Burnham series Series 2B User Manual

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

SERIES 2^®(model B)

GAS - FIRED BOILER

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

Installation Date

Boiler Serial Number

Phone Number

Heating Contractor

Address

Price - $3.00

81417032R24-10/08

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.

Dimensions [Inches]

Gas

Approx.

Shipping

Weight

[lb.]

Boiler

Model

Number

Water Recommended

Connection

For Automatic

Gas Valve

Content

[gallons]

Vent Size

[1] [2]

202

202X

203

204

205

206

207

208

209

210

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

45-5/8 8-1/2 10 [3]

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

45-5/8 8-1/2

47-1/8 9-1/8

48-1/2 9-3/4

4-3/4

5-1/4

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 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.

Figure 1

I . Installation Instructions

C. Save two of the wooden slats from the container

sleeve for use in Steps D & E.

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 ﬁled

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.

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.

2. BOILER INSTALLATION must conform to the

requirements of the authority having jurisdiction, or in

the absence of such requirements, to:

7. PROvIDE CLEARANCE and AIR for COMBUS-

TION and vENTILATION.

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.

WARNING

Adequate combustion and ventilation air must be

provided to assure proper combustion.

CANADA - "Installation Codes for Natural and LP Gas

Burning Appliances and Equipment, CAN/

CSA-B149.1.

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).

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 ﬂoor.

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).

4. LOCATE BOILER in front of or behind installation

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.

3. UNCONFINED SPACE (see deﬁnition,

paragraph (B) below) - height clearance may be

reduced to 27" (68.6cm).

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.).

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.

DANGER

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.

Do not install boiler where gasoline or other

ﬂammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals,

sprays, paint removers, fabric softeners, etc.) are

used or stored.

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.

5. REMOvE CRATE -

A. Remove all crate fasteners. Lift off outside

container.

B. Remove all screws and brackets securing boiler to

skid.

ꢁ

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 (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.

Figure ꢀ: Minimum Clearances

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.

volume [ft³](m³) = 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).

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.

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 unconﬁned space.

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

1,000 Btuh, space is considered a conﬁned

space.

d. Determine building type. A building of

unusually tight construction has the

following characteristics:

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. 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 ﬂoors, between wall-

ceiling joints, between wall panels, at

plumbing and electrical penetrations, and

at other openings.

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).

ꢂ

Table 1: Maximum Capacity of Schedule ꢁ0 Pipe in CFH For Natural Gas Pressures of ½ psig or Less

0.3 Inch w.c. Pressure Drop

0.5 Inch w.c. Pressure Drop

Length

[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

Table 3: Speciﬁc Gravity Correction Factors for

Natural Gas

Speciﬁc

Gravity

Correction

Factor

Speciﬁc

Gravity

Correction

Factor

Fitting

1¼

0.50

0.55

0.60

0.65

0.70

0.75

0.80

1.10

1.04

1.00

0.96

0.93

0.90

0.87

1.30

1.40

1.50

1.60

1.70

---

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

1.6

3.5

6.9

2.1

4.1

Tee (As Elbow)

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.

---

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 ﬁttings.

D. Speciﬁc gravity of gas.

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).

E. Correction factor for speciﬁc gravity.

9. BOILER PIPING

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

(3.5kPa).

CAUTION

Failure to properly pipe boiler may result in

improper operation and damage to boiler or

building.

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. 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 ﬂoor.

ꢃ

Figure ꢁ: Recommended Piping

for Combination Heating & Cooling

(Refrigeration) Systems

with ﬂow 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.).

Figure 3: Recommended Water Piping for

Zone Valve Zoned Heating Systems

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 ﬂow to maintain higher

boiler water temperatures.

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.

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.

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.

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.

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

Consult also I=B=R Installation Guides.

I. A hot water boiler installed above radiation level

must be provided with a low water cutoff device as

part of the installation.

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.

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.

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.

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 ﬁrst be

isolated to avoid a pressure loss due to the escape of

air trapped in the boiler.

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

ꢄ

To perform a long term pressure test including the

boiler, ALL trapped air must ﬁrst 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 ﬁrst

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 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:

Figure ꢃ

1. Repairing system leaks to eliminate the need for

addition of make-up water.

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.

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.

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.

10. INSTALL DRAFT hOOD without modiﬁcation on

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

metal screws.

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.

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 certiﬁcation will become void.

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.

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.

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.

A. Untape the blocked vent switch assembly from the

top of the boiler and uncoil the power cord.

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

switch are secure and located as shown in Figure 6.

