Burnham Series 2B Installation & Service Instructions Manual

Burnham Series 2B Installation & Service Instructions Manual

Series 2 (model b) gas - fired boiler

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Price - $3.00

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Table of Contents
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Summary of Contents for Burnham Series 2B

  • Page 1 81417032R24-10/08 ® Price - $3.00...
  • Page 2: Table Of Contents

    The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Series 2B boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.
  • Page 3: Dimensions

    [2] Refer to the National Fuel Gas Code for equivalent areas of circular and rectangular flue linings. Maximum Allowable Working Pressure - 30 PSI (Water Only) [3] 202 only. Dimension 'G' includes allowance for 4" x 3" reducer furnished with boiler. See Figure 8. WARNING...
  • Page 4: Installation Instructions

    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.
  • Page 5 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.
  • Page 6 ½ psig (3.5kPa). 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...
  • Page 7 The minimum safe water level of a hot water boiler is just above the highest water containing cavity of the boiler; that is, a hot water boiler must be full of water to operate safely. Refer to Section vI for low water cut-off piping and wiring instructions.
  • Page 8 Problems caused by oxygen contamination of boiler water are not covered by Burnham's standard warranty. There are many possible causes of oxygen contamination such as: 1.
  • Page 9 Installation Instructions. READ ThE INSTALLA- TION INSTRUCTIONS ThOROUGhLY before proceeding. The automatic gas control valve supplied on each Series 2™ boiler provides the redundancy referenced in the vent damper Installation Instructions. CAUTION Do not use one vent damper to control two heating appliances.
  • Page 10 At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common...
  • Page 11 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.
  • Page 12 Figure : Vent Damper Schematic Wiring Diagram This boiler contains controls which may cause the boiler to shut down and not restart without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weath- er;...
  • Page 13 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.
  • Page 14 Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. 3. Flame Roll-out Switch: Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.
  • Page 15 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.
  • Page 16 Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. 3. Flame Roll-out Switch: Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.
  • Page 17: Wiring Schematic, Zone Valves/Circulators

    Figure 1: Wiring Schematic, Zone Valves Figure 1: Wiring Schematic, Zone Circulators...
  • Page 18: Operating Instructions

    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.
  • Page 19 Figure 1: Top View of VR Gas Valves Figure 0: Operating Instructions, VR0 and VR30 Gas Valves...
  • Page 20 CAUTION 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. INSTRUCTIONS TO PUT ThE BOILER IN OPERATION. A. See Figure 20 for electronic ignition (EI).
  • Page 21: Green Led Status Codes

    Table : Green LED Status Codes Green LED Flash Code Indicates (X + Y) No “Call for Heat” Startup - Flame sense Flash Fast calibration Heartbeat Normal operation 5 minute Retry Delay- Pilot flame not detected during trial for ignition Recycle- Flame failed during run Flame sensed out of...
  • Page 22 Figure : Lighting Instructions...
  • Page 23 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 valve installed in the 1/8"...
  • Page 24 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...
  • Page 25: Trouble Shooting

    III. Trouble Shooting Honeywell Electronic Ignition Troubleshooting Guide Figure : Troubleshooting Guide, Honeywell Electronic Ignition (EI)
  • Page 26: Service

    Inspection should be conducted annually. Service as frequently as specified in paragraphs below. While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be "off". CAUTION Label all wires prior to disconnection when servicing controls.
  • Page 27 4 & 5 6 & 7 7 & 8 8 & 9 9 & 10 * Main burners numbered left to right as viewed from front of boiler. Between Main Burners * 40mm 1 & 2 1 & 2 2 & 3 2 &...
  • Page 28 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 29: Repair Part

    V. Repair Parts Section Assembly and Canopy Group ...30 Base Assembly ...32 Manifold and Main Burners 1 Inch Main Burners ...34 40mm Main Burners ...36 Pilot Burner and Gas Valve Continuous Ignition (Standing Pilot) ...38 Electronic Ignition ...40 Jacket Assembly ...41 Water Trim ...44 Controls ...46 Draft Hood and Vent Damper ...47...
  • Page 30: Section Assembly And Canopy Group

    Description . Canopy Group Canopy Assembly (except for 206H) Canopy Assembly 206H Carriage Bolt, 1/4-20 x 1" Flat Washer, 1/4" Nut, Hex, 1/4-20 Cerafelt Sealing Strip, 1/2" x 1" x 10' Flue Gas Baffle (*Standing Pilot 1" Burners Only) (** LP Standing Pilot 1" Burners Only) (*** Standing Pilot Models Only) Part No.
  • Page 31 THIS PAGE LEFT INTENTIONALLY BLANK...
  • Page 32: Base Assembly

    Boiler Description Size 3. Base Assembly 202X Base Assembly (Complete) Available for 1 Inch Burners Only 202X Base Tray Base Assembly Part No. Qty. 3. Base Assembly Continued 618600291 618600391 618600391 618600491 618600591 618600691 618600791 618600891 618600991 618601091 718600291 718600391...
  • Page 33 Boiler Description Size 3. Base Assembly Continued 202X Base Front Panel Assembly 202X Burner Tray (1" Main Burners) 202X Burner Tray (40mm Main Burners) Part No. Qty. 3. Base Assembly Continued 618600241 618600341 618600341 618600441 618600541 618600641 618600741 618600841 618600941...
  • Page 34: Manifold And Main Burners 1 Inch Main Burners

