Burnham Series 2B manual

81417032R24-10/08 Price - $3.00 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S 2 S E I R E S ® ) B l e d o m ( R E L I O B D E R I F - S A G , r e l i o b n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o b o t s r i a p e r r o e c i v r e[...]

2 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[...]

3 W ARNING READ THESE INSTRUCTIONS CAREFULL Y BEFORE PROCEEDING WITH THE INST ALLA TION OF BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE TECHNICIAN. MAINT AIN INSTRUCTIONS IN LEGIBLE CONDITION. Boiler Model Number Dimensions [Inches] Gas Connection For Automatic Gas V alve W ater Content [gallons] Recomme nded V ent Size [...]

4 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 led immediately against the carrier by the consignee. No cl[...]

5 e. For boiler located in a building of other than unusually tight construction , adequate combustion and ventilation air is normally provided by fresh air inltration 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 d[...]

6 A. Allowable loss of pressure to assure a burner manifold pressure of 3½" (8.9cm) water for natural gas. B. Supply of gas to be provided in cubic feet. C. Length of piping and number of ttings. D. Specic gravity of gas. E. Correction factor for specic gravity . 9. BOILER PIPING CAUTION Failure to properly pipe boiler may result in [...]

7 Figure 3: Recommended W ater Piping for Zone V alve Zoned Heating Systems Figure 4: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems W ARNING Safety relief valve discharge piping must be piped near oor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur . Do not install any[...]

8 Figure 6 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 . C. Position the mounting bracket (with switch attac[...]

9 W ARNING Failure to properly install and use this Blocked V ent Switch may result in property damage, personal injury or loss of life. 12 . TO MEET FEDERALLY MANDATED EFFICIENCIES, THIS BOILER MUST BE EQUIPPED WITH A VENT DAMPER. OPEN THE VENT DAMPER CAR TON and remove the Installation Instructions. READ THE INST ALLA- TION INSTRUCTIONS THOROUGHL[...]

10 DANGER Inspect existing chimney before installing boiler . Failure to clean or replace perforated pipe or tile lining will cause severe injury or death. A. V ent installation shall be in accordance with local building codes; or the local authority having jurisdiction; or the National Fuel Gas Code, ANSI Z223.1/NFP A 54; or the Standard for Chimn[...]

1 1 speed. Do not operate a summer exhaust fan. Close replace dampers. D. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate continuously . E. T est for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the ame of [...]

12 Figure 9: V ent Damper Schematic Wiring Diagram Heat Anticipator in Thermostat should be set to match the requirements of the control to which it is connected. See T able 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 reachin[...]

13 SEQUENCE OF OPERA TION 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 ow and ignition of main burners. 2. Where condensation of ue gas is encountered in boiler ue[...]

14 Figure 12: Wiring Diagram, Electronic Ignition (EI), Intermittent Circulation SEQUENCE OF OPERA TION NORMAL OPERA TION 1. When the thermostat calls for heat, the relay is energized. The circulator starts and the vent damper opens (see Paragraphs 17A through 17D). When the damper blade reaches the fully open position, the ignition module is energ[...]

15 Figure 13: Wiring Diagram, 24 V olt Standing Pilot with Continuous or Gravity Circulation SEQUENCE OF OPERA TION NORMAL OPERA TION 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 ow and operation of the main burners. 2. Where condensation of u[...]

16 Figure 14: Wiring Diagram, Electronic Ignition (EI), Continuous or Gravity Circulation SEQUENCE OF OPERA TION NORMAL OPERA TION 1. When the thermostat calls for heat the vent damper opens (see Paragraphs 17A through 17D). When the damper blade reaches the fully open position, the ignition module is energized opening the pilot valve and energizin[...]

17 Figure 15: Wiring Schematic, Zone V alves Figure 16: Wiring Schematic, Zone Circulators[...]

18 II. Operating Instructions 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 orices. 2. INITIAL ST AR T - A. FILL ENTIRE HEA TING SYSTEM WITH W A TER and vent air from s[...]