ꢅ

Figure ꢄ: Plug-in Damper Installation

WARNING

NOTICE

Failure to properly install and use this Blocked

Vent Switch may result in property damage,

personal injury or loss of life.

Provide adequate clearance for servicing.

WARNING

12. TO MEET FEDERALLY MANDATED

EFFICIENCIES, ThIS BOILER MUST BE

EQUIPPED WITh A vENT DAMPER.

Provide ꢃ" (1ꢂ.ꢀcm) minimum clearance between

damper and combustible construction.

C. 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. (See Figure 7).

OPEN ThE vENT DAMPER CARTON and remove

the Installation Instructions. READ ThE INSTALLA-

TION INSTRUCTIONS ThOROUGhLY before

proceeding.

The automatic gas control valve supplied on each Series

2™ boiler provides the redundancy referenced in the

vent damper Installation Instructions.

NOTICE

CAUTION

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 ꢄ in

this manual.

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.

D Continuous Ignition (Standing Pilot) Only. Remove

knockout from vent damper blade.

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

vent damper outlet.

13. INSTALL vENT CONNECTOR from reducing

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

Figure 8.

B. Mount the vent damper assembly after the draft

hood, as close to the draft hood as practicable

without modiﬁcation to the draft hood or vent

damper. (Refer to Figure 7 and 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.

ꢆ

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

ﬂéchissement.

Figure ꢅ: 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.

h. vent pipe must be inserted into but not beyond

inside wall of chimney liner. Seal tight between vent

pipe and chimney.

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

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

UL) vent damper or other obstruction in vent pipe.

WARNING

Appliances, ANSI/NFPA 211. Both of the

14. IF AN ExISTING BOILER IS REMOvED -

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 and

LP Installation Code, CAN/CSA-B149.1.

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

deﬁciencies which could cause an unsafe condition.

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

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

open ﬁreplace.

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

bathroom exhausts, so they will operate at maximum

speed. Do not operate a summer exhaust fan. Close

ﬁreplace dampers.

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. 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

remaining 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.

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 ﬂamme d’une

allumette ou d’une chandelle ou la fumée d’une

cigarette, d’un cigare ou d’une pipe.

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.

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

modiﬁée, le système devrait être modiﬁé 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.

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.

15. INSTALL A ROOM ThERMOSTAT on an inside

wall 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.

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

et les fenêtres du bâtiment et toutes les portes entre

Table ꢁ: Wiring Diagrams and Heat Anticipator Settings

Thermostat Heat Anticipator

Setting [Amps]

Wiring

Diagram Figure

Ignition Type

Circulation Method

Intermittent

Constant/Gravity

Intermittent

0.6

1.0

0.6

1.0

Continuous

(Standing Pilot)

Electronic

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.

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.

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 satisﬁed.

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.

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 satisﬁed, 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.)

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.

Figure ꢆ: Vent Damper Schematic Wiring Diagram

CAUTION

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 weath-

er; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if

the boiler is inoperative.

CAUTION

Avoid operating this boiler in an environment where saw dust, loose insulation ﬁbers, 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.

1ꢀ

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

2. Blocked vent Switch

SEQUENCE OF OPERATION

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

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 1ꢀ: 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. 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.

2. Sensor proves presence of pilot ﬂame. Main valve

3. Flame Roll-out Switch: Automatically interrupts

boiler operation when ﬂames or excessive heat are

present in vestibule. Control is single use device. If

ﬂame roll-out switch is activated do not attempt to

place boiler in operation. Correct source of blockage

and replace ﬂame roll-out switch.

opens to ignite main burners.

3. The burners and circulator will operate

simultaneously until the thermostat is satisﬁed.

4. After thermostat is satisﬁed, ignition module is de-

energized, extinguishing pilot and main ﬂame. Vent

damper closes (see paragraph 17E).

4. Igniter/Sensor: senses pilot ﬂame and causes

ignition module to turn off main burner and pilot

burner gas ﬂow should pilot burner ﬂame

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.

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.

1ꢁ

Figure 13: Wiring Diagram, ꢀꢁ 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 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 qualiﬁed service agency before

resetting switch.

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

personnel from a qualiﬁed service agency.

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. 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.

1ꢂ

Figure 1ꢁ: 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. 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.

2. Sensor proves presence of pilot ﬂame. Main valve

opens to ignite main burners.

3. Flame Roll-out Switch: Automatically interrupts

boiler operation when ﬂames or excessive heat are

present in vestibule. Control is single use device. If

ﬂame roll-out switch is activated do not attempt to

place boiler in operation. Correct source of blockage

and replace ﬂame roll-out switch.

3. The burners will operate until the thermostat is

satisﬁed.

