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Price - $3.00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS SERIES 2 (model B) GAS BOILERS For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number 2 ____-_______ Heating Contractor Address Part No. 81417032R10-11/99 Boiler Serial Number Installation Date 6_ _ _ _ _ _ _ Phone Number NOTE: The equipment shall be installed in accordance with those installation regulations in force in the area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations. SECTION I SECTION II - INSTALLATION INSTRUCTIONS OPERATING INSTRUCTIONS TROUBLE SHOOTING GUIDE SECTION III - SERVICE SECTION IV - REPAIR PARTS Page 4 Page 20 Page 27 Page 28 Page 30 The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the product. DANGER CAUTION Indicates presence of a hazard which will cause severe personal injury, death or substantial property damage if ignored. Indicates presence of a hazard which will or can cause minor personal injury or property damage if ignored. NOTICE WARNING Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. Indicates presence of a hazard which can cause severe personal injury, death or substantial property damage if ignored. WARNING FAILURE TO FOLLOW ALL INSTRUCT IONS IN PROPER ORDER CAN CAUSE PERSONAL INJURY OR DEATH. READ ALL INSTRUCTIONS BEFORE INSTALL ING. WARNING SERVICE ON THIS BOILER SHOULD BE UNDERTAKEN ONLY BY TRAINED AND SKILLED PERSONNEL . KEEP BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS. DO NOT PLACE ANY OBST RUCTION IN THE BOILER ROOM THAT WILL HINDER THE FLOW OF COMBUSTION AND VENT ILATING AIR. WARNING READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE TECHNICIAN. MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION. 2 Figure 1 Boiler Model Number 202 Dimensions [inches] A B 18-3/4 10-3/4 Gas Approx. Recommended Connection Water Shipping Vent Size Content For Weight [1] [2] Automatic [gallons] (lb.) Gas Valve C D E F G 6-3/8 4 45-5/8 8-1/2 10 [3] 1/2 2.5 3" dia. x 15 ft. 212 202X 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262 203 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262 204 23-1/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4 1/2 4 5" dia. x 15 ft. 306 205 26-1/2 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/4 1/2 4.7 6" dia. x 15 ft. 354 206 29-3/4 21-3/4 10-7/8 6 48-1/2 9-3/4 5-1/4 1/2 5.5 6" dia. x 15 ft. 414 12-1/2 7 50-1/8 10-3/8 6-5/8 3/4 6.2 7" dia. x 15 ft. 458 208 36-1/4 28-1/4 14-1/8 7 50-1/8 10-3/8 6-5/8 3/4 7 7" dia. x 15 ft. 514 209 39-1/2 31-1/2 15-3/4 8 52 11 7-1/4 3/4 7.7 8" dia. x 15 ft. 550 210 42-3/4 34-3/4 17-3/8 8 52 11 7-1/4 3/4 8.5 8" dia. x 15 ft. 608 207 33 25 [1] 15' chimney height is from bottom of draft hood opening to top of chimney. [2] Refer to the National Fuel Gas Code, Apendix G for equivalent areas of circular and rectangular flue linings. M aximum Allowable Working Pressure - 30 PSI (Water Only) [3] 202 only. Dimension 'G' includes allowance for 4" x 3" r educer furnished with boiler. See Figure 8. 3 SECTION I - INSTALLATION INSTRUCTIONS F. Slide the boiler forward or backward off the skid using the two wooden slats as runners. 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. 6. Move boiler to permanent position. 7. PROVIDE CLEARANCE and AIR for COMBUSTION and VENTILATION. 2. BOILER INSTALLATION must conform to the require- ments of the authority having jurisdiction, or in the absence of such requirements, to: U.S.A. - National Fuel Gas Code, ANSI Z223.1, obtainable from the American Gas Association, 1515 Wilson Blvd., Arlington (Rosslyn), VA 22209. A. CLEARANCES 1. ALL INSTALLATIONS - Practical service clearances must be considered (see Figure 1). A minimum of 24" from the left side and front jacket panels is recommended for servicing but may be reduced to minimum shown in Figure 2. Subject to boiler and system piping, left side clearance may be reduced to 1" if right side clearance is increased to 9". 2. ALCOVE INSTALLATIONS - An alcove is considered a closet as shown in Figure 2 less front. Height clearance may be reduced to 27". 3. UNCONFINED SPACE (see definition, Paragraph (B) below) - Height clearance may be reduced to 27". When required by the authority having jurisdiction, the installation must conform to ANSI/ASME No. CSD-1. CANADA - "Installation Codes for Natural and LP Gas Burning Appliances and Equipment, CAN/ CGA-B149.1 or .2-latest edition obtainable from the Canadian Gas Association, 55 Scarsdale Road, Don Mills, Ontario, Canada M3B 2R3. 3. These Gas Boilers are DESIGN CERTIFIED FOR INSTALLATION ON COMBUSTIBLE FLOORING. DO NOT INSTALL THESE BOILERS ON CARPETING. 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. The boiler shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, control replacement, etc.). 5. REMOVE CRATE- A. Remove all crate fasteners. Lift off outside container. B. Remove all screws and brackets securing boiler to skid. C. Save two of the wooden slats from the container sleeve for use in Steps D & E. D. Tilt the boiler to one side and slide a wooden slat under the two raised feet. E. Tilt the boiler to the other side and slide another wooden slat under the two raised feet. 4 Figure 2: Minimum Clearances per 4,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. iii.Horizontal ducts. Minimum free area of 1 square inch per 2,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. g. Ventilation Duct Louvers and Grilles. Equip outside openings with louvers to prevent entrance of rain and snow, and screens to prevent entrance of insects and rodents. Louvers and grilles must be fixed in open position or interlocked with equipment to open automatically before burner operation. Screens must not be smaller than ¼ inch mesh. Consider the blocking effect of louvers, grilles and screens when calculating the opening size to provide the required free area. If free area of louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area. 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, Section 5.3, Air for Combustion and Ventilation; Canada - Natural Gas Installation Code, CAN/CGA-B149.1, or Propane Installation Code, CAN/CGA-B149.2, Part 5, Venting Systems and Air Supply for Appliances. 1. CLOSET INSTALLATIONS (confined space) in a building of other than unusually tight construction (see definition below), provide combustion and ventilation air as shown in Figure 2. 2. Installations other than Paragraph (1) above: a. Determine volume of space (boiler room). Rooms communicating directly with space (through openings not furnished with doors) are considered part of space. Volume [ft³] = Length [ft] x Width [ft] x Height [ft] b. Determine Total Input of all appliances in space. Round result to nearest 1,000 Btu per hour (Btuh). c. Determine type of space. Divide Volume by Total Input. i. If result is greater than or equal to 50 ft³ per 1,000 Btuh, space is considered an unconfined space. ii.If result is less than 50 ft³ per 1,000 Btuh, space is considered a confined space. d. Determine building type. A building of unusually tight construction has the following characteristics: i. Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed, and ii. Weather-stripping has been added on openable windows and doors, and iii.Caulking or sealants applied in joints around window and door frames, between sole plates and floors, between wall-ceiling joints, between wall panels, at plumbing and electrical penetrations, and at other openings. e. For boiler located in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. f. For boiler located in building of unusually tight construction, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Size each opening per following: i. Direct communication with outdoors. Minimum free area of 1 square inch per 4,000 Btu per hour input of all equipment in space. ii. Vertical ducts. Minimum free area of 1 square inch 8. CONNECT GAS SERVICE from Meter to gas control assembly in accordance with Local Piping Codes and requirements of Gas Company, see Figure 1. They may require piping of larger size than Control Assembly Connection, especially if run from meter is long or includes several elbows. (See Figure 1 for size of Gas Connection to gas control assembly). This piping is to be supplied by the installer and must include a trap, a ground joint union and a manual shutoff valve upstream of the gas control assembly outside of the jacket when codes require, see Figure 1. A pipe thread compound resistant to the action of liquefied petroleum gases should be applied to all threaded joints in the gas piping. Pressure testing of the Gas Supply Piping Boiler and its connections is required before placing the boiler in operation. The boiler and shutoff valve must be disconnected from the gas supply piping system during any pressure testing at pressures greater than ½ psig. The boiler must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at pressures equal to or less than ½ psig. RECOMMENDED SIZING OF GAS SUPPLY PIPING TO BOILER FOR NATURAL GAS - shall be such as to provide the required supply of gas without undue loss of pressure between meter and the boiler. Gas supply piping should be sized in accordance with the Tables 1, 2 and 3. The following shall be taken into account: A. Allowable loss of pressure to assure a burner manifold pressure of 3½" water. B. Supply of gas to be provided in cubic feet. C. Length of piping and number of fittings. D. Specific gravity of gas. E. Correction factor for specific gravity. 