Burnham 202 Installation & Service Instructions Manual

Brand: Burnham

Model: 202

Type: Installation & Service Instructions Manual

This manual is also suitable for

Price - $3.00

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

SERIES 2 (model B)

GAS BOILERS

Part No. 81417032R10-11/99

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

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 - INSTALLATION INSTRUCTIONS Page 4

SECTION II - OPERATING INSTRUCTIONS Page 20

TROUBLE SHOOTING GUIDE Page 27

SECTION III - SERVICE Page 28

SECTION IV - REPAIR PARTS 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.

WARNING

FAILURE TO FOLLOW ALL INSTRUCTIONS IN PROPER ORDER CAN CAUSE PERSONAL

INJURY OR DEATH. READ ALL INSTRUCTIONS BEFORE INSTALLING.

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 OBSTRUCTION IN THE BOILER ROOM THAT WILL HINDER THE FLOW

OF COMBUSTION AND VENTILATING AIR.

WARNING

READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF

BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE

TECHNICIAN. MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION.

DANGER

Indicates presence of a hazard which will

cause severe personal injury, death or

substantial property damage if ignored.

CAUTION

Indicates presence of a hazard which will or

can cause minor personal injury or property

damage if ignored.

NOTICE

Indicates special instructions on installation,

operation, or maintenance which are

important but not related to personal injury

hazards.

WARNING

Indicates presence of a hazard which can

cause severe personal injury, death or

substantial property damage if ignored.

Figure 1

Boiler

Model

Number

Dimensions [inches]

Gas

Connection

For

Automatic

Gas Valve

Water

Content

[gallons]

Recommended

Vent Size

[1] [2]

Approx.

Shipping

Weight

(lb.)

ABCDE F G

202 18-3/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10 [3] 1/2 2.5 3" dia. x 15 ft. 212

202X 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262

203 20 12 6 4 45-5/8 8-1/2 4-3/4 1/2 3.2 4" dia. x 15 ft. 262

204 23-1/4 15-1/4 7-5/8 5 47-1/8 9-1/8 4-3/4 1/2 4 5" dia. x 15 ft. 306

205 26-1/2 18-1/2 9-1/4 6 48-1/2 9-3/4 5-1/4 1/2 4.7 6" dia. x 15 ft. 354

206 29-3/4 21-3/4 10-7/8 6 48-1/2 9-3/4 5-1/4 1/2 5.5 6" dia. x 15 ft. 414

207 33 25 12-1/2 7 50-1/8 10-3/8 6-5/8 3/4 6.2 7" dia. x 15 ft. 458

208 36-1/4 28-1/4 14-1/8 7 50-1/8 10-3/8 6-5/8 3/4 7 7" dia. x 15 ft. 514

209 39-1/2 31-1/2 15-3/4 8 52 11 7-1/4 3/4 7.7 8" dia. x 15 ft . 550

210 42-3/4 34-3/4 17-3/8 8 52 11 7-1/4 3/4 8.5 8" dia. x 15 ft. 608

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

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

Maximum Allowable Working Pressure - 30 PSI (Water Only)

[3] 202 only. Dimension 'G' includes allowance for 4" x 3" reducer furnished with boiler. See Figure 8.

SECTION I - INSTALLATION INSTRUCTIONS

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 short-

ages will be allowed by Boiler Manufacturer unless pre-

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

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.

When required by the authority having juris-

diction, the installation must conform to

ANSI/ASME No. CSD-1.

CANADA - "Installation Codes for Natural and LP Gas

Burning Appliances and Equipment, CAN/

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

from the Canadian Gas Association, 55 Scars-

dale Road, Don Mills, Ontario, Canada M3B

2R3.

3. 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.

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

the two wooden slats as runners.

6. Move boiler to permanent position.

7. PROVIDE CLEARANCE and AIR for COMBUS-

TION and VENTILATION.

A . CLEARANCES

1. ALL INSTALLATIONS - Practical service clearances

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

24" from the left side and front jacket panels is

recommended for servicing but may be reduced to

minimum shown in Figure 2. Subject to boiler and

system piping, left side clearance may be reduced to

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

2. ALCOVE INSTALLATIONS - An alcove is consid-

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

clearance may be reduced to 27".