19 Figure 20: Operating Instructions, VR8204 and VR8304 Gas V alves Figure 19: T op View of VR Gas V alves[...]

20 e. Reconnect pilot tubing and check pipe and ttings from meter to combination Gas V alve for leaks using soap solution or other approved method. 2. Electronic Ignition Models (Sufx I): a. T urn "ON" electric switch serving boiler . b. Open Manual Shut-off V alve upstream of Combination Gas V alve. c. Loosen or remove Inlet Pressu[...]

21 T able 7: Green LED Status Codes Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None 2 5 minute Retry Delay- Pilot ame not detected during trial for ignition Initiate new trial for ig[...]

22 Figure 22: Lighting Instructions[...]

23 B. See Figure 22 for continuous ignition system (standing pilot). 4 . CHECK GAS INPUT RA TE T O BOILER NOTICE USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially oriced to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFP A 54/ANSI Z223.1,[...]

24 Figure 27: T ypical Pilot Flame, Honeywell Q348A The pilot produces a single ame. The ame should be steady , medium hard blue enveloping 3/8 to a 1/2 inch of thermocouple. 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 21[...]

25 Figure 28: T roubleshooting Guide, Honeywell Electronic Ignition (EI) III. T r ouble Shooting Honeywell Electronic Ignition T roubleshooting Guide[...]

26 IV . Service 1. Inspection should be conducted annually . Service as frequently as specied in paragraphs below . While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be "off". CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dan[...]

27 8. Hold burner at throat. Lift front of burner to clear orice. Burner which holds pilot can only be removed by lifting the burner adjacent to its right rst. Figure 30: Burner Cleaning and Installation 9. Brush top of burners with a soft bristle brush, see Figure 30. V acuum burners. Check orices to see that drilled passageways are free [...]

28 Important Produc t Safety Information Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a know[...]

29 V . Repair Parts Section Assembly and Canopy Group ............................30 Base Assembly ..................................................................32 Manifold and Main Burners 1 Inch Main Burners .................................................. 34 40mm Main Burners ..................................................36 Pilot Burne[...]

30 Section Assembly and Canopy Group Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 2. Canopy Group 2A Canopy Assembly (except for 206H) 61 1 17022 1 --- --- --- --- --- --- --- --- --- 61 1 170300 --- 1 --- --- --- --- --- --- --- --- 61 1 170302 --- --- 1 --- --- --- --- --- --- --- 61 1 170402 --- --- --- 1 --- --[...]

31 THIS P AGE LEFT INTENTIONALL Y BLANK[...]

32 Base Assembly Key No. Description Boiler Size Part No. Qty . 3. Base Assembly 3 Base Assembly (Complete) Available for 1 Inch Burners Only 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 3A Base T ray 202 718600291 1 202X 718600391 1 [...]

33 Key No. Description Boiler Size Part No. Qty . 3. Base Assembly Continued 3C Base Front Panel Assembly 202 618600241 1 202X 618600341 1 203 618600341 1 204 618600441 1 205 618600541 1 206 618600641 1 207 618600741 1 208 618600841 1 209 618600941 1 210 618601041 1 3D Burner T ray (1" Main Burners) 202 718600205 1 202X 718600305 1 203 7186003[...]

34 Manifold and Main Burners (1 Inch Main Burners)[...]

35 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 4. Manifold and Main Burners (1 Inch Main Burners Only) 4A Main Burner 8236099 1 2 2 4 6 8 1 1 13 15 17 4B Main Burner with Pilot Bracket ----- See T able Below 4C Manifold 82260023 1 --- --- --- --- --- --- --- --- --- 82260033 --- 1 1 --- --- --- --- --- --- --- 822[...]

36 Manifold and Main Burners (40mm Main Burners) Key No. Description Part No. Quantity 202X 203 204 205 206 207 208 209 210 4. 40 MM Main Burners Only 4A Main Burner 8236135 1 1 2 3 4 5 6 7 8 4B. 40 MM Main Burner , Electronic Ignition Only 4B Main Burner with 48° Pilot Bracket 8236143 --- --- --- --- --- --- --- --- --- Main Burner with 41° Pilo[...]