4. When thermostat is satisﬁed, ignition module is de-

energized, extinguishing pilot and main ﬂame. If

boiler is equipped with circulator, circulator will

continue to run. vent damper closes (see Para-graph

17E).

4. Igniter/Sensor: senses pilot ﬂame and causes

ignition module to turn off main burner and pilot

burner gas ﬂow should pilot burner ﬂame

SAFETY ShUTDOWN

extinguish. Five to six minutes after shutdown,

ignition module restarts ignition sequence.

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.

5. For Electronic Ignition Trouble Shooting Guide, see

Page 25 of this manual.

1ꢃ

Figure 1ꢂ: Wiring Schematic, Zone Valves

Figure 1ꢃ: Wiring Schematic, Zone Circulators

1ꢄ

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 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 ﬁve gallon bucket at a suitable

ﬂoor drain or outdoor area).

4. Starting with one circuit, open zone valve.

Figure 1ꢄ: Schematic Pilot and Gas Piping

Continuous Ignition (Standing Pilot)

5. Open hose bib.

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 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 hose bib, 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).

Figure 1ꢅ: Schematic Pilot and Gas Piping

Electronic Ignition (EI)

10. Open isolation valve in boiler supply piping.

11. Remove hose from hose bib.

boiler model found on Rating Label with paragraph

heading:

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.

1. Standing Pilot Models (Sufﬁx C):

a. Keep electric switch "OFF".

b. Open Manual Shut-off valve upstream of

D. Turn "OFF" the electric switch serving boiler.

E. Open valve on main gas line at meter.

Combination Gas valve.

c. Disconnect Pilot Tubing at gas valve (Purge

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 ﬂame permitted. To

determine which of the procedures outlined in

succeeding paragraphs is applicable, match sufﬁx of

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.

1ꢅ

Figure 1ꢆ: Top View of VR Gas Valves

Figure ꢀ0: Operating Instructions, VRꢅꢀ0ꢁ and VRꢅ30ꢁ Gas Valves

1ꢆ

e. Reconnect pilot tubing and check pipe and

ﬁttings from meter to combination Gas

valve for leaks using soap solution or other

approved method.

2. Electronic Ignition Models (Sufﬁx 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 ﬁttings from meter to

Combination Gas valve using soap solution

or other approved methods.

Figure ꢀ1: LED Locations

CAUTION

Table ꢂ: Ignition Module Terminal Cross-

Reference

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.

Ignition Module

Wiring Ladder Diagram

Terminal Designation

Terminal Number

MV/PV

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

numbers in the wiring ladder diagrams. The yellow

LED indicates the status of the ﬂame, see Table 6.

The green LED indicates the status of the system,

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

Figure 28 for Troubleshooting Guide.

GND

24V (GND)

24V

SPARK

Table ꢃ: Yellow LED Flame Codes

Yellow LED Flash

Indicates

Recommended Service Action

N/A

Code^a

Heartbeat

Normal Flame Signal

Weak Flame Signal -

System will operate reliably but ﬂame signal is less than

desired.

Note: This indication may ﬂash temporarily during or

shortly after lightoff on some applications.

Perform routine maintenance to

assure optimum ﬂame signal.

Marginal Flame Signal (less than 1.1 µA) -

System may not operate reliably over time. Service call Check gas supply, pilot burner, ﬂame sense

recommended.

wiring, contamination of ﬂame rod, burner

Note: This indication may ﬂash temporarily during or

shortly after lightoff on some applications.

ground connection.

No Flame or Flame Signal -

below minimum threshold for system

operation.

OFF

N/A

^aFlash Code Descriptions

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

The ﬂash code number signiﬁes that the LED ﬂashes X times at 2Hz, remains off for two seconds, and then repeats sequence.

ꢀ0

Table ꢄ: Green LED Status Codes

Green LED

Flash Code

Indicates

Next System Action

Recommended Service Action

(X + Y)^a

OFF

No “Call for Heat”

N/A

None

Startup - Flame sense

calibration

Flash Fast

Heartbeat

Normal operation

If system fails to light on next trial

for ignition check gas supply, pilot

burner, spark and ﬂame sense wir-

ing, ﬂame rod contamination or out

of position, burner ground connec-

tion.

5 minute Retry Delay-

Pilot ﬂame not detected

during trial for ignition

Initiate new trial for ignition after retry

delay completed.

If system fails to light on next trial

for ignition check gas supply, pilot

burner, ﬂame sense wiring, ﬂame

rod contamination, burner ground

connection.

Initiate new trial for ignition. Flash

code will remain through the ignition

trial until ﬂame is proved.

