water line should be located

directly above isolation valve in boiler supply piping).

7. Allow water to overflow from bucket until discharge

Figure 17: Schematic Pilot and Gas Piping

Continuous Ignition (Standing Pilot)

from hose is bubble free for 30 seconds.

8. Open zone valve to the second zone to be purged, then

close the first. Repeat this step until all zones have been

purged, but always have one zone open. At completion,

open all zone valves.

9.Close bib cock, continue filling the system until the

pressure gauge reads 12 psi. Close fill valve. (Note - If

make-up water line is equipped with pressure reducing

valve, system will automatically fill to 12 psi. Leave

globe valve open).

10. Open isolation valve in boiler supply piping.

11. Remove hose from bib cock.

B. Turn ROOM THERMOSTAT to lowest setting.

C. Be sure that gas to pilot and main burners has been off

for at least five 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 butin all cases adequate

ventilation must be provided and no smoking or open

flame permitted. To determine which of the procedures

outlined in succeeding paragraphs is applicable, match

Figure 18: Schematic Pilot and Gas Piping

Intermittent Ignition (HSP)

"Pilot" Position. Depress and hold in this position

until purging is complete. Turn Main Gas Knob to

suffix of boiler model found on Rating Plate with

"off" position.

paragraph heading:

e. Reconnect pilot tubing and check pipe and fittings

from meter to combination Gas Valve for leaks using

soap solution or other approved method.

1.Standing Pilot Models (Suffix V):

a. Keep electric switch "OFF".

b. OpenManualShut-offValveupstreamofCombination

2.Intermittent Ignition Models (Suffix S):

Gas Valve.

a. Turn "ON" electric switch serving boiler.

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

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 fittings from meter to Combination

Gas Valve using soap solution or other approved

methods.

e. Test gas piping and connections between

Combination Gas Valve and manifold, orifices,

and pilot piping for leaks after boiler is operating.

Use soap solution or other approved method.

3. INSTRUCTIONS TO PUT THE BOILER IN OPERA-

TION. See Figure 20 for intermittent ignition. See Figure

21 for continuous ignition system (standing pilot).

Figure 19a: Top View of SV9500, SV9600 and

VR Gas Valves

21460147

Figure 20a: Operating Instructions, SV9500 and SV9600 Gas Valves

Honeywell

Figure 19b: Top View of Honeywell SV9501 and SV9601 Gas Valves

FOR YOUR SAFETY READ BEFORE OPERATING

WHAT TO DO IF YOU SMELL GAS:

WARNING

Do not try to light any appliance.

Fire or Explosion Hazard.

Can cause property damage, severe injury

or death.

Do not touch any electric switch other than the

gas valve; do not use any phone in your

building.

Force or attempted repair may result in a fire or

explosion.

Follow these instructions exactly.

Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

If you cannot reach your gas supplier, call the

fire department.

1. This appliance is equipped with an ignition device

which automatically lights the pilot. DO NOT try to

light the pilot by hand.

3. Use only your hand to slide the gas control switch to

"ON". Never use tools. If the switch does not move

by hand, DO NOT try to repair it; call a qualified

service technician. Force or attemped repair may

result in a fire or explosion.

2. BEFORE OPERATING smell all around the appliance

area for gas. Be sure to smell next to the floor

because some gas is heavier than air and settles

on the floor.

4. Do not use this appliance if any part has been

under water. Immediately call a qualified service

technician to inspect the appliance. Replace any

part of the control system and any gas control

that has been under water.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above on this

label.

Follow step 2 in the "FOR YOUR SAFETY" section

above on this label. If you do not smell gas, go to

the next step.

2. Set the thermostat to the lowest setting.

3. Turn off all electric power to the appliance.

8. Slide gas control switch to "ON".

9. Replace front door.

4. This appliance is equipped with an ignition device

that automatically lights the pilot. DO NOT try to

light the pilot by hand.

10. Turn on all electric power to the appliance.

11. Set the thermostat to desired setting.

5. Remove front door.

12. If the appliance does not operate, follow the

instructions "TO TURN OFF GAS TO APPLIANCE"

and call your service technician or gas supplier.

6. Slide gas control switch to "OFF".

7. Wait five (5) minutes to clear out any gas. Then smell

for gas, including near floor. If you smell gas, STOP!

GAS

INLET

OUTLET

IGNITION SYSTEM

CONTROL SWITCH

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

4. Slide gas control switch to "OFF". DO NOT force.

5. Replace front door.

2. Turn off all electric power to the appliance if

service is to be performed.