5 9. BOILERPIPING entering the boiler, see Figure 4. Also consult I=B=R Installation and Piping Guides. If this Boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be equipped 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.). Remove the circulator and install a pipe tee between the circulator and boiler return along with a second tee in the supply piping as shown in Figure 5. The bypass should be the same size as the supply and return lines with valves located in the bypass and supply outlet as illustrated in Figure 5 in order to regulate water flow to maintain higher boiler water temperatures. Set the by-pass and boiler supply valves to a half throttle position to start. Operate boiler until the system water temperature is at a normal operating range. Adjust the valves to provide 180° to 200°F supply water temperature. Opening the boiler supply valve will raise the system temperature, while opening the by-pass valve will lower the system supply temperature. I. A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation. J. OXYGEN CORROSION: Oxygen contamination of the boiler water will cause corrosion of the iron and steel boiler components, which can lead to failure. As such, any system must be designed to prevent oxygen absorption in the first place or prevent it from reaching the boiler. Problems caused by oxygen contamination of boiler water are not CAUTION Failure to properly pipe boiler may result in improper operation and damage to boiler or building. A. CLEARANCES - Hot water pipes do not require clearance from combustible construction. B. Install drain cock and safety relief valve as shown in Figure 4. Note - Safety relief valve must be in vertical position. C. Pipe safety relief valve discharge to floor. WARNING Safety relief valve discharge piping must be p iped near floor to elim inate potential of severe burns. Do n ot pipe in any area where f reezing could occur. Do not install any shut-off valves. D. Install circulator with flanges, gaskets and bolts provided. Five foot long circulator harness allows circulator to be mounted on supply or return. Connect harness to circulator and secure any excess conduit. E. For heating only system piping, see Figure 3. Consult also I=B=R Installation Guides. F. Space heating and domestic water heating with Alliance water heater (intermittent circulation only). Install Alliance water heater as a separate heating zone. Refer to Alliance Installation, Operating and Service Instructions for additional information. G. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop Length [Feet] ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 118 220 460 90 40 84 160 320 53 110 205 430 100 38 79 150 305 50 103 195 400 6 Table 2: Equivalent Length of Fittings Fitting Table 3: Specific Gravity Correction Factors Nominal Pipe Size ½ ¾ 1 1¼ 45° Ell 0.7 1 1.2 1.6 90° Ell 1.6 2.1 2.6 3.5 Tee (As Elbow) 3.1 4.1 5.2 6.9 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: 1. Repairing system leaks to eliminate the need for addition of make-up water. 2. Eliminating open tanks from the system. 3. Eliminating and/or repairing fittings which allow oxygen absorption. 4. Use of non-permeable materials in the distribution system. 5. Isolating the boiler from the system water by installing a heat exchanger. Specific Gravity Correction Factor Specific Gravity Correction Factor 0.50 1.10 1.30 1.07 0.55 1.04 1.40 1.04 0.60 1.00 1.50 1.00 0.65 0.96 1.6 0.97 0.7 0.93 1.7 0.94 0.75 0.9 0.8 0.87 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 Fig. 6. D. Slide the mounting bracket up tight against the lower edge of the draft hood skirt, so that the #10 sheet metal screw is above the skirt's stiffening rib. E. Secure the bracket in this position by tightening the #10 sheet metal screw against the outer surface of the draft hood skirt. F. Reinsert the excess power cord through the jacket side panel hole to take the slack out of the power cord running up to the blocked vent switch. G. Reposition the strain relief bushing around the power cord at the jacket side panel, pinch the two halves of the bushing together, and snap it back into the hole in 10. INSTALL DRAFT HOOD without modification on outlet of flue collector (See Figure 1). Secure with sheet metal screws. 11. INSTALL BLOCKED VENT SWITCH The blocked vent switch assembly shipped taped to the top of the boiler includes a power cord and a switch attached to a mounting bracket. The mounting bracket has a three tooth staggered comb stamping at one end with a #10 sheet metal screw in the center tooth. A. Untape the blocked vent switch assembly from the top of the boiler and uncoil the power cord. 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. 7 Figure 3: Boiler Piping Figure 4: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems the jacket side panel to secure the power cord to the jacket. H. Be sure the power cord, mounting bracket, and switch are secure and located as shown in Figure 6. WARNING Failure to properly install and use this Blocked Vent Switch may result in property damage, personal injury or los s of life. Figure 6 A. The vent damper should be the same size as the outlet of the Draft Hood. (See Figure 1) Unpack the damper carefully - 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 intermittent ignition control systems. B. Refer to Figure 7 in this manual. C. Mount the vent damper assembly on the draft hood without modification to either. (Refer to instructions packed with the vent damper for specific instructions). This is a must for the wiring harness to fit and the damper position indicator to be visible to the users. 12. TO MEET FEDERALLY MANDATED EFFICIENCIES, THIS BOILER MUST BE EQUIPPED WITH A VENT DAMPER. OPEN THE VENT DAMPER CARTON and remove the Installation Instructions. READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding. The automatic gas control valve supplied on each Series 2 boiler provides the reduncancy referenced in the vent damper Installation Instructions. NOTICE Please refer to the specifications, installation instructions and troubleshooting guide packed in the vent damper carton for complete detailed installation instructions. Also refer to Figure 7 in this manual. Figure 5 8 D. Install the 90° BX connector attached to the flexible conduit in the 7/8" knockout on the left side of the jacket. Plug the factory wired Vent Damper Harness into the polarized receptacle. Install a cable clamp around the flexible conduit and attach to the Jacket top panel. (See Figure 7). 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. No portion of vent pipe should run downward or have dips or sags. Vent pipe must be securely supported. H. Vent pipe must be inserted into but not beyond inside wall of chimney liner. Seal tight between vent pipe and chimney. I. Do not install non-listed (AGA, CGA, ETL or UL) vent damper or other obstruction in vent pipe. E. Continuous Ignition (Standing Pilot) Only. Remove knockout from vent damper blade. F. Size 202 Only. Install 4" x 3" reducing fitting on vent damper outlet (or draft hood outlet for Canadian boiler not equipped with vent damper). 13. INSTALL VENT CONNECTOR from reducing fitting (202 Only), draft hood or damper to chimney, see Fig. 8. 14. IF AN EXISTING BOILER IS REMOVED - A. Vent installation shall be in accordance with local building codes; or the local authority having jurisdiction; or the National Fuel Gas Code, ANSI Z223.1/ NFPA 54; or the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances, ANSI/NFPA 211. Both of the aforementioned standards, ANSI Z223.1 and ANSI/NFPA 211, specify Type B and Type L double wall metal vents and 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 Installation Code, CAN/CGA-B149.1 or the LP Gas Installation Code, CAN/CGA-B149.2 - latest edition. B. Do not connect into same leg of chimney serving an open fireplace. C. Inspect chimney for obstructions or restrictions and remove. Clean chimney if necessary. D. Vent pipe to chimney must not be smaller than outlet on draft hood or damper. Although single wall vent pipe may be used, Type B is recommended. The venting system must be arranged so that only the boiler is served by the damper device. Installation per paragraph 12 complies with this provision. E. Where two or more appliances vent into a common vent, the area of the common vent should at least equal the area of the largest vent plus 50% of the area in the additional vents. Do not connect the vent of this appliance into any portion of mechanical draft system operating under positive pressure. F. Vent pipe should have the greatest possible initial rise above the draft hood consistent with the head room available and the required clearance from adjacent combustible building structure. Vent Pipe should be 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. C. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range-hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. 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. G. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, NFPA 54/ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 in the National Fuel Gas Code, NFPA 9 Figure 7: Plug-in Damper Installation 10 16. INSTALL ELECTRIC WIRING in accordance with 54/ANSI Z223.1. 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. 