37 Key No. Description Part No. Quantity 202X 203 204 205 206 207 208 209 210 4. 40 MM Main Burners Only (Continued) 4C. 40MM Main Burner Manifold 4C Manifold 82260028 --- --- --- --- --- --- --- --- --- 82260038 1 1 --- --- --- --- --- --- --- 82260048 --- --- 1 --- --- --- --- --- --- 82260058 --- --- --- 1 --- --- --- --- --- 82260068 --- --- --[...]

38 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas V alve, 24-volt Continuous Ignition, Natural Gas (1 Inch and 40mm Main Burners) 5A Pilot Burner , Honeywell Q350A1321 8236065 1 1 1 1 1 1 *1 --- --- --- Pilot Burner , Honeywell Q327A1006 8236022 --- --- --- --- --- --- **1 1 1 1 5B Pilot Ori?[...]

39 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas V alve, 24-volt Continuous Ignition, LP/Propane (1 Inch and 40mm Main Burners) 5A Pilot Burner , Honeywell Q327A1 147 8236023 --- --- 1 1 1 1 1 1 1 1 Pilot Burner Assembly , Honeywell Q350A (Includes 5B & 5F) 8236105 1 1 --- --- --- --- ---[...]

40 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas V alve, Electronic Ignition (EI), Natural Gas 5A Pilot Burner , Honeywell Q348A1002 8236072 1 1 1 1 1 1 1 1 1 1 5B Pilot Orice, Honeywell 388146NE Included with 5A 1 1 11111111 5C Compression Nut/Fitting, 1/4" OD x 1/4 C.C. (Included wi[...]

41 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 6. Jacket Assembly , Complete 6 Jacket Assembly , Complete 604170254 1 --- --- --- --- --- --- --- --- --- 604170354 --- 1 1 --- --- --- --- --- --- --- 604170454 --- --- --- 1 --- --- --- --- --- --- 604170554 --- --- --- --- 1 --- --- --- --- --- 604170654 --- --- -[...]

42[...]

43 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 6. Jacket Assembly (Continued) 6B Jacket V estibule Panel 604170223 1 --- --- --- --- --- --- --- --- --- 604170323 --- 1 1 --- --- --- --- --- --- --- 604170423 --- --- --- 1 --- --- --- --- --- --- 604170523 --- --- --- --- 1 --- --- --- --- --- 604170623 --- --- --[...]

44 W ater T rim[...]

45 Key No. Description Part No. Quantity 7 Safety Relief V alve, 30 psi, 3/4 NPT , Conbraco 10-408-05 81660319 1 Safety Relief V alve, 50 psi, 3/4 NPT , Conbraco 10-303-10 101662-01 1 8. Circulator , Bell & Gossett SLC-30 Option (Intermittent and Continuous Circulation Only) 8A Circulator with Gaskets, Bell & Gossett NRF-22 8056174 1 8B Gas[...]

46 Key No. Description Part No. Quantity 12. T ransformer/Relay Assembly (Intermittent Circulation Only) 12A Junction Box, 4" x 4" x 1-1/2" 8136259 1 12B T ransformer/Relay , Honeywell R8285D5001 80160155U 1 12C Relay , Honeywell R8222U1006 80160096U 1 12. T ransformer (Continuous and Gravity Circulation Only) 12A Junction Box, 4&quo[...]

47 Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 16. Draft Hood Carton 16 Draft Hood 81 16067 1 1 1 --- --- --- --- --- --- --- 81 1 1702 --- --- --- 1 --- --- --- --- --- --- 81 1 1703 --- --- --- --- 1 1 --- --- --- --- 81 1 1704 --- --- --- --- --- --- 1 1 --- --- 81 1 1705 --- --- --- --- --- --- --- --- 1 1 17.[...]

48 SER VICE RECORD DA TE SERVICE PERFORMED[...]

49 SER VICE RECORD DA TE SERVICE PERFORMED[...]

50 SER VICE RECORD DA TE SERVICE PERFORMED[...]

51 A 24 V AC L WCO is used primarily for gas red boilers where a 24 volt control circuit exists within the boiler . However , a 24 V AC L WCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. How to T est Shut off fuel supply . Lower water level until water leve[...]

52 boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthorized modication, or is damaged as a result of being other[...]