Recycle- Flame failed

during run

If situation self corrects within 10

Check for pilot ﬂame. Replace gas

valve if pilot ﬂame present. If no

pilot ﬂame, cycle “Call for Heat.” If

error repeats, replace control.

seconds, control returns to normal

sequence. If ﬂame out of sequence re-

mains longer than 10 seconds, control

goes to Flash code 6+4 (see below)

Flame sensed out of

sequence

Check ﬂame sense lead wire for

Control remains in wait mode. When

damage or shorting. Check that

Flame sense leakage to

ground

the fault corrects, control resumes nor- ﬂame rod is in proper position.

mal operation after a one minute delay. Check ﬂame rod ceramic for cracks,

damage or tracking.

Check transformer and AC line for

Control remains in wait mode. When

proper input voltage to the control.

Low secondary voltage

supply- (below 15.5 Vac)

the fault corrects, control resumes nor-

Check with full system load on the

mal operation after one minute delay.

transformer.

Check gas supply, pilot burner, spark

5 minute Retry Delay-

On every third retry on

same “Call for Heat”

Initiate new trial for ignition after retry

delay completed.

and ﬂame sense wiring, ﬂame rod

contamination or out of position,

burner ground connection.

6 + 2

6 + 3

6 + 4

On every 6th ﬂame

failure during run on the

same “Call for Heat”

Check gas supply, pilot burner, ﬂame

sense wiring, contamination of ﬂame

rod, burner ground connection.

5 minute retry delay, then initiate new

trial for ignition.

Control waits until ﬂame is no longer

sensed and then goes to soft lockout.

Flash code continues. Control auto

Check for pilot ﬂame. Replace gas

valve if pilot ﬂame present. If no

pilot ﬂame, cycle “Call for Heat.” If

Flame sensed out of

sequence- longer than

10 seconds

resets from soft lockout after one hour. error repeats, replace control.

Soft lockout due to error

detected during self

check sequences

Control auto resets from soft lockout

after one hour.

Reset by cycling “Call for Heat.” If

error repeats, replace the control

^aFlash Code Descriptions:

Flash Fast: rapid blinking

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

A single ﬂash code number signiﬁes that the LED ﬂashes X times at 2Hz, remains off for two seconds, and then

repeats the sequence.

X + Y ﬂash codes signify that the LED ﬂashes X times at 2Hz, remains off for two seconds, ﬂashes Y times at 2

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

ꢀ1

Figure ꢀꢀ: Lighting Instructions

ꢀꢀ

more accurate check on input is necessary see

(2) below.

B. See Figure 22 for continuous ignition system

(standing pilot).

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.

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

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'.

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:

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.

Gas Input

(cu. ft.)

Btuh Input

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.

Heating

Value

Multiplier

from

per 3 min.

of Gas

Table 3

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 ﬁnished.

(Btu / cu. ft.

5. MAIN BURNER FLAMES should have a clearly

deﬁned 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.

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.

Figure ꢀꢁ: 1 Inch Main Burner Flame

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 instructions

in Section Iv. Service.

Figure ꢀ3: ꢁ0mm Main Burner Flame

E. Natural Gas Input

6. ChECK PILOT BURNER FLAME.

A. Continuous Ignition (Standing Pilot)

LP gas Models 202 and 202x. See Figure 25.

1. Appx. Input - Adjust regulator on Gas valve so

that manifold pressure is three and a half (3½)

inches water column. Turning Regulator

Natural gas Models 202 through 206 and 207 with

1" diameter burners. See Figure 25.

Adjusting Screw Clockwise increases pressure,

Counterclockwise rotation decreases pressure. If

ꢀ3

Figure ꢀꢂ: Typical Pilot Flame, Honeywell Q3ꢂ0

The pilot produces a single ﬂame. The ﬂame should

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

inch of thermocouple.

Figure ꢀꢄ: Typical Pilot Flame, Honeywell Q3ꢁꢅA

B. Continuous Ignition (Standing Pilot)

7. ChECK ThERMOSTAT OPERATION. Raise and

lower temperature setting as required to start and stop

burners.

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

diameter burners and 208 through 210.

See Figure 26.

8. ChECK hIGh LIMIT CONTROL. Jumper

Thermostat Terminals or Thermostat connections in

Limit Control. Allow burners to operate until shutdown

by limit. REMOvE JUMPER.

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.

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.

Figure ꢀꢃ: Typical Pilot Flame, Honeywell Q3ꢀꢄ

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

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.

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.

C. Return the high limit and thermostat to their desired

settings.

ꢀꢁ

III. Trouble Shooting

Honeywell Electronic Ignition Troubleshooting Guide

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

ꢀꢂ

IV. Service

Reinstall Jacket Top Panel, draft hood, blocked vent

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

pipe.