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. National Electric Code or the Canadian Electrical Code and local regulations. See Figures 11 through 14 for applicable wiring diagram. A separate Electrical Circuit should be run from meter with a Fused Disconnect Switch in this Circuit. When installed, the boiler must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electrical Code, if an external electrical source is utilized. For zone valve wiring, a separate 24V transformer is required rather than attempting to use the boiler mounted control. Consult zone valve manufacturer for assistance. 17. VENT DAMPER SEQUENCE OF OPERATION Effikal and Johnson Damper Figure 8: Typical Vent Installation Table 4: Wiring Diagrams and Heat Anticipator Settings Wiring Diagram Ignition Type Circulation Method Thermostat Heat Anticipator Setting [ Amps] Figure Number P age Number Continuous (S tanding P ilot) Intermittent 0.6 11 13 Constant/Gravity 1.0 14 18 Intermittent 0.6 12 14 Constant/Gravity 1.0 13 16 Intermittent I f 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. 11 is deenergized - closing contacts which energize the damper motor. This causes the damper to close. When the damper blade reaches the fully closed position, the damper motor is de-energized. A. The Vent Damper is continuously powered at Terminal 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. 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 POWER FAILURE - The damper blade will stop in the position it was in when power failed. (Combustion can never take place unless the damper blade is in the fully open position.) Figure 9: Vent Damper Schematic Wiring Diagram 12 Figure 11: Wiring Diagram, 24 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 interruptNORMAL OPERATION ing power to the gas valve. The main burners will be 1. When the thermostat call for heat, the vent damper extinguished immediately, the circulator will continue will open (see paragraphs 17A through 17D). The to operate, and the vent damper will remain open until circulator is started through a relay and at the same the thermostat is turned off. The source of blockage time the gas valve is energized allowing main gas flow must be corrected by trained and skilled personnel and ignition of main burners. from a qualified service agency before resetting 2. Where condensation of flue gas is encountered in boiler flues a reverse acting circulator control should switch. be installed to stop the circulator before the boiler 3. Flame Rollout Switch water temperature drops to that which flue gas In the event excessive blockage in the boiler section condensation may occur. flue passageways is developed the flame rollout switch 3. After the thermostat is satisfied the main valve will will open interrupting power to the gas valve. The close and main burner flames will be extinguished. main burners will be extinguished immediately, the The vent damper will close (see paragraph 17E). circulator will continue to operate and the vent damper will remain open until the thermostat is SAFETY SHUTDOWN turned off. If the flame rollout switch is activated do 1. High Limit Switch not attempt to place the boiler in operation. The source In the event excessive boiler water temperature is of blockage must be corrected and the flame rollout developed the high limit switch will open interrupting switch replaced by trained and skilled personnel from power to the gas valve. The main burners will be a qualified service agency. extinguished immediately, and the vent damper will 4. Pilot close at the same time, but the circulator will continue The thermocouple proves pilot flame and in the to operated. Normal operation will be resumed when absence of such within 45-90 seconds causes the the boiler water temperature drops to a point where combination gas valve, which is equipped with a the high limit switch closes. 100% shut-off provision, to be de-energized, thus, preventing main gas or pilot gas flow. 13 Figure 12: Wiring Diagram, Intermittent Ignition and Intermittent Circulation 14 SEQUENCE OF OPERATION developed the blocked vent switch will open interrupting power to the VENT DAMPER and GAS VALVE. Main burners and pilot burner will be extinguished immediately, the VENT DAMPER will close and the CIRCULATOR will continue to operate. The source of blockage must be corrected by trained and skilled personnel from a qualified service agency before resetting switch. NORMAL OPERATION 1. When the THERMOSTAT calls for heat, the RELAY is energized. The CIRCULATOR starts and the VENT DAMPER is opened (see Paragraphs 17A through 17D). When the damper blade reaches the fully open position, the GAS VALVE powers the igniter circuit and opens the pilot valve. 3. Flame Rollout Switch In the event excessive blockage in the boiler section flue passageways is developed the flame rollout switch will open interrupting power to the VENT DAMPER and the GAS VALVE. Main burners and pilot burner will be extinguished immediately. The VENT DAMPER will close and the CIRCULATOR will continue to operate. If the flame rollout switch is activated do not attempt to place the boiler in operation. The source of blockage must be corrected and the flame rollout switch replaced by trained and skilled personnel from a qualified service agency. 4. Pilot 2. The sensing circuit between the Q3450 or Q3480 pilot and the GAS VALVE proves presence of pilot flame.* 3. The GAS VALVE de-energizes the igniter and opens the main valve, allowing main gas to flow and ignition of main burners. 4. Where condensation of flue gas is encountered in boiler flues, a REVERSE ACTING CIRCULATOR CONTROL should be installed to stop the CIRCULATOR before the boiler water temperature drops to that at which flue gas condensation may occur. 5. The burners and CIRCULATOR will operate simultaneously until the THERMOSTAT is satisfied. A. Any pilot failure on the Q3450 or Q3480 Pilot will close the main gas valve and energize the igniter. 6. After the THERMOSTAT is satisfied the main valve, pilot valve and the circulator will be de-energized and main burner and pilot flames will be extinguished. The VENT DAMPER will close (see Paragraph 17E). B. If the igniter breaks or becomes disconnected, the pilot valve coil loses power, closing the pilot valve. SAFETY SHUTDOWN 1. 2. High Limit Switch In the event excessive boiler water temperature is developed the High Limit Switch will open, interrupting power to the VENT DAMPER and the GAS VALVE. Main Burners and Pilot Burner will be extinguished immediately. Normal operation will be resumed when the boiler water temperature drops to a point where the High Limit Switch closes. 5. For TROUBLE SHOOTING GUIDE, see Figure 28. * · SV9500 and SV9600 Gas Valves: The igniter and pilot gas valve will stay energized until either the pilot lights or the call for heat ends. · SV9501 and SV9601 Gas Valves: If the pilot fails to light after a 90 second trial for ignition, the igniter will be de-energized and the pilot gas valve will close. After a 5 minute delay, the igniter will be re-energized and the pilot gas valve will re-open. This continuous retry cycle will end either when the pilot lights or the call for heat ends. Blocked Vent Switch In the event excessive blockage in the vent system is 15 Figure 13: Wiring Diagram, Intermittent Ignition and Continuous or Gravity Circulation 16 SEQUENCE OF OPERATION 2. In the event excessive blockage in the vent system is developed the blocked vent switch will open interrupting power to the ignition module and dual combination gas valve. Main burners and pilot burner will be extinguished immediately and the vent damper will close. The source of blockage must be corrected by trained and skilled personnel from a qualified service agency before resetting switch. NORMAL OPERATION 1. When THERMOSTAT calls for heat, the VENT DAMPER is opened (see Paragraphs 17A through 17D). When the damper blade reaches the fully open position, the GAS VALVE powers the igniter circuit and opens the pilot valve. 2. The sensing circuit between the Q3450 or Q3480 pilot and the GAS VALVE proves presence of pilot flame.* 3. Flame Rollout Switch In the event excessive blockage in the boiler section flue passageways is developed the flame rollout switch will open interrupting power to the ignition module and the dual combination gas valve. Main burners and pilot burner will be extinguished immediately and the vent damper will close. If the flame rollout switch is activated do not attempt to place the boiler in 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. The GAS VALVE de-energizes the igniter and opens the main valve, allowing main gas to flow and ignition of main burners. 4. On Boilers equipped with Circulators that are wired to run continuously and, where condensation of flue gas is encountered in boiler flues, a REVERSE ACTING CIRCULATOR CONTROL should be installed to stop the Circulator before the Boiler Water Temperature drops to that at which flue gas condensation may occur. 4. 5. The Burners will operate until the THERMOSTAT is satisfied. Pilot A. Any pilot failure on the Q3450 or Q3480 pilot will close the main gas valve and energize the igniter. 