3. Remove front door.

Figure 20b: Operating Instructions, SV9501 and SV9601 Gas Valves

81460177

Figure 21: Lighting Instructions

4. CHECK GAS INPUT RATE TO BOILER

USA boilers built for installation at altitudes greater than

2,000 feet above sea level have been specially orificed to

reduce gas input rate 4 percent per 1,000 feet above sea level

per the National Fuel Gas Code, NFPA 54/ANSI Z223.1,

Section 8.1.2 and Appendix F. Canadian boilers' orifice

sizing is indicated on the rating label. High altitude boiler

models are identifiable by the fourth digit after the dash in the

model number. 2: 0-2000', 4 or 5: above 2000'.

5. MAIN BURNER FLAMES should have a clearly

defined inner cone (see Figure 22 or 23) with no yellow

tipping. Orange-yellow streaks caused by dust should

not be confused with true yellow tipping.

The main burners in this boiler will not operate

cleanly or efficiently if they are contaminated with dirt

and/or construction dust. Burners should be cleaned and

the combustion chamber vacuumed following instruc-

tions in Section III - Service.

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.

6. CHECK PILOT BURNER FLAME.

A. Continuous Ignition (Standing Pilot)

Models 202 and 202X with 1" diameter burners. See

Figure 24.

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

while boiler is firing - 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 cock installed

in the 1/8" outlet pressure tap in the gas valve (See

Figure 19). By installing gas cock upstream of

manometer, gas pressure can be introduced gradually -

without shut-off cock, surge of pressure when boiler is

turned on, could blow liquid out of manometer.

Replace plug in gas valve when rate check is finished.

D. LP Gas Input:

Models 202 and 202X with 40mm (1-9/16") diameter

burners. See Figure 25.

Natural gas Models 203 through 206 and 207 with 1"

diameter burners. See Figure 25.

The pilot produces a single flame. The flame should

be steady, medium hard blue enveloping 3/8 to a 1/2

inch of thermocouple.

Adjust Regulator on Gas Valve so that manifold

pressure is 10 inches water column. Turning Regula-

tor Adjusting Screw Clockwise increases pressure.

Counterclockwise rotation decreases pressure.

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 (three inches water column for high

altitude with 1" main burners). Turning Regulator

Adjusting Screw Clockwise increases pressure,

Counterclockwise rotation decreases pressure. If

more accurate check on input is necessary see (2)

below.

Figure 22: 40mm and 50mm Main Burner Flame

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

orifices and drill one size larger. Reinstall and

recheck input rate.

2.Additional Check on Input - Since input is a function

of heating value, specific gravity, and volume of gas

flow contact your utility for the first 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 flow

should be in this 3 minute period to give the input

shown on the Rating Label:

Figure 23: 1 Inch Main Burner Flame

B. Continuous Ignition (Standing Pilot)

Natural gas Models 207 with 40mm (1-9/16") diam-

eter burners and 208 through 210. See Figure 26

LP gas Models 203 through 210. See Figure 26.

The pilot produces three (3) flames. The center flame

should be steady, medium hard blue enveloping 3/8 to

a 1/2 inch of thermocouple.

8. CHECK HIGH LIMIT CONTROL. Jumper Thermo-

stat Terminals or Thermostat connections in Limit Control.

Allow burners to operate until shutdown by limit. RE-

MOVE JUMPER.

9. CHECK DAMPER OPERATION if Boiler is equipped

with Vent Damper. Vent Damper must be open when

boiler is running. Start boiler, refer to instructions on

damper to determine if damper is in the full open position.

C. Intermittent Ignition

Models 202 with 1" diameter burners and 202X

through 210. See Figure 27.

The pilot produces three (3) flames. The center flame

should be steady, medium hard blue enveloping 3/8 to

a ½ inch of sensing probe.

10. CHECK IGNITION SYSTEM SAFETY SHUT-OFF

DEVICE.

A. 24 volt-loosen thermocouple at gas valve.

B. Intermittent Ignition - Remove pilot lead wires from

gas valve.

D. Intermittent Ignition

Model 202 with a 40mm (1-9/16") diameter burner.

See Figure 27a.

The pilot produces a single flame. The flame should

be steady, medium hard blue enveloping 3/8 to a ½

inch of sensing probe.

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 contain

a cornstarch based binder that must be burned out at

installation to prevent odors during subsequent boiler

operation.

7. CHECK THERMOSTAT OPERATION. Raise and

lower temperature setting as required to start and stop

burners.

Figure 24: Typical Pilot Flame, Robertshaw 7CL-6

Figure 26: Typical Pilot Flame, Honeywell Q327

Figure 25: Typical Pilot Flame, Honeywell Q350

Figure 27: Typical Pilot Flame, Honeywell Q3480

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

maximum setting, set the thermostat to call for heat.