3. UNCONFINED SPACE (see definition, Paragraph (B)

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

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.

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.

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

9. BOILER PIPING

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 radia-

tion 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 tempera-

ture.

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

Length

[Feet]

0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop

½¾ 11¼½¾ 11¼

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

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.

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 Instruc-

tions 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

WARNING

Safety relief valve discharge piping must

be piped near floor to eliminate potential

of severe burns. Do not pipe in any area

where freezing could occur. Do not install

any shut-off valves.

Table 2: Equivalent Length of Fittings Table 3: Specific Gravity Correction Factors

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

Figure 3: Boiler Piping

covered by Burnham's standard warranty.

There are many possible causes of oxygen contamina-

tion such as:

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

system leaks.

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.

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.

Fitting

Nominal Pipe Size

½¾ 11¼

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

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

0.70.931.70.94

0.75 0.9

0.8 0.87

Figure 4: Recommended Piping for Combination

Heating & Cooling (Refrigeration) Systems

Figure 5

the jacket side panel to secure the power cord to the

jacket.

H. Be sure the power cord, mounting bracket, and switch

are secure and located as shown in Figure 6.

Figure 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.

WARNING

Failure to properly install and use this

Blocked Vent Switch may result in property

damage, personal injury or loss of life.

NOTICE

Please refer to the specifications,

installation instructions and troubleshooting

guide packed in the vent damper carton for

complete detailed installation instructions.

Also refer to Figure 7 in this manual.

D. Install the 90° BX connector attached to the flexible

conduit in the 7/8" knockout on the left side of the

jacket. Plug the factory wired Vent Damper Harness

into the polarized receptacle. Install a cable clamp

around the flexible conduit and attach to the Jacket top

panel. (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.

14. IF AN EXISTING BOILER IS REMOVED -

When an existing boiler is removed from a common

venting system, the common venting system is likely to be too

large for proper venting of the appliances remaining to it.

At the time of removal of an existing boiler, the follow-

ing steps shall be followed with each appliance remaining

connected to the common venting system placed in operation,

while the other appliances remaining connected to the

common venting system are not in operation:

A. Seal any unused openings in the common venting

system.

B. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion, and other deficiencies

which could cause an unsafe condition.

C. Insofar as is practical, close all building doors and

windows and all doors between the space in which the

appliances remaining connected to the common venting

system are located and other spaces of the building.

Turn on clothes dryers and any appliance not connected

to the common venting system. Turn on any exhaust

fans, such as range-hoods and bathroom exhausts, so

they will operate at maximum speed. Do not operate a

summer exhaust fan. Close fireplace dampers.

D. Place in operation the appliance being inspected. Follow

the Lighting (or Operating) Instructions. Adjust

thermostat so appliance will operate continuously.

E. Test for spillage at the draft hood relief opening after 5

minutes of main burner operation. Use the flame of a

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

pipe.

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

ing connected to the common venting system properly

vents when tested as outlined above, return doors,

windows, exhaust fans, fireplace dampers and any other

gas burning appliance to their previous conditions of use.

G. Any improper operation of the common venting system

should be corrected so the installation conforms with the

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

resizing any portion of the common venting system, the

common venting system should be resized to approach

the minimum size as determined using the appropriate

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

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.

A. Vent installation shall be in accordance with local

building codes; or the local authority having jurisdic-

tion; or the National Fuel Gas Code, ANSI Z223.1/

NFPA 54; or the Standard for Chimneys, Fireplaces,

Vents, and Solid Fuel Burning Appliances, ANSI/NFPA

211. Both of the aforementioned standards, ANSI

Z223.1 and ANSI/NFPA 211, specify Type B and Type

L double wall metal vents and fire clay tile lined

masonry chimneys as suitable chimney constructions

for Category I, draft hood equipped appliances, such as

this Series 2 boiler. Both standards prohibit the use of

unlined masonry construction as a chimney, with the

exception in ANSI Z223.1/NFPA 54 that "Where

permitted by the authority having jurisdiction, existing

chimneys shall be permitted to have their use continued

when an appliance is replaced by an appliance of similar

type, input rating, and efficiency." ANSI/NFPA 211

prohibits the use of single wall metal vent as a chimney,

while ANSI Z223.1 allows it under very restrictive

conditions. In Canada refer to the Natural Gas Installa-

tion 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

Figure 7: Plug-in Damper Installation

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.

