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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
Part No. 81417032R10-11/99
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NOTE: The equipment shall be installed in accordance with those installation regulations in force in the area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Ele
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Figure 1 Gas Approx. Dimensions [inches] Boiler Connection Water Recommended Shipping Model For Content Vent Size Weight Number Automatic [gallons] [1] [2] AB C D E F G (lb.) Gas Valve 202 18-3/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10 [3] 1/2 2.5 3" dia. x 15 ft. 212 202X 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262 203 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262 204 23-1/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4 1/2 4 5" dia. x 15 ft. 306 205 26-1/2 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/
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SECTION I - INSTALLATION INSTRUCTIONS F. Slide the boiler forward or backward off the skid using 1. INSPECT SHIPMENT carefully for any signs of damage. the two wooden slats as runners. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of Boiler to 6. Move boiler to permanent position. the carrier in good condition. Any claims for damage or 7. PROVIDE CLEARANCE and AIR for COMBUS- shortage in shipment must be filed immediately against the TION
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B. PROVIDE COMBUSTION AND VENTILATION AIR in per 4,000 Btu per hour input of all equipment in accordance with applicable provisions of local building space. Duct cross-sectional area shall be same as codes, or: U.S.A. - National Fuel Gas Code, NFPA 54/ opening free area. ANSI Z223.1, Section 5.3, Air for Combustion and iii.Horizontal ducts. Minimum free area of 1 square Ventilation; Canada - Natural Gas Installation Code, inch per 2,000 Btu per hour input of all equipment in CAN/CGA-B149.1, or
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entering the boiler, see Figure 4. Also consult I=B=R 9. BOILER PIPING Installation and Piping Guides. If this Boiler is connected to heating coils located in CAUTION air handling units where they may be exposed to Failure to properly pipe boiler may result in refrigerated air, the boiler piping must be equipped with flow control valves to prevent gravity circulation improper operation and damage to boiler or of boiler water during the operation of the cooling building. system. H. Use a boiler
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Table 2: Equivalent Length of Fittings Table 3: Specific Gravity Correction Factors Specific Correction Specific Correction Nominal Pipe Size Fitting Gravity Factor Gravity Factor ½¾ 1 1¼ 0.50 1.10 1.30 1.07 45° Ell 0.7 1 1.2 1.6 0.55 1.04 1.40 1.04 90° Ell 1.6 2.1 2.6 3.5 0.60 1.00 1.50 1.00 Tee (As Elbow) 3.1 4.1 5.2 6.9 0.65 0.96 1.6 0.97 covered by Burnham's standard warranty. 0.70.931.7 0.94 There are many possible causes of oxygen contamina- 0.75 0.9 tion such as: 1.Addition of excessive m
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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 Figure 6 damage, personal injury or loss of life. A. The vent damper should be the same size as the outlet of the Draft Hood. (See Figure 1) Unpack the dampe
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E. Continuous Ignition (Standing Pilot) Only. Remove installed above the bottom of chimney to prevent knockout from vent damper blade. blockage. F. Size 202 Only. Install 4" x 3" reducing fitting on vent G. Vent pipe should slope upward from draft hood to damper outlet (or draft hood outlet for Canadian boiler chimney not less than one inch in four feet. No portion not equipped with vent damper). of vent pipe should run downward or have dips or sags. Vent pipe must be securely supported. H. Ve
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Figure 7: Plug-in Damper Installation 10
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54/ANSI Z223.1. 16. INSTALL ELECTRIC WIRING in accordance with National Electric Code or the Canadian Electrical Code and 15. INSTALL A ROOM THERMOSTAT on an inside wall local regulations. See Figures 11 through 14 for applicable about four feet above floor. Never install thermostat on an wiring diagram. A separate Electrical Circuit should be run outside wall or where it will be influenced by drafts, hot or cold from meter with a Fused Disconnect Switch in this Circuit. water pipes, lighting fi
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is deenergized - closing contacts which energize the A. The Vent Damper is continuously powered at Terminal damper motor. This causes the damper to close. When 1. the damper blade reaches the fully closed position, the B. When there is a call for heat, the damper relay coil is damper motor is de-energized. energized through Terminal 5 if all limits ahead of the damper are satisfied. POWER FAILURE - The damper blade will stop in the C. The relay coil closes contacts which energize the position it
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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 NORMAL OPERATION developed the blocked vent switch will open interrupt- 1. When the thermostat call for heat, the vent damper ing power to the gas valve. The main burners will be will open (see paragraphs 17A through 17D). The extinguished immediately, the circulator will continue circulator is started through a relay an
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Figure 12: Wiring Diagram, Intermittent Ignition and Intermittent Circulation 14
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SEQUENCE OF OPERATION developed the blocked vent switch will open interrupt- ing power to the VENT DAMPER and GAS VALVE. NORMAL OPERATION Main burners and pilot burner will be extinguished immediately, the VENT DAMPER will close and the 1. When the THERMOSTAT calls for heat, the RELAY CIRCULATOR will continue to operate. The source is energized. The CIRCULATOR starts and the of blockage must be corrected by trained and skilled VENT DAMPER is opened (see Paragraphs 17A personnel from a qualifie
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Figure 13: Wiring Diagram, Intermittent Ignition and Continuous or Gravity Circulation 16
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SEQUENCE OF OPERATION 2. Blocked Vent Switch In the event excessive blockage in the vent system is NORMAL OPERATION developed the blocked vent switch will open interrupt- 1. When THERMOSTAT calls for heat, the VENT ing power to the ignition module and dual combina- DAMPER is opened (see Paragraphs 17A through tion gas valve. Main burners and pilot burner will be 17D). When the damper blade reaches the fully open extinguished immediately and the vent damper will position, the GAS VALVE powers th
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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 NORMAL OPERATION developed the blocked vent switch will open interrupt- ing power to the gas valve. The main burners will be 1. When the thermostat call for heat, the vent damper extinguished immediately and the vent damper will will open (see paragraphs 17A through 17D). The gas remain open until the thermosta
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Figure 15: Wiring Schematic, Zone Valves Figure 16: Wiring Schematic, Zone Circulators 19
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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