Allow the boiler to fire 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.

Figure 27a: Typical Pilot Flame, Honeywell Q3450

Figure 28: Troubleshooting Guide, Honeywell Intermittent Ignition

SECTION III - SERVICE

1. Inspection should be conducted annually. Service as

NOTICE

frequently as specified in paragraphs below. While service

or maintenance is being done, Electrical Power and all Gas

Supply to the Boiler must be "off".

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 Figures 17 and 18)..

3.Disconnect thermocouple (standing pilot) or pilot lead

wires (intermittent ignition) at the gas valve.

4.40mm and 50 mm burners only. Remove injection

shield assembly, where used. (See Figure 30).

5.Remove wires to flame roll-out switch.

6.Remove the burner access panel.

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.

7.50mm dia. burners only. Remove orifice hitch pin

clips.

D. Proper support - no sags, particularly in horizontal

runs.

E. Tightness of joints.

F. Proper vent damper operation - see Section II, para-

graph 9.

G. Remove all accumulations of soot with wire brush and

vacuum, see Fig. 29. Remove all obstructions. Replace

all deteriorated parts and support properly. Seal all

joints.

3. CLEANING BOILER FLUES, see Fig. 29.

Flue passageways in the boiler sections should be

checked annually for any blockage or accumulation of soot.

To obtain access to flueways:

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 - flueways are now exposed.

D. Models with flue gas baffles only: Remove baffles by

lifting out of flueways.

Using flashlight, examine all flue passageways. If

passageways are free of soot and obstruction, replace

canopy (and flue gas baffles, if applicable), and seal.

Reinstall Jacket Top Panel, draft hood, blocked vent

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

pipe.

If the flue passageways need cleaning, remove burners

as described in paragraph 4 below. Using long handle

wire or bristle flue brush and vacuum, brush flueways

thoroughly from top of boiler as illustrated in Fig. 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.

Figure 29: Cleaning of Vent System and

Boiler Flues

8.Mark the location of the pilot main burner on the

manifold if the marking on manifold is missing or

obliterated.

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 5

Check burners to see that they are located properly in

slot at rear of burner tray, see Fig. 30. Reinstall

injection shield assembly (40mm and 50mm burners

only, where used) and burner access panel. Reconnect

flame roll-out switch wires, pilot gas supply, thermo-

couple lead or pilot lead.

9.Hold burner at throat,

a. 1 inch and 40mm diameter burners. Lift front of

burner to clear orifice. Burner which holds pilot

can only be removed by lifting the burner adjacent

to its right first.

b. 50 mm dia. burners only. Push toward the rear until

the burner face plate clears the orifice. Lift burner

out.

D. CHECK MAIN BURNER and PILOT FLAMES, see

procedure Section II, paragraphs 5 and 6.

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

Fig. 30. Vacuum burners. Check orifices to see

that drilled passageways are free of lint or dirt.

11.Vacuum tip of Pilot Burner.

5. CHECK ALL CONTROL AND DAMPER OPERA-

TION ANNUALLY see procedure in Section II, paragraphs

7 through 10.

B. CLEAN FIREBOX by vacuuming. Exercise care not

to disturb insulation inside the base.

6. REMOVAL OR REPLACEMENT OF PILOT AS-

SEMBLY OR PILOT ASSEMBLY PARTS

1" Burner

If pilot assembly, thermocouple or pilot orifice need

replacing, remove main burner with pilot using procedure

described in Paragraph 4.

A. To replace orifice:

1.Disconnect pilot tubing. The Robertshaw 7CL-6,

Honeywell Q350 and Q3450 pilot orifices are insert

type retained by the compression fitting. The Honey-

well Q327 and Q3480 pilot orifice is a spud type

screwed into pilot burner. Replace with desired

orifice. See Key No. 5B.

50mm Burner

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 Q3450 or Q3480 igniter-sensor rod

assembly:

1.Remove spring clip by pulling it away from the pilot

burner.

2.Remove assembly from pilot burner and disconnect

harness from gas valve.

40mm Burner

3.Replace with equal.

D. 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.

E. Reinstall main burner following procedure described

in Paragraph 4.

Figure 30: Burner Cleaning and Installation

the service technician or the User. Circulator bearings are

water lubricated.