Table 4: Wiring Diagrams and Heat Anticipator Settings

16. INSTALL ELECTRIC WIRING in accordance with

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

Ignition Type Circulation Method

Thermostat Heat

Anticipator Setting [Amps]

Wiring Diagram

Figure Number Page Number

Continuous

(Standing Pilot)

Intermittent 0.6 11 13

Constant/Gravity 1.0 14 18

Intermittent

Intermittent 0.6 12 14

Constant/Gravity 1.0 13 16

If system tends to overheat above thermostat's temperature setting, reduce heat anticipator setting by 0.1

or 0.2 amps. If system tends to shortcycle without reaching desired room temperature, increase heat

anticipator setting by 0.1 or 0.2 amps.

A. The Vent Damper is continuously powered at Terminal

B. When there is a call for heat, the damper relay coil is

energized through Terminal 5 if all limits ahead of the

damper are satisfied.

C. The relay coil closes contacts which energize the

damper motor, causing the damper to open.

D. When the damper blade reaches the fully open posi-

tion, power is sent back to the ignition circuit through

Terminal 2 and the damper motor is de-energized.

E. When the call for heat is satisfied, the damper relay coil

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.

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

SEQUENCE OF OPERATION

NORMAL OPERATION

1. When the thermostat call for heat, the vent damper

will open (see paragraphs 17A through 17D). The

circulator is started through a relay and at the same

time the gas valve is energized allowing main gas flow

and ignition of main burners.

2. Where condensation of flue gas is encountered in

boiler flues a reverse acting circulator control should

be installed to stop the circulator before the boiler

water temperature drops to that which flue gas

condensation may occur.

3. After the thermostat is satisfied the main valve will

close and main burner flames will be extinguished.

The vent damper will close (see paragraph 17E).

SAFETY SHUTDOWN

1. High Limit Switch

In the event excessive boiler water temperature is

developed the high limit switch will open interrupting

power to the gas valve. The main burners will be

extinguished immediately, and the vent damper will

close at the same time, but the circulator will continue

to operated. Normal operation will be resumed when

the boiler water temperature drops to a point where

the high limit switch closes.

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

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing power to the gas valve. The main burners will be

extinguished immediately, the circulator will continue

to operate, and the vent damper will remain open until

the thermostat is turned off. The source of blockage

must be corrected by trained and skilled personnel

from a qualified service agency before resetting

switch.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame rollout switch

will open interrupting power to the gas valve. The

main burners will be extinguished immediately, the

circulator will continue to operate and the vent

damper will remain open until the thermostat is

turned off. If the flame rollout switch is activated do

not attempt to place the boiler in operation. The source

of blockage must be corrected and the flame rollout

switch replaced by trained and skilled personnel from

a qualified service agency.

4. Pilot

The thermocouple proves pilot flame and in the

absence of such within 45-90 seconds causes the

combination gas valve, which is equipped with a

100% shut-off provision, to be de-energized, thus,

preventing main gas or pilot gas flow.

Figure 12: Wiring Diagram, Intermittent Ignition and Intermittent Circulation

SEQUENCE OF OPERATION

NORMAL OPERATION

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.

2. The sensing circuit between the Q3450 or Q3480 pilot

and the GAS VALVE proves presence of pilot flame.*

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

the main valve, allowing main gas to flow and

ignition of main burners.

4. Where condensation of flue gas is encountered in

boiler flues, a REVERSE ACTING CIRCULATOR

CONTROL should be installed to stop the CIRCULA-

TOR before the boiler water temperature drops to that

at which flue gas condensation may occur.

5. The burners and CIRCULATOR will operate simulta-

neously until the THERMOSTAT is satisfied.

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).