1. Inspection should be conducted annually. Service as

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".

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 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.

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 ﬁls avant

de les débrancher. Les erreurs de câblage

peuvent nuire au bon fonctionnement et être

dangereuses.

NOTICE

4. BURNERS AND FIREBOx ShOULD BE CLEANED

ANNUALLY, AND IF NECESSARY ADJUSTED

ONCE A YEAR BY A QUALIFIED SERvICE

AGENCY.

S’assurer que l’appareil fonctionne

adéquatement une fois l’entretien terminé.

A. TO REMOvE BURNERS FOR CLEANING,

ChANGING ORIFICE PLUGS, OR REPAIRS.

1. Remove the jacket front panel.

2. vENT SYSTEM. vent system (see Figure 8 for typical

installation) should be checked annually for:

A. Obstructions.

2. Disconnect pilot tubing at the gas valve. See

Figure 17.

B. Accumulations of soot.

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 ﬂame 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.

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 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.

Figure ꢀꢆ: Cleaning of Vent System

and Boiler Flues

ꢀꢃ

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

clear oriﬁce. Burner which holds pilot can only

be removed by lifting the burner adjacent to its

right ﬁrst.

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" Burner

1. Disconnect pilot tubing. The honeywell Q350

pilot oriﬁces are insert type retained by the

compression ﬁtting. The Honeywell Q327 and

Q348A pilot oriﬁces are spud type screwed into

pilot burner. Replace with desired oriﬁce. 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.

ꢁ0mm Burner

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.

Figure 30: Burner Cleaning and Installation

1. Use round wire gauge to check spark gap.

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

performance.

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

Figure 30. Vacuum burners. Check oriﬁces to see

that drilled passageways are free of lint or dirt.

E. Reinstall main burner following procedure described

in paragraph 4.

10. vacuum tip of Pilot Burner.

7. LUBRICATION

B. CLEAN FIREBOx by vacuuming. Exercise care

There are no parts requiring lubrication on the part of

the service technician or the User. Circulator bearings

are water lubricated.

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.

Table ꢅ: Pilot Burner Location

Pilot Burner Located

Main Burner with

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 ﬂame roll-out switch wires, pilot gas

supply, thermocouple lead or pilot lead.

Between Main

Boiler

Pilot Bracket *

Burners *

Model

1 Inch

40mm

1 Inch

1 & 2

2 & 3

3 & 4

4 & 5

6 & 7

7 & 8

8 & 9

9 & 10

40mm

---

202

202X

203

204

205

206

207

208

209

210

1 & 2

2 & 3

3 & 4

4 & 5

5 & 6

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

* Main burners numbered left to right as viewed from

front of boiler.

ꢀꢄ

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.

ꢀꢅ

V. Repair Parts

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

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

Manifold and Main Burners

1 Inch Main Burners..................................................34

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

Quantity

202 202X 203 204 205 206 207 208 209 210

Key

Description

No.

Part No.

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

---

ꢀꢆ

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

ꢀ. Canopy Group

61117022

611170300

611170302

611170402

611170502

611170602

611170702

611170802

611170902

611171002

6111706010

80860115

80860603

80860407

6206001

---

Canopy Assembly (except for 206H)

---

Canopy Assembly 206H

---

2B Carriage Bolt, 1/4-20 x 1"

2C Flat Washer, 1/4"

2D Nut, Hex, 1/4-20

2E Cerafelt Sealing Strip, 1/2" x 1" x 10'

Flue Gas Bafﬂe (*Standing Pilot 1"

Burners Only)

(** LP Standing Pilot 1" Burners Only)

71106001

1***

---

2**

3**

4**

5**

6**

(*** Standing Pilot Models Only)

Section Assembly and Canopy Group

THIS PAGE LEFT INTENTIONALLY BLANK

Base Assembly

Key

No.

Boiler

Size

Key

No.

Boiler

Size

Description

Part No. Qty.

Description

Part No.

Qty.

3. Base Assembly Continued

3. Base Assembly

202

718600211

718600311

718600411

718600511

718600611

718600711

718600811

718600911

718601011

720601

202

202X

203

204

205

206

207

208

209

210

202

202X

203

204

205

206

207

208

209

210

618600291

618600391

618600491

618600591

618600691

618600791

618600891

618600991

618601091

718600291

718600391

718600491

718600591

718600691

718600791

718600891

718600991

718601091

202X

203

204

205

206

207

208

209

210

All

Base Assembly

(Complete)

Available for 1 Inch

3B Base Wrapper

Burners Only

3B1 Base End Insulation

202

202X

203

204

205

206

207

208

209

210

72060025

72060035

72060045

72060055

72060065

72060075

72060085

72060095

72060105

3A Base Tray

3B2 Base Rear Insulation

3ꢀ

Key

No.