7. LUBRICATION

There are no parts requiring lubrication on the part of

Table 5: Pilot Burner Location

Main Burner with

Pilot Burner Located Between Main Burners*

Pilot Bracket *

Boiler Model

1 Inch

50mm

40mm

1 Inch

1 & 2

2 & 3

3 & 4

4 & 5

6 & 7

7 & 8

8 & 9

9 & 10

50 mm

---

40mm

---

202

202X

203

204

205

206

207

208

209

210

---

1 & 2

2 & 3

3 & 4

4 & 5

5 & 6

1 & 2

2 & 3

3 & 4

4 & 5

5 & 6

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

SECTION IV REPAIR PARTS

Section Assembly and Canopy Group .................................. 32

Base Assembly ...................................................................... 34

Manifold and Main Burners

1 Inch Main Burners ..................................................... 36

50mm Main Burners ..................................................... 38

40mm Main burners ...................................................... 40

Pilot Burner and Gas Valve

Continuous Ignition (Standing Pilot)............................ 42

Intermittent Ignition ...................................................... 44

Jacket Assembly .................................................................... 46

Water Trim ........................................................................... 48

Controls................................................................................. 50

Draft Hood and Vent Damper .............................................. 51

All Series 2 repair parts may be obtained through your local Burnham Wholesale Distributor. Should you require assistance in

locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts,

please contact your Burnham Regional Sales Office as listed below.

Burnham Corporation Regional Offices

A. Burnham Corporation - Central & Western Regions

P.O. Box 3079

C. Burnham Corporation - Metropolitan Region

P.O. Box 3079

Lancaster, PA 17604-3079

Phone: (717) 481-8400

Lancaster, PA 17604-3079

Phone: (717) 481-8400

FAX: (717) 481-8408

FAX: (717) 481-8409

B. Burnham Sales Corporation - Northeast Region

19-27 Mystic Avenue

D. Burnham Corporation - Mid-Atlantic Region

P.O. Box 3079

Somerville, MA 02145

Lancaster, PA 17604-3079

Phone: (717) 481-8400

Phone: (617) 625-9735

FAX: (617) 625-9736

FAX: (717) 481-8409

Contact Regional Office Indicated for your State

Alabama

Alaska

Nebraska

Oregon

Nevada

Pennsylvania

Rhode Island

South Carolina

South Dakota

Tennessee

Te xas

Arizona

New Hampshire

New Jersey

Arkansas

California

Colorado

Connecticut

Delaware

Florida

Atlantic, Burlington, Camden,

Cape May, Cumberland,

Gloucester, Mercer,

Monmouth, Ocean, Salem

Counties

Utah

Ve rm ont

Georgia

Hawaii

All other Counties

Virginia

New Mexico

Arlington,Accomack,Clarke,

Idaho

New York

Albany, Fulton, Montgomery,

Fairfax,Frederick,Fauquier,

Loudoun,Northampton and

Prince William Counties

All other Counties

Illinois

Indiana

Rensselaer, Saratoga,

Schenectady, Schoharie,

Warren, Washington Counties

All Other Counties

Iowa

Kansas

Washington

Kentucky

Louisiana

Maine

Washington, D.C.

West Virginia

Wisconsin

North Carolina

North Dakota

Ohio

Maryland

Massachusetts

Michigan

Minnesota

Mississippi

Missouri

Montana

Wyoming

Athens, Belmont, Gallia,

Jefferson, Lawrence, Meigs,

Monroe, and Washington

Counties

All other Counties

Oklahoma

Canada

Figure 33: Section Assembly and Canopy Group

Quantity

Key

No.

De scrip tio n

Part No.

202 202X 203 204 205 206 207 208 209 210

1. Section Assembly (Intermittent and Continuous Circulation Only)

617170221

617170321

617170421

617170521

617170621

617170721

617170821

617170921

617171021

---

Section Assembly, Complete

---

1. Section Assembly (Gravity circulation Only)

617170231

617170331

617170431

617170531

617170631

617170731

617170831

617170931

617171031

---

Section Assembly, Complete

---

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

2. Canopy Group

61117022

611170300

611170302

611170402

611170502

611170602

611170702

611170802

611170902

611171002

---

----

---

----

---

Canopy Assembly

(except for 206H)

---

Canopy Assembly 206H

6111706010

---

Common

Hardware

2B Carriage Bolt, ¼-20 x 1"

2C Flat Washer, ¼"

Common

Hardware

Common

Hardware

2D Nut, Hex, ¼-20

Cerafelt Sealing Strip, ½" x 1" x 10'

6206001

(Canopy to Section Assy)

Flue Gas Baffle (*Standing Pilot 1"

and 50mm Burners Only)

(** LP Standing Pilot 1" and 50mm

Burners Only) (+2H Models Only)

(*** Standing Pilot Models Only)

71106001

1***

---

2**+ 3**+ 4**+ 5**+ 6**

Figure 34: Base Assembly

Key

Boiler

Size

Key

No.

Boiler

Size

Description

No.

3. Base Assembly Continued

Part No. Qty.