6. After the THERMOSTAT is satisfied the GAS VALVE will be de-energized. The Main Burners and Pilot Burner will be extinguished. If Boiler is equipped with circulator, Circulator will continue to run. The VENT DAMPER will close (see Paragraph 17E). B. If the igniter breaks or becomes disconnected, the pilot valve coil loses power, closing the pilot valve. SAFETY SHUTDOWN 1. Blocked Vent Switch High Limit Switch 5. For TROUBLE SHOOTING GUIDE, see Figure 28. * · SV9500 and SV9600 Gas Valves: The igniter and pilot gas valve will stay energized until either the pilot lights or the call for heat ends. · SV9501 and SV9601 Gas Valves: If the pilot fails to light after a 90 second trial for ignition, the igniter will be de-energized and the pilot gas valve will close. After a 5 minute delay, the igniter will be re-energized and the pilot gas valve will re-open. This continuous retry cycle will end either when the pilot lights or the call for heat ends. In the event excessive boiler water temperature is developed, the High Limit will open, interrupting power to the IGNITION MODULE and the DUAL COMBINATION GAS VALVE. Main Burners and Pilot Burner will be extinguished immediately and the vent damper will close. Normal operation will be resumed when the Boiler Water Temperature drops to a point where the High Limit Switch closes. 17 Figure 14: Wiring Diagram, 24 Volt Standing Pilot with Continuous or Gravity Circulation SEQUENCE OF OPERATION 2. Blocked Vent Switch In the event excessive blockage in the vent system is developed the blocked vent switch will open 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. 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. 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. 18 Figure 15: Wiring Schematic, Zone Valves Figure 16: Wiring Schematic, Zone Circulators 19 SECTION II - OPERATING INSTRUCTIONS Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13b-1994. 1. MAIN BURNER CHECK - Check main burners to see that they were not dislodged during shipment. Rear of burners should be in the slots in the rear of burner tray and the front of the burners should be seated completely on the orifices. 2. INITIAL START - A. FILL ENTIRE HEATING SYSTEM WITH WATER and vent air from system. Use the following procedure 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 bib cock located just below isolation valve in boiler supply piping. (Note - Terminate hose in five gallon bucket at a suitable floor drain or outdoor area). 4. Starting with one circuit, open zone valve. 5. Open bib cock. 6. Open fill valve (Make-up water line should be located directly above isolation valve in boiler supply piping). 7. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. 8. Open zone valve to the second zone to be purged, then close the first. Repeat this step until all zones have been purged, but always have one zone open. At completion, open all zone valves. 9. Close bib cock, continue filling the system until the pressure gauge reads 12 psi. Close fill valve. (Note - If make-up water line is equipped with pressure reducing valve, system will automatically fill to 12 psi. Leave globe valve open). 10. Open isolation valve in boiler supply piping. 11. Remove hose from bib cock. B. Turn ROOM THERMOSTAT to lowest setting. C. Be sure that gas to pilot and main burners has been off for at least five minutes and vent damper (if used) has been in the open position. D. Turn "OFF" the electric switch serving boiler. E. Open valve on main gas line at meter. F. PURGE AIR FROM GAS PIPING. This procedure will vary with equipment furnished 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 boiler model found on Rating Plate with paragraph heading: 1. Standing Pilot Models (Suffix V): a. Keep electric switch "OFF". b. Open Manual Shut-off Valve upstream of Combination Gas Valve. c. Disconnect Pilot Tubing at gas valve (Purge must not be into combustion chamber). d. Turn Main Gas Knob on Combination Gas Valve to Figure 17: Schematic Pilot and Gas Piping Continuous Ignition (Standing Pilot) Figure 18: Schematic Pilot and Gas Piping Intermittent Ignition (HSP) "Pilot" Position. Depress and hold in this position until purging is complete. Turn Main Gas Knob to "off" position. 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. Intermittent Ignition Models (Suffix S): a. Turn "ON" electric switch serving boiler. b. Open Manual Shut-off Valve upstream of Combination Gas Valve. 20 c. Loosen or remove Inlet Pressure Tap Plug in Combination Gas Valve and when purging is complete, tighten or replace plug. (See Figure 19). d. Check pipe and fittings from meter to Combination Gas Valve using soap solution or other approved methods. e. Test gas piping and connections between Combination Gas Valve and manifold, orifices, and pilot piping for leaks after boiler is operating. Use soap solution or other approved method. 3. INSTRUCTIONS TO PUT THE BOILER IN OPERA- Figure 19a: Top View of SV9500, SV9600 and VR Gas Valves TION. See Figure 20 for intermittent ignition. See Figure 21 for continuous ignition system (standing pilot). 21460147 Figure 20a: Operating Instructions, SV9500 and SV9600 Gas Valves 21 Honeywell Figure 19b: Top View of Honeywell SV9501 and SV9601 Gas Valves FOR YOUR SAFETY READ BEFORE OPERATING WHAT TO DO IF YOU SMELL GAS: WARNING Do not try to light any appliance. Do not touch any electric switch other than the gas valve; do not use any phone in your building. Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the fire department. 3. Use only your hand to slide the gas control switch to "ON". Never use tools. If the switch does not move by hand, DO NOT try to repair it; call a qualified service technician. Force or attemped repair may result in a fire or explosion. Fire or Explosion Hazard. Can cause property damage, severe injury or death. Force or attempted repair may result in a fire or explosion. Follow these instructions exactly. 1. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand. 2. BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and settles on the floor. 4. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance. Replace any part of the control system and any gas control that has been under water. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2. Set the thermostat to the lowest setting. 3. Turn off all electric power to the appliance. 4. This appliance is equipped with an ignition device that automatically lights the pilot. DO NOT try to light the pilot by hand. 5. Remove front door. 6. Slide gas control switch to "OFF". 7. Wait five (5) minutes to clear out any gas. Then smell for gas, including near floor. If you smell gas, STOP! Honeywell Follow step 2 in the "FOR YOUR SAFETY" section above on this label. If you do not smell gas, go to the next step. 8. Slide gas control switch to "ON". 9. Replace front door. 10. Turn on all electric power to the appliance. 11. Set the thermostat to desired setting. 12. If the appliance does not operate, follow the instructions "TO TURN OFF GAS TO APPLIANCE" and call your service technician or gas supplier. GAS INLET OUTLET IGNITION SYSTEM CONTROL SWITCH TO TURN OFF GAS TO APPLIANCE 1. Set the thermostat to the lowest setting. 2. Turn off all electric power to the appliance if service is to be performed. 3. Remove front door. 4. Slide gas control switch to "OFF". DO NOT force. 5. Replace front door. Figure 20b: Operating Instructions, SV9501 and SV9601 Gas Valves 22 81460177 Figure 21: Lighting Instructions 23 4. CHECK GAS INPUT RATE TO BOILER USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers' orifice sizing is indicated on the rating label. High altitude boiler models are identifiable by the fourth digit after the dash in the model number. 2: 0-2000', 4 or 5: above 2000'. A. Input Rate and Maximum Inlet Pressure shown on Rating Label must not be exceeded. Inlet pressure must not be lower than minimum inlet pressure shown on Rating Label. B. All Rate checks and all adjustments are to be made while boiler is firing - all other appliances connected to the same meter as the boiler must be off. C. With boiler off, water Manometer or water column gauge should be connected to a shut-off cock installed in the 1/8" outlet pressure tap in the gas valve (See Figure 19). By installing gas cock upstream of manometer, gas pressure can be introduced gradually without shut-off cock, surge of pressure when boiler is turned on, could blow liquid out of manometer. Replace plug in gas valve when rate check is finished. D. LP Gas Input: 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. E. Natural Gas Input 1. Appx. Input - Adjust regulator on Gas Valve so that manifold pressure is three and a half (3½) inches water column (three inches water column for high altitude with 1" main burners). Turning Regulator Adjusting Screw Clockwise increases pressure, Counterclockwise rotation decreases pressure. If more accurate check on input is necessary see (2) below. For minor input changes readjust Regulator Gas Valve to increase or decrease manifold pressure to obtain corresponding increase or decrease in gas input. If it is necessary to increase manifold pressure more than 0.3" of water to obtain rated input, remove orifices and drill one size larger. Reinstall and recheck input rate. 2. Additional Check on Input - Since input is a function of heating value, specific gravity, and volume of gas flow contact your utility for the first two items in order to utilize the formula below. The gas meter should then be clocked for three (3) minutes with stop watch and substituting the appropriate values in the formula below, determine what the gas flow should be in this 3 minute period to give the input shown on the Rating Label: 5. MAIN BURNER FLAMES should have a clearly defined inner cone (see Figure 22 or 23) with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping. The main burners in this boiler will not operate cleanly or efficiently if they are contaminated with dirt and/or construction dust. Burners should be cleaned and the combustion chamber vacuumed following instructions in Section III - Service. 