Boiler

Size

Key

No.

Boiler

Size

Description

Part No. Qty.

Description

Part No. Qty.

3. Base Assembly Continued

3E Base Leg Assembly

3E1 Base Leg

All

6186001

71860021

8186006

202

618600241

All

202X 618600341

3E2 Nylon Glide

203

204

205

206

207

208

209

210

202

618600341

618600441

618600541

618600641

618600741

618600841

618600941

618601041

718600205

202

718600261

202X 718600361

Base Front Panel

Assembly

203

204

205

206

207

208

209

210

718600361

718600461

718600561

718600661

718600761

718600861

718600961

718601061

3F Burner Access Panel

202X 718600305

203

204

205

206

207

208

209

210

202

202X

203

204

205

206

207

208

209

210

718600305

718600405

718600505

718600605

718600705

718600805

718600905

718601005

718600206

71806037

71806047

71806057

71806067

71806077

718600806

718600906

718601006

Cerafelt Sealing Strip,

3G 1" x 2" x 10' (Section

Assembly to Base)

All

6206002

Burner Tray (1" Main

Burners)

202

thru

206

80860700

Self-Tapping Screw,

1/4" -20 x 1/2"

207

thru

210

Self-Tapping Screw,

All

80860717

80860601

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

Flat Washer, 5/16",

USS

Hex Lock Nut,

5/16 -18

All

80860464

Burner Tray

(40mm Main Burners)

Manifold and Main Burners

(1 Inch Main Burners)

3ꢁ

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

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

4A Main Burner

8236099

-----

4B Main Burner with Pilot Bracket

See Table Below

82260023

82260033

82260043

82260053

82260063

82260073

82260083

82260093

82260103

-----

---

4C Manifold

---

4D Main Burner Oriﬁce

See Table Below

Screw, Machine, Slotted Round Head,

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

80860800

80860874

80860700

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"

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

Main Burner with 70° Q350 Pilot

Bracket and Offset Lancings

8236097

8236098

---

Main Burner with 60° Pilot Bracket

---

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

4B Main Burner with 45° Pilot Bracket

8236111

---

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

4B 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, #45 (Pink)

822710

822711

---

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

Main Burner Oriﬁce, 1.25 mm (Purple)

4D Main Burner Oriﬁce, #55 (Green)

Main Burner Oriﬁce, 3/64" (Blue)

822705

822708

822704

---

3ꢂ

Manifold and Main Burners

(ꢁ0mm Main Burners)

Quantity

202X 203 204 205 206 207 208 209 210

Key

No.

Description

Part No.

ꢁ. ꢁ0 MM Main Burners Only

Main Burner

8236135

ꢁB. ꢁ0 MM Main Burner, Electronic Ignition Only

Main Burner with 48° Pilot Bracket

Main Burner with 41° Pilot Bracket

8236143

8236136

---

ꢁB. ꢁ0 MM Main Burner, ꢀꢁ-volt Continuous Ignition (Standing Pilot) Natural Gas Only

Main Burner with 48° Pilot Bracket

Main Burner with 41° Pilot Bracket

8236143

8236136

---

ꢁB. ꢁ0 MM Main Burner, ꢀꢁ-volt Continuous Ignition (Standing Pilot) LP Gas Only

Main Burner with 48° Pilot Bracket

Main Burner with 41° Pilot Bracket

8236143

8236136

---

3ꢃ

Quantity

Key

No.

Description

Part No.

202X 203 204 205 206 207 208 209 210

ꢁ. ꢁ0 MM Main Burners Only (Continued)

ꢁC. ꢁ0MM Main Burner Manifold

82260028

82260038

82260048

82260058

82260068

82260078

82260088

82260098

82260108

---

Manifold

---

ꢁD. ꢁ0 MM Main Burner, Natural Gas, ꢀ001-ꢂ000 Ft. USA Only

#43

#39

#38

822713

822727

822720

---

ꢁD. ꢁ0 MM Main Burner, LP Gas, ꢀ001-ꢂ000 Ft. USA Only

#54

#53

822734

822722

---

ꢁD. ꢁ0 MM Main Burner, Natural Gas, ꢂ001-ꢆ000 Ft. USA Only

#41

#40

822729

822728

N/A

---

ꢁD. ꢁ0 MM Main Burner, LP Gas, ꢂ001-ꢆ000 Ft. USA Only

#54

#53

822734

822722

N/A

---

ꢁD. ꢁ0 MM Main Burner, Natural Gas, ꢀ001-ꢁꢂ00 Ft. Canada Only

#37

#36

822719

822771

N/A

---

ꢁD. ꢁ0 MM Main Burner, LP Gas, ꢀ001-ꢁꢂ00 Ft. Canada Only

#52

822721

N/A

Screw, Machine, Slotted Round Head,

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

80860800

Screw, Machine, Philips Head

w/Captive Lockwasher, #10-32 x 1/4"