Description

Part No. Qty.

3. Base Assembly

202 718600211

202 618600291

202X 618600391

203 618600391

204 618600491

205 618600591

206 618600691

207 618600791

208 618600891

209 618600991

210 618601091

202 718600291

202X 718600391

203 718600391

204 718600491

205 718600591

206 718600691

207 718600791

208 718600891

209 718600991

210 718601091

202X 718600311

203 718600311

204 718600411

205 718600511

206 718600611

207 718600711

208 718600811

209 718600911

210 718601011

Base Assembly

(Complete)

3B Base Wrapper

Available for 1 Inch

Burners Only

3B1 Base End Insulation

All

720601

202

72060025

202X 72060035

203

204

205

206

207

208

209

210

72060035

72060045

72060055

72060065

72060075

72060085

72060095

72060105

3A Base Tray

3B2 Base Rear Insulation

Key

No.

Boiler

Size

Key

No.

Boiler

Size

Description

Part No. Qty.

Description

Part No. Qty.

3. Base Assembly Continued

202

618600241

618600341

All

6186001

71860021

8186006

3E Base Leg Assembly

3E1 Base Leg

202X

203

All

618600341

618600441

618600541

3E2 Nylon Glide

204

202

202X

203

204

205

206

207

208

209

210

718600261

718600361

718600461

718600561

718600661

718600761

718600861

718600961

718601061

205

Base Front Panel

Assembly

206

207

208

618600641

618600741

618600841

3F Burner Access Panel

209

618600941

210

202

618601041

718600205

718600305

202X

203

204

718600305

718600405

Cerafelt Sealing Strip,

1" x 2" x 10' (Section

All

6206002

Assembly to Base)

Burner Tray

205

206

207

208

209

210

203

204

718600505

718600605

718600705

718600805

718600905

718601005

7817038

(1" Main Burners)

202

thru

206

80860700

3H Self-Tapping Screw,

¼" - 20 x ½"

207

thru

210

80860700

80860717

Self-Tapping Screw,

5/16" - 18 x 1-1/4"

All

7817048

Flat Washer, 5/16",

Common

Hardware

All

205

206

207

208

209

210

202

202X

203

204

205

206

207

208

209

210

7817058

7817068

USS

Burner Tray

Common

Hardware

3L Lock Washer, 5/16"

3M Hex Nut, 5-16,

(50 mm Main Burners)

7817078

Common

Hardware

7817088

7817098

7817108

718600206

71806037

71806047

71806057

71806067

71806077

718600806

718600906

718601006

Burner Tray

(40mm Main Burners)

Figure 35: Manifold and Main Burners

(1 Inch Main Burners)

Quantity

Key

No.

Description

Part No.

202

202X

203

204

205

206

207

208

209

210

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

Main Burner

8236099

----

Main Burner with Pilot Bracket

See Table Below

82260023

82260033

----

82260043

82260053

82260063

82260073

82260083

82260093

----

Manifold

----

82260103

----

Main Burner Orifice

See Table Below

Screw, Machine, Slotted Round Head,

10-32 x 3/16" (Standing Pilot)

80860800

Screw, Machine, Philips Head

w/Captive Lockwasher, #10-32 x ¼"

(Intermittent Ignition)

80860874

80860700

Screw, Self Tapping, Phillips Pan

Head, ¼-20 x ½"

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

Main Burner with 70° 7CL-6 Pilot

Bracket and Offset Lancings

8231706

---

Main Burner with 70° Q350 Pilot

Bracket and Offset Lancings

8236097

8236098

---

Main Burner with 60° Pilot Bracket

---

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

Main Burner with 70° 7CL-6 Pilot

Bracket and Offset Lancings

8231706

8236111

---

Main Burner with 45° Pilot Bracket

---

4B. 1 Inch Main Burner with Pilot Bracket, Intermittent Ignition Only

Main Burner with 60° Pilot Bracket

8236098

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

Main Burner Orifice, #47 (White)

Main Burner Orifice, #44 (Orange)

Main Burner Orifice, #45 (Pink)

822710

822712

822711

---

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

Main Burner Orifice, 1.25 mm

(Purple)

822705

---

Main Burner Orifice, #55 (Green)

Main Burner Orifice, 3/64" (Blue)

822708

822704

---

Continuous Pilot Ignition:

- Q327A Only

- Not suitable for use with Q350A 24V Continuous

Pilot Ignition

Intermittent Ignition: Q3480C

Figure 36: Manifold and Main Burners

(50 mm Main Burners)

Quantity

Key

No.

Description

Part No.