    Manifold and Main Burners (1 Inch Main Burners)
  • Page 35 Description . Manifold and Main Burners (1 Inch Main Burners Only) Main Burner Main Burner with Pilot Bracket Manifold Main Burner Orifice Screw, Machine, Slotted Round Head, #10 -32 x 3/16" (Standing Pilot) Screw, Machine, Philips Head w/Captive Lockwasher, #10 -32 x 1/4" (Electronic Ignition) Screw, Self Tapping, Philips Pan Head, 1/4 - 20 x 1/2"...
  • Page 36: 40Mm Main Burners

    Description . 0 MM Main Burners Only Main Burner B. 0 MM Main Burner, Electronic Ignition Only Main Burner with 48° Pilot Bracket Main Burner with 41° Pilot Bracket B. 0 MM Main Burner, -volt Continuous Ignition (Standing Pilot) Natural Gas Only Main Burner with 48°...
  • Page 37: Electronic Ignition

    Description . 0 MM Main Burners Only (Continued) C. 0MM Main Burner Manifold Manifold D. 0 MM Main Burner, Natural Gas, 001-000 Ft. USA Only D. 0 MM Main Burner, LP Gas, 001-000 Ft. USA Only D. 0 MM Main Burner, Natural Gas, 001-000 Ft. USA Only D.
  • Page 38 * 1" Burner Only ** 0mm Burner Only Description . Pilot Burner and Gas Valve, -volt Continuous Ignition, Natural Gas (1 Inch and 0mm Main Burners) Pilot Burner, Honeywell Q350A1321 Pilot Burner, Honeywell Q327A1006 Pilot Orifice, Honeywell 390686-22 .012" Pilot Orifice, Honeywell 388146AG .026" Adptr, 1/4"OD x 1/4"...
  • Page 39 Description 5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, LP/Propane (1 Inch and 40mm Main Burners) Pilot Burner, Honeywell Q327A1147 Pilot Burner Assembly, Honeywell Q350A (Includes 5B & 5F) Pilot Orifice, Honeywell 388146KR (.014") Pilot Orifice, Honeywell 390686-23 (.008") Adptr, 1/4"OD x 1/4"...
  • Page 40 Description . Pilot Burner and Gas Valve, Electronic Ignition (EI), Natural Gas Pilot Burner, Honeywell Q348A1002 Pilot Orifice, Honeywell 388146NE Compression Nut/Fitting, 1/4" OD x 1/4 C.C. (Included with 5A and 5E) Pilot Tubing, 1/4" OD x 30" Pilot Tubing, 1/4" OD x 40" Gas Valve, Honeywell VR8204C3007 Gas Valve, Honeywell VR8304P4306 Igniter/Sensor Cable, 36", Honeywell 394800...
  • Page 41: Jacket Assembly

    Description . Jacket Assembly, Complete Jacket Assembly, Complete . Jacket Assembly Jacket Wrap-Around Panel Part No. 202 202X 203 204 205 206 207 208 209 210 604170254 604170354 604170454 604170554 604170654 604170754 604170854 604170954 604171054 604170215 604170315 604170415 604170515 604170615 604170715 604170815 604170915...
  • Page 43 Description . Jacket Assembly (Continued) Jacket Vestibule Panel Jacket Top Panel Jacket Front Removable Door Jacket Lower Front Panel Sheet Metal Screw, Type AB, Phillips Truss Head, #8 x 1/2" Snap Bushing, Heyco SB-1093-15 Snap Bushing, Heyco SB-437-5 Part No. 202 202X 203 204 205 206 207 208 209 210 604170223 604170323...
  • Page 44: Water Trim

    Water Trim...
  • Page 45 Description Safety Relief Valve, 30 psi, 3/4 NPT, Conbraco 10-408-05 Safety Relief Valve, 50 psi, 3/4 NPT, Conbraco 10-303-10 . Circulator, Bell & Gossett SLC-30 Option (Intermittent and Continuous Circulation Only) Circulator with Gaskets, Bell & Gossett NRF-22 Gasket, Bell & Gossett NRF-22 .
  • Page 46 Description 12. Transformer/Relay Assembly (Intermittent Circulation Only) Junction Box, 4" x 4" x 1-1/2" Transformer/Relay, Honeywell R8285D5001 Relay, Honeywell R8222U1006 1. Transformer (Continuous and Gravity Circulation Only) Junction Box, 4" x 4" x 1-1/2" Transformer, 40VA, Honeywell AT140D1012 or AT72D1188 13.
  • Page 47 Description 1. Draft Hood Carton Draft Hood 1. Vent Damper 4" 5" 6" 7" 8" 1. Vent Reducer Reducer, 4" x 3" Part No. 202 202X 203 204 205 206 207 208 209 210 8116067 8111702 8111703 8111704 8111705 8116321 8116322 8116323 8116324...
  • Page 48: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 49 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 50 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 51: Low Water Cut Off

    The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.
  • Page 52: Limited Warranty

    If the heat exchanger model involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the Burnham hydronics Repair parts price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.

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