(Electronic Ignition)

80860874

Screw, Self Tapping, Philips Pan Head,

1/4 -20 x 1/2"

80860700

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

3ꢄ

* 1" Burner Only

** ꢁ0mm Burner Only

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

ꢂ. Pilot Burner and Gas Valve, ꢀꢁ-volt Continuous Ignition, Natural Gas (1 Inch and ꢁ0mm Main Burners)

Pilot Burner, Honeywell Q350A1321

Pilot Burner, Honeywell Q327A1006

Pilot Oriﬁce, Honeywell 390686-22 .012"

Pilot Oriﬁce, Honeywell 388146AG .026"

8236065

8236022

---

**1

---

Included

with 5A

---

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

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

8236122

8236123

81660143

---

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

---

1**

---

Gas Valve, Honeywell VR8200C3005

Gas Valve, Honeywell VR8300C4027

Gas Valve, Honeywell VR8200C6065

Gas Valve, Honeywell VR8300C4266

---

81660154 ---

100333-01 1**

100334-01 ---

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

---

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

5F Thermocouple, 30", Honeywell Q309A

8236024

3ꢅ

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)

Pilot Burner, Honeywell Q327A1147

8236023

---

Pilot Burner Assembly, Honeywell Q350A

(Includes 5B & 5F)

8236105

---

Pilot Oriﬁce, Honeywell 388146KR (.014")

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

---

Included

with 5A

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

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

8236122

8236123

81660144

---

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

---

Gas Valve, Honeywell VR8200C3013

Gas Valve, Honeywell VR8300C4035

---

81660163 ---

8236024

---

5F Thermocouple, 30", Honeywell Q309A

3ꢆ

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

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

5A Pilot Burner, Honeywell Q348A1002

8236072

Included

with 5A

5B Pilot Oriﬁce, Honeywell 388146NE

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

(Included with 5A and 5E)

8236109

Pilot Tubing, 1/4" OD x 30"

8236122

8236123

81660145

---

Pilot Tubing, 1/4" OD x 40"

Gas Valve, Honeywell VR8204C3007

---

Gas Valve, Honeywell VR8304P4306

81660161 ---

---

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

5G Ground Wire Assembly

8236084

6136054

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

5A Pilot Burner, Honeywell Q348A1010

8236081

Included

with 5A

5B Pilot Oriﬁce, Honeywell 388146KP

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

(Included with 5A and 5E)

8236109

Pilot Tubing, 1/4" OD x 30"

8236122

8236123

81660146

---

Pilot Tubing, 1/4" OD x 40"

---

Gas Valve, Honeywell VR8204C3015

Gas Valve, Honeywell VR8304P4314

81660160 ---

---

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

5G Ground Wire Assembly

8236084

6136054

ꢁ0

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

ꢃ. Jacket Assembly, Complete

604170254

604170354

604170454

604170554

604170654

604170754

604170854

604170954

604171054

---

Jacket Assembly, Complete

---

ꢃ. Jacket Assembly

604170215

604170315

604170415

604170515

604170615

604170715

604170815

604170915

604171015

---

Jacket Wrap-Around Panel

---

ꢁ1

ꢁꢀ

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

ꢃ. Jacket Assembly (Continued)

604170223

604170323

604170423

604170523

604170623

604170723

604170823

604170923

604171023

604170233

604170333

604170433

604170533

604170633

604170733

604170833

604170933

604171033

604170242

604170342

604170442

604170542

604170642

604170742

604170842

604170942

604171042

604170216

604170316

604170416

604170516

604170616

604170716

604170816

604170916

604171016

---

Jacket Vestibule Panel

---

Jacket Top Panel

---

Jacket Front Removable Door

---

Jacket Lower Front Panel

---

Sheet Metal Screw, Type AB, Phillips

Truss Head, #8 x 1/2"

80860000

6G Snap Bushing, Heyco SB-1093-15

6H Snap Bushing, Heyco SB-437-5

8136257

8136048

ꢁ3

Water Trim

ꢁꢁ

Key

No.

Description

Part No.