202

202X

203

204

205

206

207

208

209

210

4. Manifold and Main Burners (50 mm Main Burners Only)

Main Burner

8236091

8236092

---

Main Burner with 45° Pilot Bracket

82260034

82260044

82260054

82260064

82260074

82260084

82260094

82260104

---

Manifold

---

50 mm Main Burner Orifices, Natural Gas, High Altitude, U.S.A. and Canada, 2000-5000 Ft. Altitude

Main Burner Orifice, #38

Main Burner Orifice, #37

822680

822601

---

50 mm Main Burner Orifices, LP/Propane, High Altitude, U.S.A. and Canada, 2000-5000 Ft. Altitude

Main Burner Orifice, #53

Main Burner Orifice, #52

External Hitch Pin Clip

8226002

822641

822604

---

Screw, Machine, Philips Head

w/Captive Lockwasher, #10-32 x ¼"

80860874

80860700

---

Screw, Self Tapping, Phillips Pan

Head, ¼-20 x ½"

618600301

618600401

618600501

618600601

618600701

618600801

618600901

618601001

718600303

718600403

718600503

718600603

718600703

718600803

718600903

718601003

80860900

---

Lower Injection Shield

---

Upper Injection Shield

---

Wing Nut, ¼-20, Size B

Figure 36a: Manifold and Main Burners

(40mm Main Burners)

Quantity

202 202X 203 204 205 206 207 208 209 210

Key

No.

Description

Part No.

4. 40MM MAIN BURNERS ONLY

4A Main Burner

8236135

---

Intermittent Ignition Only

Main Burner with 48° Pilot Bracket

Main Burner with 41° Pilot Bracket

8236143

8236136

---

24-volt Continuous Ignition (Standing Pilot) Natural Gas Only

Main Burner with 48° Pilot Bracket

Main Burner with 41° Pilot Bracket

8236143

8236136

---

24-volt Continuous Ignition (Standing Pilot) LP Gas Only

Main Burner with 48° Pilot Bracket

Main Burner with 41° Pilot Bracket

8236143

8236136

---

Quantity

Key

No.

Description

Part No.

202 202X 203

204

205

206 207

208

209

210

4. 40MM MAIN B URNERS ONLY(Continued)

82260028

---

82260038

82260048

82260058

82260068

82260078

82260088

---

Manifold

---

82260098

82260108

---

Natural Gas, Sea Level to 2000 Ft.

Main Burner Orifice, 3.00 mm

822780

822729

---

Main Burner Orifice, #41

---

Main Burner Orifice, #36

822771

822772

---

Main Burner Orifice, 7/64"

---

LP Gas, Sea Level to 2000 Ft.

Main Burner Orifice, #49

822709

822722

---

Main Burner Orifice, #53

Main Burner Orifice, #51

---

822733

---

Natural Gas, High Altitude (2000-5000 Ft.) U.S.A. Only

Main Burner Orifice, #36

Main Burner Orifice, #44

Main Burner Orifice, #41

Main Burner Orifice, #40

822771

822712

822729

822728

---

Main Burner Orifice, #39

822727

---

LP Gas, High Altitude (2000-5000 Ft.) U.S.A. Only

Main Burner Orifice, #52

Main Burner Orifice, #55

Main Burner Orifice, #53

822721

822708

822722

---

Natural Gas, High Altitude (2000-4500 Ft.) Canada Only

Main Burner Orifice, 7/64"

Main Burner Orifice, #43

Main Burner Orifice, #38

Main Burner Orifice, #37

822772

822713

822720

822719

---

LP Gas, High Altitude (2000-4500 Ft.) Canada Only

Main Burner Orifice, #50

Main Burner Orifice, #54

Main Burner Orifice, #52

822732

822734

822721

---

Screw, Machine, Slotted Round Head,

#10-32 x 3/16" (Standing Pilot)

80860800

80860874

80860700

Screw, Machine, Phillips Head

w/Captive Lockwasher, #10-32 x ¼"

(Intermittent Ignition)

Screw, Self Tapping, Phillips Pan Head,

¼-20 x ½"

Injection Shield Assembly

A/R

* 1" Burner Only

** 40mm Burner Only

Figure 37

Quantity

205 206

Key

No.

Description

Part No.