6. CHECK PILOT BURNER FLAME. A. Continuous Ignition (Standing Pilot) Models 202 and 202X with 1" diameter burners. See Figure 24. Models 202 and 202X with 40mm (1-9/16") diameter burners. See Figure 25. Natural gas Models 203 through 206 and 207 with 1" diameter burners. See Figure 25. The pilot produces a single flame. The flame should be steady, medium hard blue enveloping 3/8 to a 1/2 inch of thermocouple. Figure 22: 40mm and 50mm Main Burner Flame Figure 23: 1 Inch Main Burner Flame 24 B. Continuous Ignition (Standing Pilot) Natural gas Models 207 with 40mm (1-9/16") diameter burners and 208 through 210. See Figure 26 LP gas Models 203 through 210. See Figure 26. The pilot produces three (3) flames. The center flame should be steady, medium hard blue enveloping 3/8 to a 1/2 inch of thermocouple. C. Intermittent Ignition Models 202 with 1" diameter burners and 202X through 210. See Figure 27. The pilot produces three (3) flames. The center flame should be steady, medium hard blue enveloping 3/8 to a ½ inch of sensing probe. D. Intermittent Ignition Model 202 with a 40mm (1-9/16") diameter burner. See Figure 27a. The pilot produces a single flame. The flame should be steady, medium hard blue enveloping 3/8 to a ½ inch of sensing probe. 7. CHECK THERMOSTAT OPERATION. Raise and lower temperature setting as required to start and stop burners. 8. CHECK HIGH LIMIT CONTROL. Jumper Thermo- Figure 24: Typical Pilot Flame, Robertshaw 7CL-6 Figure 26: Typical Pilot Flame, Honeywell Q327 Figure 25: Typical Pilot Flame, Honeywell Q350 Figure 27: Typical Pilot Flame, Honeywell Q3480 stat Terminals or Thermostat connections in Limit Control. Allow burners to operate until shutdown by limit. REMOVE JUMPER. 9. CHECK DAMPER OPERATION if Boiler is equipped with Vent Damper. Vent Damper must be open when boiler is running. Start boiler, refer to instructions on damper to determine if damper is in the full open position. 10. CHECK IGNITION SYSTEM SAFETY SHUT-OFF DEVICE. A. 24 volt-loosen thermocouple at gas valve. B. Intermittent Ignition - Remove pilot lead wires from gas valve. If burners do not shut down determine cause of malfunction. Replace necessary items and check operation. 11. COMBUSTION CHAMBER BURN-OFF A. The mineral wool combustion chamber panels contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation. 25 B. Ventilate the boiler room, set the high limit to its maximum setting, set the thermostat to call for heat. Allow the boiler to fire for at least an hour or until the odor from the cornstarch has dissipated. C. Return the high limit and thermostat to their desired settings. Figure 27a: Typical Pilot Flame, Honeywell Q3450 26 Figure 28: Troubleshooting Guide, Honeywell Intermittent Ignition 27 SECTION III - SERVICE 1. Inspection should be conducted annually. Service as NOTICE frequently as specified in paragraphs below. While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be "off". 4. BURNERS AND FIREBOX SHOULD BE CLEANED 2. VENT SYSTEM. Vent system (see Figure 8 for typical A. TO REMOVE BURNERS FOR CLEANING, CHANGING ORIFICE PLUGS, OR REPAIRS. 1. Remove the jacket front panel. 2. Disconnect pilot tubing at the gas valve. (See Figures 17 and 18).. 3. Disconnect thermocouple (standing pilot) or pilot lead wires (intermittent ignition) at the gas valve. 4. 40mm and 50 mm burners only. Remove injection shield assembly, where used. (See Figure 30). 5. Remove wires to flame roll-out switch. 6. Remove the burner access panel. 7. 50mm dia. burners only. Remove orifice hitch pin clips. ANNUALLY, AND IF NECESSARY ADJUSTED ONCE A YEAR BY A QUALIFIED SERVICE AGENCY. installation) should be checked annually for: A. Obstructions. B. Accumulations of soot. C. Deterioration of vent pipe or vent accessories due to condensation or other reasons. D. Proper support - no sags, particularly in horizontal runs. E. Tightness of joints. F. Proper vent damper operation - see Section II, paragraph 9. G. Remove all accumulations of soot with wire brush and vacuum, see Fig. 29. Remove all obstructions. Replace all deteriorated parts and support properly. Seal all joints. 3. CLEANING BOILER FLUES, see Fig. 29. Flue passageways in the boiler sections should be checked annually for any blockage or accumulation of soot. To obtain access to flueways: A. Remove vent pipe, damper (if boiler is so equipped), blocked vent switch, and draft hood. B. Remove sheet metal screws securing Jacket Top Panel, lift panel and rotate about relief valve piping until top of boiler is exposed. C. Remove bolts securing Canopy to Boiler Sections. Remove Canopy - flueways are now exposed. D. Models with flue gas baffles only: Remove baffles by lifting out of flueways. Using flashlight, examine all flue passageways. If passageways are free of soot and obstruction, replace canopy (and flue gas baffles, if applicable), and seal. Reinstall Jacket Top Panel, draft hood, blocked vent switch, damper (if boiler is so equipped), and vent pipe. If the flue passageways need cleaning, remove burners as described in paragraph 4 below. Using long handle wire or bristle flue brush and vacuum, brush flueways thoroughly from top of boiler as illustrated in Fig. 29. Replace canopy and seal with boiler putty. Reinstall Jacket Top Panel, draft hood, blocked vent switch, damper (if boiler is so equipped), and vent pipe. Figure 29: Cleaning of Vent System and Boiler Flues 28 8. Mark the location of the pilot main burner on the manifold if the marking on manifold is missing or obliterated. 9. Hold burner at throat, a. 1 inch and 40mm diameter burners. Lift front of burner to clear orifice. Burner which holds pilot can only be removed by lifting the burner adjacent to its right first. b. 50 mm dia. burners only. Push toward the rear until the burner face plate clears the orifice. Lift burner out. 10.Brush top of burners with a soft bristle brush, see Fig. 30. Vacuum burners. Check orifices to see that drilled passageways are free of lint or dirt. 11.Vacuum tip of Pilot Burner. 5. CHECK ALL CONTROL AND DAMPER OPERA- B. CLEAN FIREBOX by vacuuming. Exercise care not to disturb insulation inside the base. 1" Burner 6. REMOVAL OR REPLACEMENT OF PILOT AS- C. INSTALL BURNERS by reversing procedure used to remove burners. Make sure burner with pilot assembly is in same location as original installation - see Table 5 Check burners to see that they are located properly in slot at rear of burner tray, see Fig. 30. Reinstall injection shield assembly (40mm and 50mm burners only, where used) and burner access panel. Reconnect flame roll-out switch wires, pilot gas supply, thermocouple lead or pilot lead. D. CHECK MAIN BURNER and PILOT FLAMES, see procedure Section II, paragraphs 5 and 6. TION ANNUALLY see procedure in Section II, paragraphs 7 through 10. SEMBLY OR PILOT ASSEMBLY PARTS If pilot assembly, thermocouple or pilot orifice need replacing, remove main burner with pilot using procedure described in Paragraph 4. A. To replace orifice: 1. Disconnect pilot tubing. The Robertshaw 7CL-6, Honeywell Q350 and Q3450 pilot orifices are insert type retained by the compression fitting. The Honeywell Q327 and Q3480 pilot orifice is a spud type screwed into pilot burner. Replace with desired orifice. See Key No. 5B. 2. Reconnect pilot tubing and check for leaks. 50mm Burner B. To replace Honeywell Q309A thermocouple in Q327 or Q350 pilot: 1. Loosen attachment nut securing thermocouple to barrel of pilot burner. Disconnect other end at combination gas valve. 2. Remove thermocouple and replace with equal. C. To replace Q3450 or Q3480 igniter-sensor rod assembly: 1. Remove spring clip by pulling it away from the pilot burner. 2. Remove assembly from pilot burner and disconnect harness from gas valve. 3. Replace with equal. 40mm Burner D. To replace complete pilot assembly. 1. Remove machine screws holding pilot burner to pilot bracket. 2. Disconnect pilot piping. 3. Disconnect all other leads to pilot. 4. Select pilot assembly with identical model number, reconnect leads and pilot tubing - resecure to pilot bracket. E. Reinstall main burner following procedure described in Paragraph 4. Figure 30: Burner Cleaning and Installation 29 7. LUBRICATION the service technician or the User. Circulator bearings are water lubricated. There are no parts requiring lubrication on the part of Table 5: Pilot Burner Location Main Burner with Pilot Bracket * Boiler Model Pilot Burner Located Between Main Burners* 1 Inch 50mm 40mm 1 Inch 50 mm 40mm 202 1 --- 1 1& 2 --- --- 202X 1 --- 1 1& 2 --- 1& 2 203 1 1 1 1& 2 1& 2 1& 2 204 2 2 2 2& 3 2& 3 2& 3 205 3 2 2 3& 4 2& 3 2& 3 206 4 3 3 4& 5 3& 4 3& 4 207 6 3 3 6& 7 3& 4 3& 4 208 7 4 4 7& 8 4& 5 4& 5 209 8 4 4 8& 9 4& 5 4& 5 210 9 5 5 9 & 10 5& 6 5& 6 * Main burners numbered left to right as viewed from front of boiler. SECTION IV REPAIR PARTS Section Assembly and Canopy Group .................................. 32 Base Assembly ...................................................................... 34 Manifold and Main Burners 1 Inch Main Burners ..................................................... 36 50mm Main Burners ..................................................... 38 40mm Main burners ...................................................... 40 Pilot Burner and Gas Valve Continuous Ignition (Standing Pilot) ............................ 42 Intermittent Ignition ...................................................... 44 Jacket Assembly .................................................................... 46 Water Trim ........................................................................... 