Quantity

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

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

81660319

101662-01

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

Circulator with Gaskets, Bell & Gossett NRF-22

Gasket, Bell & Gossett NRF-22

8056174

806602029

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

Circulator with Gaskets, Grundfos UP 15-42F

Gasket, Grundfos 510179

8056173

806602016

ꢅ. Circulator, Taco 00ꢄ Option (Intermittent and Continuous Circulation Only)

Circulator with Gaskets, Taco 007F

Gasket, Taco '00' Series

8056170

806602006

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

Circulator with Gaskets, Taco 0010

Gasket, Taco '00' Series

8056176

806602006

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

Flange, 1-1/4 NPT

806602013

80861301

80860406

Screw, Cap Hex Head, 7/16 -14 x 1-1/2"

Nut, Hex, 7/16 -14

10. Limit Control

10A

10B

10C

10D

Limit, Honeywell L4080D1234

100189-01

----

Well, 1/2 NPT (Included w/10A)

Limit, Honeywell L4080B1212 (Dual Limit Only)

Well, 3/4 NPT, Honeywell 123870A (Dual Limit Only)

80160474

80160426

11. Miscellaneous Trim

11A

11B

11C

11D

11E

Drain Valve, Conbraco 35-302-03

806603061

8056164U

806600005

806601002

806600028

Temperature - Pressure Gauge

Nipple, 1-1/4 NPT x 3"

1 or 2

Tee, 1-1/4 x 3/4 x 1-1/4 NPT

Nipple, 1-1/4 NPT x 4"

ꢁꢂ

Key

No.

Description

Part No.

Quantity

12. Transformer/Relay Assembly (Intermittent Circulation Only)

12A Junction Box, 4" x 4" x 1-1/2"

8136259

80160155U

80160096U

12B Transformer/Relay, Honeywell R8285D5001

12C Relay, Honeywell R8222U1006

1ꢀ. Transformer (Continuous and Gravity Circulation Only)

12A Junction Box, 4" x 4" x 1-1/2"

8136259

12D Transformer, 40VA, Honeywell AT140D1012 or AT72D1188

13. Flame Rollout Switch

80160039

13A Flame Rollout Switch

80160044

7186018

13B Flame Rollout Switch Mounting Bracket

1ꢁ. Blocked Vent Switch

Blocked Vent Switch Replacement Assembly

6016058

1ꢂ. Ignition Module (EI Only)

15A Ignition Module, Honeywell S8610M3009

15B Ignition Module Support Bracket

100958-01

7016001

ꢁꢃ

Quantity

Key

No.

Description

Part No.

202 202X 203 204 205 206 207 208 209 210

1ꢃ. Draft Hood Carton

8116067

8111702

8111703

8111704

8111705

---

Draft Hood

---

1ꢄ. Vent Damper

8116321

8116322

8116323

8116324

8116325

---

1ꢅ. Vent Reducer

Reducer, 4" x 3"

---

ꢁꢄ

SERVICE RECORD

DATE

SERVICE PERFORMED

ꢁꢅ

SERVICE RECORD

DATE

SERVICE PERFORMED

ꢁꢆ

SERVICE RECORD

DATE

SERVICE PERFORMED

ꢂ0

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 speciﬁcally identiﬁed for Low Water Cut Off.

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

manufacturers recommend an annual inspection of the

probe.

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 ﬂoor level as the boiler). In

addition, some jurisdictions require the use of a LWCO

with a hot water boiler.

How to Wire

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

conﬁgurations. The 120 VAC conﬁguration 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).

Where

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.

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 ﬂoat 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.

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas ﬁred 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.

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.

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 ﬁlling the system.

The boiler should attempt to operate once the water

level is above the LWCO.

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

ꢂ1

Limited Warranty

FOR RESIDENTIAL CAST IRON WATER BOILERS

Subject to the terms and conditions set forth below, U.S. Boiler

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

modiﬁcation, 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 insufﬁcient water, allowing the boiler to freeze,

subjecting the boiler to ﬂood conditions, and operation with unapproved

water or fuel additives which cause deposits or corrosion.

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:

ONEYEAR 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.

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.

LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER

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.

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 ﬁrst 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:

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.

Years

In Service

1-10

Service Charge

as % of

Retail Price

Charge

Years

In Service

25 and

above

Service Charge

as % of

Retail Price

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.

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.

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.

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.

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.

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.

ThIS WARRAnTy gIvES yoU SpECIfIC LEgAL RIghTS AnD

yoU mAy ALSo hAvE oThER RIghTS WhICh vARy fRom STATE

To STATE.

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. speciﬁcally 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

03/03

ꢂꢀ

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