202 202X

203

204

207

208

209

210

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

Pilot Burner, Robertshaw 7CL-6

5A Pilot Burner, Honeywell Q350A1644

Pilot Burner, Honeywell Q327A1949

8231702

8236102

8236103

---

1** 1**

---

1**

---

Pilot Orifice, Robertshaw 76376-1 .010"

5B Pilot Orifice, Honeywell 390686-22 .012"

Pilot Orifice, Honeywell 388146AG .026"

Included

with 5A

1** 1**

1**

---

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

8236109

8236108

8236110

8236100

81660143

81660182

81660183

81660241

81660242

8231704

8236024

8236047

822630

---

Adptr, 1/8"OD x 1/4" NPT Included w/5A & 5E

2** 2**

1** 1**

Pilot Tubing, 1/8" OD x 30" LG

Pilot Tubing, 1/8" OD x 40" LG

---

Gas Valve, Honeywell VR8200C3005

Gas Valve, Honeywell VR8200C6008

---

5E Gas Valve, Honeywell VR8300C4134

---

Gas Valve, Honeywell VR8200C6032

Gas Valve, Honeywell VR8300C4183

---

1** 1**

1** 1** 1** 1**

---

1** 1** 1** 1**

Thermocouple, 30", Robertshaw 42930

Thermocouple, 30", Honeywell Q309A

---

1** 1**

5G Pilot Tubing, 1/4" OD x 9" LG

---

5H Male Adapter, 1/4" OD x 1/8" NPT

5J Regulator, 3.5" w.c., Maxitrol RV12LT

5K Pilot Tubing, 1/4" OD x 6" LG

8231705

8236094

8236046

5L Compression Coupling, 1/4" x 1/4" x 90°

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

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

Pilot Burner, Robertshaw 7CL-6

Pilot Burner, Honeywell Q327A1915

Pilot Burner, Honeywell Q350A2279

8231703

8236106

8236105

---

1**

Pilot Orifice, Robertshaw 27270-1 (.008")

Pilot Orifice, Honeywell 388146KR (.014")

Pilot Orifice, HoneywelL 390686-23 (.008")

---

Included

With 5A

---

1**

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

Adptr, 1/8"OD x 1/4" NPT Included w/5A & 5E

8236109

8236108

---

2**

²**

Pilot Tubing, 1/8" OD x 30" LG

8236110

8236100

81660144

81660243

81660244

8231704

---

1**

Pilot Tubing, 1/8" OD x 40" LG

---

Gas Valve, Honeywell VR8200C3013

Gas Valve, Honeywell VR8200C6040

Gas Valve, Honeywell VR8300C4548

Thermocouple, 30", Robertshaw 42930

---

1**

---

1**

Thermocouple, 30", Honeywell Q309A

Pilot Tubing, 1/4" OD x 18" LG

8236024

8236048

8236046

8236047

---

5L Compression Coupling, 1/4" x 1/4" x90°

5M Pilot Tubing, 1/4" OD x 9" LG

1" Burner Only

** 40mm Burner Only

Figure 38

Quantity

Key

No.

Description

Part No.

202

202X 203

204

205

206

207

208

209

210

5. Pilot B urner and Gas Valve, Intermittent Ignition, Natural Gas

Pilot Burner, Honeywell Q3480C1197

Pilot Burner, Honeywell Q3450B1039

Pilot Burner, Honeywell Q3480C1254

8236124

8236144

8236133

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

Pilot Orifice, Honeywell with NE22

Orifice, 388146NE (.022")

1**

---

Included

with 5A

Pilot Orifice, Honeywell with BCR18

Orifice, 390686-4 (.018")

Adapter, 1/4" OD x 1/4" NPT

Included with 5A and 5E

8236109

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

8236122

8236123

81660213

81660216

81660237

81660238

---

Pilot Tubing,1/4" OD x 40" LG

Gas Valve, Honeywell SV9501P2004

Gas Valve, Honeywell SV9601P4107

Gas Valve, Honeywell SV9501P2087

Gas Valve, Honeywell SV9601P4172

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

Ignitor/Sensor Assembly with clip

Honeywell Q3400A1024 (Included

with 5A)

8236114

5. Pilot Burner and Gas Valve, Intermittent Ignition, LP/Propane

Pilot Burner, Honeywell Q3480C1437

Pilot Burner, Honeywell Q3450B1047

Pilot Burner, Honeywell Q3480C1452

8236125

8236145

8236134

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

---

1**

Pilot Orifice, Honeywell with KR14

Orifice, 388146KP (.014")

1**

---

Included

with 5A

Pilot Orifice, Honeywell with BBR12

Orifice, 390686-25 (.012")

Adapter, 1/4" OD x 1/4" NPT

Included with 5A and 5E

8236109

Pilot Tubing, 1/4" OD x30" LG

8236122

8236123

81660215

81660239

81660240

---

Pilot Tubing, 1/4" OD x40" LG

---

Gas Valve, Honeywell SV9601P4115

Gas Valve, Honeywell SV9501P2020

Gas Valve, Honeywell SV9601P4164

---

1**

---

1**

---

1**

---

1**

---

Ignitor/Sensor Assembly with clip

Honeywell Q3400A1024

(Included with 5A)

8236114

** 40mm Burners Only

Service Notes

Figure 39

Quantity

202 202X 203 204 205 206 207 208 209 210

Key

No.