48 Controls ................................................................................. 50 Draft Hood and Vent Damper .............................................. 51 30 All Series 2 repair parts may be obtained through your local Burnham Wholesale Distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact your Burnham Regional Sales Office as listed below. Burnham Corporation Regional Offices A. Burnham Corporation - Central & Western Regions P.O. Box 3079 Lancaster, PA 17604-3079 Phone: (717) 481-8400 FAX: (717) 481-8408 C. Burnham Corporation - M etropolitan Region P.O. Box 3079 Lancast er, PA 17604-3079 Phone: (717) 481-8400 FAX: (717) 481-8409 B. B urnham Sales Corporation - Northeast Region 19-27 M ystic Avenue Somervil le, MA 02145 Phone: (617) 625-9735 FAX: (617) 625-9736 D. B urnham Corporati on - Mi d-At lanti c Region P.O . Box 3079 Lancaster, PA 17604-3079 Phone: (717) 481-8400 FAX: (717) 481-8409 Contact Regional Office Indicated for your State Al abama A Ne bra ska A Oreg on A Ala ska A N eva da A Pennsyl van ia D Arizo na A New Ha mpshire B Rh ode Isla nd B Arkan sas A Ne w Jersey South Caroli na A Cal iforn ia A Atlan tic, Burlington, Camd en, South Dakota A Col ora do A Ca pe May, C umbe rla nd, Tennessee A Te xas A D Conn ecticut B Gloucester, Mercer, Del aware D Monmouth, Ocean, Salem Utah A Fl ori da A Co unties Ve rmont B Ge org ia A All other Counties Hawa ii A New Mexico Ida ho A Ne w York Ill inois A Alb any, Fulton, Montgomery, India na A Re nssela er, Sara to ga, Io wa A Sch enectady, Scho harie, Kan sas A Warre n, Washingto n Co unties Kentucky A All Other Co unties Loui sia na A Mai ne C A Virgin ia Arling ton,Acco mack,Cl arke, Fairfax,Frederick,Fauq uier, Loudoun ,North ampto n a nd B D Prince Wil liam Co unties All other Counties A Washing ton A C Wash ington , D.C. D N orth Caroli na A West Virgin ia D B No rth Dakota A Wisconsin A Maryla nd D Oh io Wyomi ng A Ma ssach use tts B Ath ens, Belmont, Gall ia, Michig an A Jeffe rson, Lawrence, Meig s, Min nesota A Mo nroe, an d Washington Mississip pi A Co unties Missouri A All other Counties Monta na A Cana da A Okl ahoma D A A 31 Figure 33: Section Assembly and Canopy Group Key No. De sc rip tio n Part No. Qua ntity 202 202X 203 204 205 206 207 208 209 210 1. S ectio n Assemb ly (In termittent and Co ntin uo us Circu latio n O nly) 1 Section Assembly, Comple te 6 17 1 70 221 1 --- --- --- --- --- --- --- --- --- 6 17 1 70 3 21 --- 1 1 --- --- --- --- --- --- --- 6 17 1 70 4 21 --- --- --- 1 --- --- --- --- --- --- 6 17 1 70 5 21 --- --- --- --- 1 --- --- --- --- --- 6 17 1 70 6 21 --- --- --- --- --- 1 --- --- --- --- 6 17 1 70 7 21 --- --- --- --- --- --- 1 --- --- --- 6 17 1 70 8 21 --- --- --- --- --- --- --- 1 --- --- 6 17 1 70 9 21 --- --- --- --- --- --- --- --- 1 --- 6 17 1 71 0 21 --- --- --- --- --- --- --- --- --- 1 1. Sectio n Assembly (Gravi ty circu latio n O nly) 1 Section Assembly, Comple te 6 17 1 70 231 1 --- --- --- --- --- --- --- --- --- 6 17 1 70 3 31 --- 1 1 --- --- --- --- --- --- --- 6 17 1 70 4 31 --- --- --- 1 --- --- --- --- --- --- 6 17 1 70 5 31 --- --- --- --- 1 --- --- --- --- --- 6 17 1 70 6 31 --- --- --- --- --- 1 --- --- --- --- 6 17 1 70 7 31 --- --- --- --- --- --- 1 --- --- --- 6 17 1 70 8 31 --- --- --- --- --- --- --- 1 --- --- 6 17 1 70 9 31 --- --- --- --- --- --- --- --- 1 --- 6 17 1 71 0 31 --- --- --- --- --- --- --- --- --- 1 32 Key Description No. Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 61117022 1 --- --- --- --- --- --- --- --- --- 611170300 --- 1 --- --- --- --- --- --- --- --- 611170302 --- --- 1 --- --- --- --- --- --- --- 611170402 ---- --- --- 1 --- --- --- --- --- --- 611170502 --- --- --- --- 1 --- --- --- --- --- 611170602 --- --- --- --- --- 1 --- --- --- --- 611170702 --- --- --- --- --- --- 1 --- --- --- 611170802 --- --- --- --- --- --- --- 1 --- --- 611170902 --- --- --- --- --- --- --- --- 1 --- 611171002 ---- --- --- --- --- --- --- --- --- 1 Canopy Assembly 206H 6111706010 --- --- --- --- --- 1 --- --- --- --- 2B Carriage Bolt, ¼-20 x 1" Common Hardware 2 2 2 2 2 2 2 2 2 2 2C Flat Washer, ¼" Common Hardware 2 2 2 2 2 2 2 2 2 2 2D Nut, Hex, ¼-20 Common Hardware 2 2 2 2 2 2 2 2 2 2 2E Cerafelt Sealing Strip, ½" x 1" x 10' (Canopy to Section Assy) 6206001 1 1 1 1 1 1 1 1 1 1 2F Flue Gas Baffle (*Standing Pilot 1" and 50mm Burners Only) (** LP Standing Pilot 1" and 50mm Burners Only) (+2H Models Only) (*** Standing Pilot Models Only) 71106001 1*** --- 2**+ 6** 7* 8* 9* 2. Canopy Group 2A Canopy Assembly (except for 206H) 33 3**+ 4**+ 5**+ Figure 34: Base Assembly Key No. Descri ption Boiler Size Part N o. Key No. Qty. 3 3A Base Tray Boiler Size Part No. Qty. 202 718600211 1 202X 718600311 1 203 718600311 1 204 718600411 1 205 718600511 1 206 718600611 1 207 718600711 1 208 718600811 1 209 718600911 1 210 718601011 1 All 720601 2 202 72060025 1 202X 72060035 1 203 72060035 1 204 72060045 1 205 72060055 1 206 72060065 1 207 72060075 1 208 72060085 1 209 72060095 1 210 72060105 1 3. Base Assembly Continued 3. Base Assembly Base Assembly (Complete) Available for 1 Inch Burners Only Description 202 618600291 1 202X 618600391 1 203 618600391 1 204 618600491 1 205 618600591 1 206 618600691 1 207 618600791 1 208 618600891 1 209 618600991 1 210 618601091 1 202 718600291 1 202X 718600391 1 203 718600391 1 204 718600491 1 205 718600591 1 206 718600691 1 207 718600791 1 208 718600891 1 209 718600991 1 210 718601091 1 3B 3B1 3B2 34 Base Wrapper Base End Insulation Base Rear Insulation Key No. Description Boiler Size Part No. Qty. 202 618600241 1 202X 618600341 1 203 618600341 1 204 618600441 1 205 618600541 1 206 618600641 207 Key No. 3. Base Assembly Continued 3C Base F ront Panel Assembly Burner Tray (1 " Main Burners) 3D Burner Tray (50 mm Main Burners) Burner Tray (40 mm Main Burners) Description Boiler Size Part No. Qty. 3. Base Assembly Continued 3E Base Leg Assembly All 6186001 4 3E1 Base Leg All 71860021 4 All 8186006 4 202 718600261 1 202X 718600361 1 1 203 718600361 1 618600741 1 204 718600461 1 208 618600841 1 205 718600561 1 209 618600941 1 206 718600661 1 210 618601041 1 207 718600761 1 202 718600205 1 208 718600861 1 209 718600961 1 202X 718600305 1 210 718601061 1 203 718600305 1 204 718600405 1 All 6206002 1 205 718600505 1 206 718600605 1 207 718600705 1 202 thru 206 80860700 20 208 718600805 1 209 718600905 1 80860700 21 210 718601005 1 207 thru 210 203 7817038 1 204 7817048 1 205 7817058 1 206 7817068 1 207 7817078 1 208 7817088 1 209 7817098 1 210 7817108 1 202 718600206 1 202X 71806037 1 203 71806037 1 204 71806047 1 205 71806057 1 206 71806067 1 207 71806077 1 208 718600806 1 209 718600906 1 210 718601006 1 3E2 Nylon Glide 3F 3G 3H 35 Burner Access Panel Cerafelt Sealing Strip, 1" x 2" x 10' (Section Assembly to Base) Self-Tapping Screw, ¼" - 20 x ½" 3J Self-Tapping Screw, 5/16" - 18 x 1-1/4" All 80860717 4 3K Flat Washer, 5/16", USS All Common Hardware 4 3L Lock Washer, 5/16" All Common Hardware 4 3M Hex Nut, 5-16, All Common Hardware 4 Figure 35: Manifold and Main Burners (1 Inch Main Burners) 36 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 2 4 6 8 11 13 15 17 4. Manifold and Main Burners (1 Inch Main Burners Only) 4A Main Burner 4B Main Burner with Pilot Bracket 4C 4D 4E 4F Manifold Main Burner Orifice 8236099 1 2 ---- See Table Below 82260023 1 ---- ---- ---- ---- ---- ---- ---- ---- ---- 82260033 ---- 1 1 ---- ---- ---- ---- ---- ---- ---- 82260043 ---- ---- ---- 1 ---- ---- ---- ---- ---- ---- 82260053 ---- ---- ---- ---- 1 ---- ---- ---- ---- ---- 82260063 ---- ---- ---- ---- ---- 1 ---- ---- ---- ---- 82260073 ---- ---- ---- ---- ---- ---- 1 ---- ---- ---- 82260083 ---- ---- ---- ---- ---- ---- ---- 1 ---- ---- 82260093 ---- ---- ---- ---- ---- ---- ---- ---- 1 ---- 82260103 ---- ---- ---- ---- ---- ---- ---- ---- ---- 1 ---- See Table Below Screw, Machine, Slotted Round Head, 80860800 10-32 x 3/16" (Standing Pilot) 2 2 2 2 2 2 2 2 2 2 Screw, Machine, Philips Head w/Captive Lockwasher, #10-32 x ¼" (Intermittent Ignition) 80860874 1 1 1 1 1 1 1 1 1 1 Screw, Self Tapping, Phillips Pan Head, ¼-20 x ½" 80860700 4 4 4 4 4 4 4 4 4 4 4B. 1 Inch Main Burner with Pilot Bracket, 24-volt Continuous Ignition (Standing Pilot) Natural Gas Only 4B Main Burner with 70° 7CL-6 Pilot Bracket and Offset Lancings 8231706 1 1 --- --- --- --- --- --- --- --- Main Burner with 70° Q350 Pilot Bracket and Offset Lancings 8236097 --- --- 1 1 1 1 1 --- --- --- Main Burner with 60° Pilot Bracket 8236098 --- --- --- --- --- --- --- 1 1 1 4B. 1 Inch Main Burner with Pilot Bracket, 24-volt Continuous Ignition (Standing Pilot) LP Gas Only 4B Main Burner with 70° 7CL-6 Pilot Bracket and Offset Lancings 8231706 1 1 --- --- --- --- --- --- --- --- Main Burner with 45° Pilot Bracket 8236111 --- --- 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4B. 1 Inch Main Burner with Pilot Bracket, Intermittent Ignition Only 4B Main Burner with 60° Pilot Bracket 8236098 1 1 1 4D. 1 Inch Main Burner Orifices, Natural Gas, Normal Altitude, U.S.A. and Canada 4D Main Burner Orifice, #47 (White) 822710 2 3 --- --- --- --- 12 14 16 18 Main Burner Orifice, #44 (Orange) 822712 --- Main Burner Orifice, #45 (Pink) 822711 --- --- 3 --- --- --- --- --- --- --- --- --- 5 7 9 --- --- --- --- 4D. 1 Inch Main Burner Orifices, LP/Propane, Normal Altitude, U.S.A. and Canada 4D Main Burner Orifice, 1.25 mm (Purple) 822705 2 --- --- 5 7 9 --- --- --- --- Main Burner Orifice, #55 (Green) 822708 --- --- 3 --- --- --- --- --- --- --- Main Burner Orifice, 3/64" (Blue) 822704 --- 3 --- --- --- --- 12 14 