SAFETY SHUTDOWN

1. High Limit Switch

In the event excessive boiler water temperature is

developed the High Limit Switch will open, interrupt-

ing power to the VENT DAMPER and the GAS

VALVE. Main Burners and Pilot Burner will be

extinguished immediately. Normal operation will be

resumed when the boiler water temperature drops to a

point where the High Limit Switch closes.

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing power to the 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.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame rollout switch

will open interrupting power to the VENT DAMPER

and the GAS VALVE. Main burners and pilot burner

will be extinguished immediately. The VENT

DAMPER will close and the CIRCULATOR will

continue to operate. If the flame rollout switch is

activated do not attempt to place the boiler in opera-

tion. The source of blockage must be corrected and the

flame rollout switch replaced by trained and skilled

personnel from a qualified service agency.

4. Pilot

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

close the main gas valve and energize the igniter.

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

valve coil loses power, closing the pilot valve.

5. For TROUBLE SHOOTING GUIDE, see Figure 28.

* · SV9500 and SV9600 Gas Valves:

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.

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

SEQUENCE OF OPERATION

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. 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.

5. The Burners will operate until the THERMOSTAT is

satisfied.

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).

SAFETY SHUTDOWN

1. High Limit Switch

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.

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing power to the ignition module and dual combina-

tion gas valve. Main burners and pilot burner will be

extinguished immediately and the vent damper will

close. The source of blockage must be corrected by

trained and skilled personnel from a qualified service

agency before resetting switch.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame rollout switch

will open interrupting power to the ignition module

and the dual combination gas valve. Main burners and

pilot burner will be extinguished immediately and the

vent damper will close. If the flame rollout switch is

activated do not attempt to place the boiler in opera-

tion. The source of blockage must be corrected and the

flame rollout switch replaced by trained and skilled

personnel from a qualified service agency.

4. Pilot

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

close the main gas valve and energize the igniter.

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

valve coil loses power, closing the pilot valve.

5. For TROUBLE SHOOTING GUIDE, see Figure 28.

* · SV9500 and SV9600 Gas Valves:

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.

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

SEQUENCE OF OPERATION

NORMAL OPERATION

1. When the thermostat call for heat, the vent damper

will open (see paragraphs 17A through 17D). The gas

valve is energized allowing main gas to 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.

2. Blocked Vent Switch

In the event excessive blockage in the vent system is

developed the blocked vent switch will open interrupt-

ing power to the gas valve. The main burners will be

extinguished immediately and the vent damper will

remain open until the thermostat is turned off. The

source of blockage must be corrected by trained and

skilled personnel from a qualified service agency

before resetting switch.

3. Flame Rollout Switch

In the event excessive blockage in the boiler section

flue passageways is developed the flame rollout switch

will open interrupting power to the gas valve. The

main burners will be extinguished immediately and

the vent damper will remain open until the thermostat

is turned off. If the flame rollout switch is activated do

not attempt to place the boiler in operation. The source

of the blockage must be corrected and the flame

rollout switch replaced by trained and skilled person-

nel from a qualified service agency.

4. Pilot

The thermocouple proves pilot flame and in the

absence of such within 45-90 seconds causes the

combination gas valve, which is equipped with a

100% shut-off provision, to be de-energized, thus,

preventing main gas or pilot gas flow.

Figure 15: Wiring Schematic, Zone Valves

Figure 16: Wiring Schematic, Zone Circulators

SECTION II - OPERATING INSTRUCTIONS

Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when

the boiler underwent tests specified in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers,

ANSI Z21.13b-1994.

1. MAIN BURNER CHECK - Check main burners to see

that they were not dislodged during shipment. Rear of burners

should be in the slots in the rear of burner tray and the front

of the burners should be seated completely on the orifices.

2. INITIAL START -

A. FILL ENTIRE HEATING SYSTEM WITH WATER

and vent air from system. Use the following procedure

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 18: Schematic Pilot and Gas Piping

Intermittent Ignition (HSP)

Figure 17: Schematic Pilot and Gas Piping

Continuous Ignition (Standing Pilot)

"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.

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Burnham 202 Installation & Service Instructions Manual

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Model: 202

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