Description

Part No.

6. Jacket Assembly, Complete

604170254

604170354

604170454

604170554

604170654

604170754

604170854

604170954

604171054

---

Jacket Assembly, Complete

---

6. Jacket Assembly

604170215

604170315

604170415

604170515

604170615

604170715

604170815

604170915

604171015

---

Jacket Wrap-Around Panel

---

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

6. Jacket Assembly (Continued)

604170223

604170323

604170423

604170523

604170623

604170723

604170823

604170923

604171023

604170233

604170333

---

Jacket Vestibule Panel

---

604170433

604170533

604170633

604170733

604170833

604170933

604171033

604170242

604170342

604170442

604170542

604170642

604170742

604170842

604170942

---

Jacket Top Panel

---

Jacket Front Removable Door

---

604171042

604170216

604170316

---

604170416

604170516

604170616

604170716

604170816

604170916

604171016

---

Jacket Lower Front Panel

---

Sheet Metal Screw, Type AB,

Phillips Truss Head, #8 x ½"

80860000

Snap Bushing, Heyco SB-1093-15

Snap Bushing, Heyco SB-437-5

8136257

8136048

Figure 40: Water Trim

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

Safety Relief Valve, 30 psi, ¾ NPT,

Conbraco 10-408-05

81660319

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

Circulator with Gaskets,

8056174

Bell & Gossett NRF-22

8B G asket, Bell & Gossett NRF-22

806602029

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

Circulator with Gaskets,

8056173

Grundfos UP15-42F

8B Ga sket, Grundfos 510179

806602016

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

8A Circulator with Gaskets, Taco 007F

8B Gasket, Taco '00' Series

8056170

806602006

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

8A Circulator with Gaskets, Taco 0010 8056176

8B Gasket, Taco '00' Series 806602006

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

9A Flange, 1¼ NPT

806602013

80861301

80860406

Screw, Cap Hex Head, 7/16-14 x

1½"

9C Nut, Hex, 7/16-14

10. Limit Control

10A Limit, Honeywell L4080D1036

10B Well, ½ NPT (Included w/10A)

80160156

-----

Limit, Honeywell L4080B1212

10C

80160474

80160426

(Dual Limit Only)

We ll, ¾ NPT, Ho neywell 123870A

10D

(Dual Limit Only)

11. Miscellaneous Trim

11A Drain Cock, Conbraco 31-606-02

11B Temperature-Pressure Gauge,

11C Nipple, 1¼ NPT x 3"

806603011

8056164U

806600005

Figure 41

Quantity

202 202X 203 204 205 206 207 208 209 210

Key

No.

Description

Part No.

12. Transformer/Relay Assembly (Intermittent Circulation Only)

12A

12B

12C

Junction Box, 4" x 4" x 1½"

8136259

Transformer/Relay, Honeywell

R8285D5001 (Includes Key No. 80160155U

12C) 50VA

Relay, Honeywell R8222U1006 80160096U

12. Transformer (Continuous and Gravity Circulation Only)

12A

12D

Junction Box, 4" x 4" x 1½"

8136259

Transformer, 40VA, Honeywell

AT140D1012 or AT72D1188

80160039

13. Flame Rollout Switch

13A

13B

Flame Rollout Switch

80160044

7186018

Flame Rollout Switch Mounting

Bracket (*40mm Burner Only)

14. Blocked Vent Switch

Blocked Vent Switch

6016058

Replacement Assembly

Figure 42

Quantity

Key

No.

Description

Part No.

202

202X

203

204

205

206

207

208

209

210

16. Draft Hood Carton

8116067

8111702

8111703

8111704

8111705

---

Draft Hood

---

17. Vent Damper Carton (U.S.A. - Standard; Canada - Optional)

Automatic Vent Damper, 4"

Effikal RVGP-KS-4; or

Johnson Y15A

8116143

8116122

---

Automatic Vent Damper, 5"

Effikal RVGP-KS-5; or

Johnson Y15B

8116144

8116123

---

Automatic Vent Damper, 6"

Effikal RVGP-KS-6; or

Johnson Y15C

8116145

8116124

---

Automatic Vent Damper, 7"

Effikal RVGP-KS-7; or

Johnson Y15D

8116146

8116125

---

Automatic Vent Damper, 8"

Effikal RVGP-KS-8; or

Johnson Y15E

8116147

8116126

---

18. Vent Reducer

Reducer, 4" x 3"

8116164

---

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