16 18 37 * Continuous Pilot Ignition: - Q327A Only - Not suitable for use with Q350A 24V Continuous Pilot Ignition Intermittent Ignition: Q3480C Figure 36: Manifold and Main Burners (50 mm Main Burners) 38 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 4. Manifold and Main Burners (50 mm Main Burners Only) 4A Main Burner 8236091 --- --- 1 2 3 4 5 6 7 8 4B Main Burner with 45° Pilot Bracket 8236092 --- --- 1 1 1 1 1 1 1 1 82260034 --- --- 1 --- --- --- --- --- --- --- 82260044 --- --- --- 1 --- --- --- --- --- --- 82260054 --- --- --- --- 1 --- --- --- --- --- 82260064 --- --- --- --- --- 1 --- --- --- --- 82260074 --- --- --- --- --- --- 1 --- --- --- 82260084 --- --- --- --- --- --- --- 1 --- --- 82260094 --- --- --- --- --- --- --- --- 1 --- 82260104 --- --- --- --- --- --- --- --- --- 1 4C Manifold 50 mm Main Burner Orifices, Natural Gas, High Altitude, U.S.A. and Canada, 2000-5000 Ft. Altitude 4E Main Burner Orifice, #38 822680 --- --- 2 --- --- --- --- --- --- --- Main Burner Orifice, #37 822601 --- --- --- 3 4 5 6 7 8 9 50 mm Main Burner Orifices, LP/Propane, High Altitude, U.S.A. and Canada, 2000-5000 Ft. Altitude Main Burner Orifice, #53 8226002 --- --- 2 --- --- --- --- --- --- --- Main Burner Orifice, #52 822641 --- --- --- 3 4 5 6 7 8 9 4F External Hitch Pin Clip 822604 --- --- 2 3 4 5 6 7 8 9 4G Screw, Machine, Philips Head w/Captive Lockwasher, #10-32 x ¼" 80860874 --- --- 1 1 1 1 1 1 1 1 4H Screw, Self Tapping, Phillips Pan Head, ¼-20 x ½" 80860700 --- --- 4 4 4 4 4 4 4 4 618600301 --- --- 1 --- --- --- --- --- --- --- 618600401 --- --- --- 1 --- --- --- --- --- --- 618600501 --- --- --- --- 1 --- --- --- --- --- 618600601 --- --- --- --- --- 1 --- --- --- --- 618600701 --- --- --- --- --- --- 1 --- --- --- 618600801 --- --- --- --- --- --- --- 1 --- --- 618600901 --- --- --- --- --- --- --- --- 1 --- 618601001 --- --- --- --- --- --- --- --- --- 1 718600303 --- --- 1 --- --- --- --- --- --- --- 718600403 --- --- --- 1 --- --- --- --- --- --- 718600503 --- --- --- --- 1 --- --- --- --- --- 718600603 --- --- --- --- --- 1 --- --- --- --- 718600703 --- --- --- --- --- --- 1 --- --- --- 718600803 --- --- --- --- --- --- --- 1 --- --- 718600903 --- --- --- --- --- --- --- --- 1 --- 718601003 --- --- --- --- --- --- --- --- --- 1 80860900 --- --- 2 2 2 2 3 3 3 3 4J 4K 4L Lower Injection Shield Upper Injection Shield Wing Nut, ¼-20, Size B 39 Figure 36a: Manifold and Main Burners (40mm Main Burners) Key Description No. Quantity Part N o. 202 202X 203 204 205 206 207 208 209 210 8236135 --- 1 1 2 3 4 5 6 7 8 Main Burner with 48° Pilot Bracket 8236143 1 --- --- --- --- --- --- --- --- --- Main Burner with 41° Pilot Bracket 8236136 1 1 1 1 1 1 1 1 1 4. 40MM MAIN BURNERS ONLY 4A Main Burner Intermittent Ignition Only 4B 24-volt Continuous Ignition (Standing Pilot) Natural Gas Only 4B Main Burner with 48° Pilot Bracket 8236143 1 1 1 1 1 1 --- --- --- --- Main Burner with 41° Pilot Bracket 8236136 --- --- --- --- --- --- 1 1 1 1 24-volt Continuous Ignition (Standing Pilot) LP Gas Only 4B Main Burner with 48° Pilot Bracket 8236143 1 1 --- --- --- --- --- --- --- --- Main Burner with 41° Pilot Bracket 8236136 --- --- 1 1 1 1 1 1 1 1 40 K ey N o. De sc rip tio n P art N o. Qu an tity 202 202X 203 204 205 206 207 208 209 210 82260028 1 --- --- --- --- --- --- --- --- --- 82260038 --- 1 1 --- --- --- --- --- --- --- 82260048 --- --- --- 1 --- --- --- --- --- --- 82260058 --- --- --- --- 1 --- --- --- --- --- 82260068 --- --- --- --- --- 1 --- --- --- --- 82260078 --- --- --- --- --- --- 1 --- --- --- 82260088 --- --- --- --- --- --- --- 1 --- --- 82260098 --- --- --- --- --- --- --- --- 1 --- 82260108 --- --- --- --- --- --- --- --- --- 1 4. 40MM MA IN B URNERS ONLY (Continued) 4C Manifold Nat ural G as, S ea Le vel t o 2000 Ft. 4D Main Burner Orific e, 3.0 0 mm 822780 1 --- --- --- --- --- --- --- --- --- Main Burner O rifice, #41 822729 --- 2 --- --- --- --- --- --- --- --- Main Burner O rifice, #36 822771 --- --- 2 --- --- --- --- --- --- --- Main B urner O rifice, 7/64" 822772 --- --- --- 3 4 5 6 7 8 9 Main Burner O rifice, #49 822709 1 --- --- --- --- --- --- --- --- -- Main Burner O rifice, #53 822722 --- 2 --- --- --- --- --- --- --- --- Main Burner O rifice, #51 822733 --- --- 2 3 4 5 6 7 8 9 --- --- --- --- --- --- --- --- --- LP G as, S ea Le vel to 2000 Ft. 4D Natura l Gas , High A ltitude (2000-5000 Ft.) U.S .A . Only 4D Main Burner O rifice, #36 822771 1 Main Burner O rifice, #44 822712 --- 2 --- --- --- --- --- --- --- --- Main Burner O rifice, #41 822729 --- --- 2 --- --- --- --- --- --- --- Main Burner O rifice, #40 822728 --- --- --- 3 --- --- --- --- --- --- Main Burner O rifice, #39 822727 --- --- --- --- 4 5 6 7 8 9 LP Gas , High A ltitude (2000-5000 Ft.) U.S .A . Only 4D Main Burner O rifice, #52 822721 1 --- --- --- --- --- --- --- --- --- Main Burner O rifice, #55 822708 --- 2 --- --- --- --- --- --- --- --- Main Burner O rifice, #53 822722 --- --- 2 3 4 5 6 7 8 9 Natu ral Ga s, High Altitude (2000-4500 Ft.) Ca nada Only 4D Main B urner O rifice, 7/64" 822772 1 --- --- --- --- --- --- --- --- --- Main Burner O rifice, #43 822713 --- 2 --- --- --- --- --- --- --- --- Main Burner O rifice, #38 822720 --- --- 2 --- --- --- --- --- --- --- Main Burner O rifice, #37 822719 --- --- --- 3 4 5 6 7 8 9 LP Ga s, High Altitude (2000-4500 Ft.) Ca nada Only Main Burner O rifice, #50 822732 1 --- --- --- --- --- --- --- --- --- Main Burner O rifice, #54 822734 --- 2 --- --- --- --- --- --- --- --- Main Burner O rifice, #52 822721 --- --- 2 3 4 5 6 7 8 9 Screw, Machine, Slotted Round Head, #10-32 x 3/16" (Standing P ilot) 80860800 2 2 2 2 2 2 2 2 2 2 Sc rew, Machine, P hillips Head w/Captiv e Lockwasher, #10-32 x ¼" (Intermittent Ignition) 80860874 1 1 1 1 1 1 1 1 1 1 4F Screw, Self Tapping, Phillips P an Head, ¼-20 x ½" 80860700 4 4 4 4 4 4 4 4 4 4 4G Injec tion Shield Assembly A/R A/R A/R A/R A/R A/R A/R A/R A/R A/R 4D 4E 41 * 1" Burner Only ** 40mm Burner Only Figure 37 Key No. Description Quantity Part No. 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner a nd Gas Valve, 24-volt Continuous Ignition, Natura l Ga s (1 Inc h and 40mm Main Burners Only) 5A Pilot Burner, Robertshaw 7CL-6 8231702 1* 1* --- --- --- --- --- --- --- --- Pilot Burner, Honeywell Q350A1644 8236102 1** 1** 1 1 1 1 1* --- --- --- Pilot Burner, Honeywell Q327A1949 8236103 --- --- --- --- --- --- 1** 1 1 1 1* 1* --- -- --- --- --- --- --- --- 1** 1** 1 1 1 1 1* --- --- --- --- --- --- --- --- --- 1** 1 1 1 Pilot Orifice, Robertshaw 76376-1 .010" 5B Pilot Orifice, Honeywell 390686-22 .012" Included with 5A Pilot Orifice, Honeywell 388146AG .026" Adptr, 1/4"OD x 1/4" NPT Included w/5A & 5E 8236109 2* 2* --- --- --- --- --- --- --- --- Adptr, 1/8"OD x 1/4" NPT Included w/5A & 5E 8236108 2** 2** 2 2 2 2 2 2 2 2 Pilot Tubing, 1/8" OD x 30" LG 8236110 1** 1** 1 1 1 1 1 --- --- --- Pilot Tubing, 1/8" OD x 40" LG 8236100 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell VR8200C3005 81660143 1* 1* --- --- --- --- --- --- --- --- Gas Valve, Honeywell VR8200C6008 81660182 --- --- 1* 1* 1* 1* --- --- --- --- Gas Valve, Honeywell VR8300C4134 81660183 --- --- --- --- --- --- 1* 1 1 1 Gas Valve, Honeywell VR8200C6032 81660241 1** 1** 1** 1** 1** 1** --- --- --- --- Gas Valve, Honeywell VR8300C4183 81660242 --- --- --- --- --- --- 1** 1** 1** 1** Thermocouple, 30", Robertshaw 42930 8231704 1* 1* --- --- --- --- --- --- --- --- Thermocouple, 30", Honeywell Q309A 8236024 1** 1** 1 1 1 1 1 1 1 1 5G Pilot Tubing, 1/4" OD x 9" LG 8236047 2* 2* --- --- --- --- --- --- --- --- 5H Male Adapter, 1/4" OD x 1/8" NPT 822630 2* 2* --- --- --- --- --- --- --- --- 5J Regulator, 3.5" w.c., Maxitrol RV12LT 8231705 1* 1* --- --- --- --- --- --- --- --- 5K Pilot Tubing, 1/4" OD x 6" LG 8236094 1* 1* --- --- --- --- --- --- --- --- 5L Compression Coupling, 1/4" x 1/4" x 90° 8236046 1* 1* --- --- --- --- --- --- --- --- 5C 5D 5E 5F 42 Key No. Description Quantity Part No. 202 202X 203 204 205 206 207 208 209 210 5 . Pilot Burner and Gas Va lve, 2 4-volt Continuous Ignition, LP/Propane (1 Inch and 40m m Main Burners Only) 5A Pilot Burner, Robertshaw 7CL-6 8231703 1* 1* --- --- --- --- --- --- --- --- Pilot Burner, Honeywell Q327A1915 8236106 --- --- 1 1 1 1 1 1 1 1 Pilot Burner, Honeywell Q350A2279 8236105 1** 1** --- --- --- --- --- --- --- --- 1* 1* --- --- --- --- --- --- --- --- --- --- 1 1 1 1 1 1 1 1 1** 1** --- --- --- --- --- --- --- Pilot Orifice, Robertshaw 27270-1 (.008") 5B Pilot Orifice, Honeywell 388146KR (.014") Included With 5A Pilot Orifice, HoneywelL 390686-23 (.008") Adptr, 1/4"OD x 1/4" NPT Included w/5A & 5E 8236109 2* 2* --- --- --- --- --- --- --- --- Adptr, 1/8"OD x 1/4" NPT Included w/5A & 5E 8236108 2** 2** 2 2 2 2 2 2 2 2 Pilot Tubing, 1/8" OD x 30" LG 8236110 1** 1** 1 1 1 1 1 --- --- --- Pilot Tubing, 1/8" OD x 40" LG 8236100 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell VR8200C3013 81660144 1* 1* --- --- --- --- --- --- --- --- Gas Valve, Honeywell VR8200C6040 81660243 1** 1** 1 1 1 1 --- --- --- --- Gas Valve, Honeywell VR8300C4548 81660244 --- --- --- --- --- --- 1 1 1 1 Thermocouple, 30", Robertshaw 42930 8231704 1* 1* --- --- --- --- --- --- --- --- Thermocouple, 30", Honeywell Q309A 8236024 1** 1** 1 1 1 1 1 1 1 1 5G Pilot Tubing, 1/4" OD x 18" LG 8236048 1* 1* --- --- --- --- --- --- --- --- 5L Compression Coupling, 1/4" x 1/4" x90° 8236046 1* 1* --- --- --- --- --- --- --- --- 5M Pilot Tubing , 1/4" OD x 9" LG 8236047 1* 1* --- --- --- --- --- --- --- --- 5C 5D 5E 5F * 1" Burner Only ** 40mm Burner Only 43 Figure 38 Key No. Descr iption Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 5. Pilot B urner and Gas Valve , Interm ittent Ignition, Natural Ga s 5A 5B 5C 5D 5E 5F Pilot Burner, Honeywell Q3480C1197 8236124 1 1 1 1 1 1 1 1 1 1 Pilot Burner, Honeywell Q 3450B1039 8236144 1** --- --- --- --- --- --- --- --- --- Pilot Burner, Honeywell Q3480C1254 8236133 --- 1** 1** 1** 1** 1** 1** 1** 1** 1** 1 1 1 1 1 1 1 1 1 1 1** --- --- --- --- --- --- --- --- --- Pilot Orifice, Honeywell with NE22 Orifice, 388146NE (.022") Pilot Orifice, Honeywell with BCR18 Orifice, 390686-4 (.018") Included with 5A Adapter, 1/4" OD x 1/4" NPT Included with 5A and 5E 8236109 2 2 2 2 2 2 2 2 2 2 Pilot Tubing,1/4" OD x 30" LG 8236122 1 1 1 1 1 1 1 --- --- --- Pilot Tubing,1/4" OD x 40" LG 8236123 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell SV9501P2004 81660213 1 1 1 1 1 1 --- --- --- --- Gas Valve, Honeywell SV9601P4107 81660216 --- --- --- --- --- --- 1 1 1 1 Gas Valve, Honeywell SV9501P2087 81660237 1** 1** 1** 1** 1** 1** --- --- --- --- Gas Valve, Honeywell SV9601P4172 81660238 --- --- --- --- --- --- 1** 1** 1** 1** 8236114 1 1 1 1 1 1 1 1 1 1 Ignitor/Sensor Assembly with clip Honeywell Q3400A1024 (Included with 5A) 5. Pilot Burner and Gas Valve, Intermittent Ignition, LP/Propane 5A 5B 5C 5D 5E 5F Pilot Burner, Honeywell Q3480C1437 8236125 1 1 1 1 1 1 1 1 1 1 Pilot Burner, Honeywell Q 3450B1047 8236145 1** --- --- --- --- --- --- --- --- --- Pilot Burner, Honeywell Q3480C1452 8236134 --- 1** 1** 1** 1** 1** 1** 1** 1** 1** 1 1 1 1 1 1 1 1 1 1 1** --- --- --- --- --- --- --- --- --- Pilot Orifice, Honeywell with KR14 Orifice, 388146KP (.014") Pilot Orifice, Honeywell with BBR12 Orifice, 390686-25 (.012") Included with 5A Adapter, 1/4" OD x 1/4" NPT Included with 5A and 5E 8236109 2 2 2 2 2 2 2 2 2 2 Pilot Tubing, 1/4" OD x30" LG 8236122 1 1 1 1 1 1 1 --- --- --- Pilot Tubing, 1/4" OD x40" LG 8236123 --- --- --- --- --- --- --- 1 1 1 Gas Valve, Honeywell SV9601P4115 81660215 --- --- --- --- --- --- 1 1 1 1 Gas Valve, Honeywell SV9501P2020 81660239 1 1 1 1 1 1 --- --- --- --- Gas Valve, Honeywell SV9601P4164 81660240 --- --- --- --- --- --- 1** 1** 1** 1** 8236114 1 1 1 1 1 1 1 1 1 1 Ignitor/Sensor Assembly with clip Honeywell Q3400A1024 (Included with 5A) ** 40m m B ur ners Only 44 Service Notes 45 Figure 39 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 604 170254 1 -- - -- - -- - -- - -- - -- - -- - -- - -- - 604 170354 -- - 1 1 -- - -- - -- - -- - -- - -- - -- - 604 170454 -- - -- - -- - 1 -- - -- - -- - -- - -- - -- - 604 170554 -- - -- - -- - -- - 1 -- - -- - -- - -- - -- - 604 170654 -- - -- - -- - -- - -- - 1 -- - -- - -- - -- - 604 170754 -- - -- - -- - -- - -- - -- - 1 -- - -- - -- - 604 170854 -- - -- - -- - -- - -- - -- - -- - 1 -- - -- - 604 170954 -- - -- - -- - -- - -- - -- - -- - -- - 1 -- - 604 171054 -- - -- - -- - -- - -- - -- - -- - -- - -- - 1 604 170215 1 -- - -- - -- - -- - -- - -- - -- - -- - -- - 604 170315 -- - 1 1 -- - -- - -- - -- - -- - -- - -- - 604 170415 -- - -- - -- - 1 -- - -- - -- - -- - -- - -- - 604 170515 -- - -- - -- - -- - 1 -- - -- - -- - -- - -- - 604 170615 -- - -- - -- - -- - -- - 1 -- - -- - -- - -- - 604 170715 -- - -- - -- - -- - -- - -- - 1 -- - -- - -- - 604 170815 -- - -- - -- - -- - -- - -- - -- - 1 -- - -- - 604 170915 -- - -- - -- - -- - -- - -- - -- - -- - 1 -- - 604 171015 -- - -- - -- - -- - -- - -- - -- - -- - -- - 1 6. Jacket Assembly, Complete 6 Jacket Assembly, Complete 6. Jacket Assembly 6A Jacket Wrap -Around Panel 46 Key No. Description P art No. Quantity 202 202X 203 204 205 206 207 208 209 210 604 170223 1 --- --- --- --- --- --- --- --- --- 604 170323 --- 1 1 --- --- --- --- --- --- --- 604 170423 --- --- --- 1 --- --- --- --- --- --- 604 170523 --- --- --- --- 1 --- --- --- --- --- 604 170623 --- --- --- --- --- 1 --- --- --- --- 604 170723 --- --- --- --- --- --- 1 --- --- --- 604 170823 --- --- --- --- --- --- --- 1 --- --- 604 170923 --- --- --- --- --- --- --- --- 1 --- 604171023 --- --- --- --- --- --- --- --- --- 1 604 170233 1 --- --- --- --- --- --- --- --- --- 1 1 --- --- --- --- --- --- --- 6. Jacket Assembly (Continued) 6B Jac ket Vestibule P anel 604 170333 6C Jac ket Top P anel 604 170433 --- --- --- 1 --- --- --- --- --- --- 604 170533 --- --- --- --- 1 --- --- --- --- --- 604 170633 --- --- --- --- --- 1 --- --- --- --- 604 170733 --- --- --- --- --- --- 1 --- --- --- 604 170833 --- --- --- --- --- --- --- 1 --- --- 604 170933 --- --- --- --- --- --- --- --- 1 --- 604 171033 --- --- --- --- --- --- --- --- --- 1 604 170242 1 --- --- --- --- --- --- --- --- --- 1 1 --- --- --- --- --- --- --- 604 170342 6D 6E Jac ket Fron t Removable Do or Jacket Lower Front Panel 604 170442 --- --- --- 1 --- --- --- --- --- --- 604 170542 --- --- --- --- 1 --- --- --- --- --- 604 170642 --- --- --- --- --- 1 --- --- --- --- 604 170742 --- --- --- --- --- --- 1 --- --- --- 604 170842 --- --- --- --- --- --- --- 1 --- --- 604 170942 --- --- --- --- --- --- --- --- 1 --- 604 171042 --- --- --- --- --- --- --- --- --- 1 604 170216 1 --- --- --- --- --- --- --- --- --- 604 170316 --- 1 1 --- --- --- --- --- --- --- 604 170416 --- --- --- 1 --- --- --- --- --- --- 604 170516 --- --- --- --- 1 --- --- --- --- --- 604 170616 --- --- --- --- --- 1 --- --- --- --- 604 170716 --- --- --- --- --- --- 1 --- --- --- 604 170816 --- --- --- --- --- --- --- 1 --- --- 604 170916 --- --- --- --- --- --- --- --- 1 --- 604 171016 --- --- --- --- --- --- --- --- --- 1 80 860000 26 26 26 26 26 26 26 26 26 26 6F Sheet Metal Screw, Type AB, Phillips Truss Head, #8 x ½" 6G Snap Bushing, Heyco SB -1093-15 8 136257 2 2 2 2 2 2 2 2 2 2 6H Snap Bushing , Heyco SB-437 -5 8 136048 1 1 1 1 1 1 1 1 1 1 47 Figure 40: Water Trim 48 Key Description No. 7 S afety Relie f Valv e, 30 psi, ¾ NPT, C onbraco 10-408-05 Part No. 81660319 Quantity 202 202X 203 204 205 206 207 208 209 210 1 1 1 1 1 1 1 1 1 1 8. C irc ulator, Bell & Gosse tt SLC-30 Option (Intermitten t an d C on tin uous Circ ula tio n Only) 8A C irculator with Gaskets, Bell & Go ssett NRF-22 8B G aske t, Bell & Go ssett NRF-22 8056174 1 1 1 1 1 1 1 1 1 1 806602029 2 2 2 2 2 2 2 2 2 2 8. Circulator, Grundfo s Option (Intermitten t an d C on tin uous Circ ula tio n Only) 8A C irculator with Gaskets, Grun dfos UP15-42F 8B Ga sket, G rundfos 510179 8056173 1 1 1 1 1 1 1 1 1 1 806602016 2 2 2 2 2 2 2 2 2 2 8. Circulator, Ta co 007 Option (Inter mitten t an d C on tin uous Circ ula tio n Only ) 8A C irculator with Ga skets, Ta co 007F 8B Ga sket, Taco '00' Se ries 8056170 1 1 1 1 1 1 1 1 1 1 806602006 2 2 2 2 2 2 2 2 2 2 8. Circ ula to r, Tac o 0010 Option (Intermitten t an d C on tin uous Circ ula tio n Only ) 8A Circulator with Gaskets, Taco 0010 8B Ga sket, Taco '00' Se ries 8056176 1 1 1 1 1 1 1 1 1 1 806602006 2 2 2 2 2 2 2 2 2 2 9. Misce llane ous C irculato r Hardwa re (Intermitten t an d C on tin uous Circula tio n Only ) 9A Flange, 1¼ NPT 806602013 2 2 2 2 2 2 2 2 2 2 9B S cr ew, Ca p Hex Hea d, 7/16-14 x 1½" 80861301 4 4 4 4 4 4 4 4 4 4 9C Nut, Hex, 7/16-14 80860406 4 4 4 4 4 4 4 4 4 4 10A Limit, Hone ywell L4080D1036 80160156 1 1 1 1 1 1 1 1 1 1 10B Well, ½ NPT (In cluded w/10A) ----- 1 1 1 1 1 1 1 1 1 1 10. Limit C on trol 10C Limit, Ho ney we ll L4080B1212 (Dua l Limit Only ) 80160474 1 1 1 1 1 1 1 1 1 1 10D We ll, ¾ NPT, Ho neywe ll 123870A (Dua l Limit Only ) 80160426 1 1 1 1 1 1 1 1 1 1 11. Miscella neo us Trim 11A Drain Co ck, C onbraco 31-606-02 806603011 1 1 1 1 1 1 1 1 1 1 11B Te mperature-Pressure Gauge, 8056164U 1 1 1 1 1 1 1 1 1 1 11C Nip ple, 1¼ NPT x 3" 806600005 1 1 1 1 1 1 1 1 1 1 49 Figure 41 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 12. Transformer/Relay Assembly (Intermittent Circulation Only) 12A Junction Box, 4" x 4" x 1½" 12B 12C 8136259 1 1 1 1 1 1 1 1 1 1 Transformer/Relay, Honeywell R8285D5001 (Includes Key No. 80160155U 12C) 50VA 1 1 1 1 1 1 1 1 1 1 Relay, Honeywell R8222U1006 1 1 1 1 1 1 1 1 1 1 80160096U 12. Transformer (Continuous and Gravity Circulation Only) 12A Junction Box, 4" x 4" x 1½" 8136259 1 1 1 1 1 1 1 1 1 1 12D Transformer, 40VA, Honeywell AT140D1012 or AT72D1188 80160039 1 1 1 1 1 1 1 1 1 1 13. Flame Rollout Switch 13A Flame Rollout Switch 80160044 1 1 1 1 1 1 1 1 1 1 13B Flame Rollout Switch Mounting Bracket (*40mm Burner Only) 7186018 1* 1 1 1 1 1 1 1 1 1 6016058 1 1 1 1 1 1 1 1 1 1 14. Blocked Vent Switch 14 Blocked Vent Switch Replacement Assembly 50 Figure 42 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 8116067 1 1 1 --- --- --- --- --- --- --- 8111702 --- --- --- 1 --- --- --- --- --- --- 8111703 --- --- --- --- 1 1 --- --- --- --- 8111704 --- --- --- --- --- --- 1 1 --- --- 8111705 --- --- --- --- --- --- --- --- 1 1 16. Draft Hood Carton 16 Draft Hood 17. Vent Damper Carton (U.S.A. - Standard; Canada - Optional) 17 Automatic Vent Damper, 4" Effikal RVGP-KS-4; or Johnson Y15A 8116143 8116122 1 1 1 --- --- --- --- --- --- --- Automatic Vent Damper, 5" Effikal RVGP-KS-5; or Johnson Y15B 8116144 8116123 --- --- --- 1 --- --- --- --- --- --- Automatic Vent Damper, 6" Effikal RVGP-KS-6; or Johnson Y15C 8116145 8116124 --- --- --- --- 1 1 --- --- --- --- Automatic Vent Damper, 7" Effikal RVGP-KS-7; or Johnson Y15D 8116146 8116125 --- --- --- --- --- --- 1 1 --- --- Automatic Vent Damper, 8" Effikal RVGP-KS-8; or Johnson Y15E 8116147 8116126 --- --- --- --- --- --- --- --- 1 1 8116164 1 --- --- --- --- --- --- --- --- --- 18. Vent Reducer 18 Reducer, 4" x 3" 51 52
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