Burnham SERIES 3 Installation, Operating And Service Instructions
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Burnham SERIES 3 Installation, Operating And Service Instructions

Series 3 gas-fired boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
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
3 _ _
Heating Contractor
Address
102998-01R1-7/10
SERIES 3™
Gas - Fired Boiler
Boiler Serial Number
9700609
Installation Date
Phone Number

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Summary of Contents for Burnham SERIES 3

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 3™ Gas - Fired Boiler 9700609 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.
  • Page 2 WARNINGS foR the hoMeoWNeR FOLLOW ALL INSTRUCTIONS and warnings outdoor temperatures are below 32°F, first turn off printed in this manual and posted on the boiler. your home’s main water supply and drain the water from all pipes. INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician DO NOT BLOCK AIR FLOW into or around the follow the Service checklist near the end of this...
  • Page 3 Congratulations on your purchase of a new Burnham boiler—designed and constructed to provide you ® with years of reliable service. • Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger. Ours is made proudly by our foundry in Zanesville, Ohio.

  • Page 4: Specifications

    SPECIFICATIONS Ratings Series 3 Input (MBH) DOE Heating Capacity (MBH) Net I=B=R Rating (MBH) AFUE (%) Boiler Model Electrical Requirements: 120VAC, 60 Hz, 1-ph, 15A Dimensions and Connections Boiler Supply NPT Return NPT Vent Gas NPT Relief Valve Drain Depth Width Height...
  • Page 5 SPeCIfICAtIoNS (continued) Figure S-1: Minimum Clearances to Combustibles and Closet Dimensions...

  • Page 6: Table Of Contents

    BOILER QUICk-START Installation: Unpack the crate ..................... 7 Position the boiler .................... 7 Provide combustion air ..................8 Connect venting ....................9 Connect gas piping ..................10 Connect boiler water piping ................10 Connect electrical wiring ................12 Program the controls ..................13 Check for gas and water leaks ..............

  • Page 7: Unpack The Crate

    1. UNPACk THE CRATE Tip the boiler and shimmy it off the skid. THE BOILER IS TOP-HEAVY. Do not allow it to tip over. Remove the sleeve. Remove the contents from the skid, except the boiler. Remove the four (4) hex-drive lag screws holding the boiler to the skid (Figure 1-a).

  • Page 8: Provide Combustion Air

    3. PROVIDE COMBUSTION AIR Like all fuel-burning appliances, boilers need air to INSUFFICIENT COMBUSTION AIR operate reliably and safely. SUPPLY may result in the production and release of deadly carbon monoxide (CO) into the Provide combustion air using the instructions in home which can cause severe personal injury or Appendix A—Combustion Air.

  • Page 9: Connect Venting

    . CONNECT VENTING built chimney as required by NFPA 54 IMPROPER VENTING may result in and applicable local codes for Category I property damage and the release of flue appliances. If venting this appliance into gases which contain deadly carbon monoxide (CO) a masonry chimney, the chimney must be into the home, which can cause severe personal lined with a listed chimney lining system as...

  • Page 10: Connect Gas Piping

    5. CONNECT GAS PIPING Size gas piping according to Appendix C – Gas nipples and street ells are not approved for Piping use as gas piping. SHUT OFF GAS SUPPLY before Pipe through the left jacket panel, and servicing the boiler. complete drip leg as shown (Figure 5-a).
  • Page 11 IQ Options. nipple into the water return tapping “R”. Screw the supplied drain valve into tapping “D”. Item Description Burnham Part Number 1¼ x 1¼ x ½ Tee 806601021 Immersion Well, ½ NPT 80160456 1¼ x 6 Nipple 806600029 1¼...

  • Page 12: Connect Electrical Wiring

    7. CONNECT ELECTRICAL WIRING DISCONNECT ELECTRICAL POWER to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock electrical boxes to prevent someone from inadvertently restoring power before the heating system is safe to operate. NEVER DEFEAT OR JUMP OUT safety devices.

  • Page 13: Program The Controls

    8. PROGRAM THE CONTROLS Using IQ Boiler Control Display Viewing the operating Mode options In operating mode the user may view (but not The IQ Boiler Control is located inside the boiler change) boiler operating status, settings and front door, just above the IQ Option Panel (Figure troubleshooting information.
  • Page 14 Press the Up ñ and Down ò keys to adjust Using the IQ option Panel the displayed setpoint to the desired value. IQ Option Cards are available from Burnham To return to the normal operating mode distributors and are the simplest way to add from the Adjustment Mode, when the "bAc”...

  • Page 15: Check For Gas And Water Leaks

    LCD Display Kit includes a mounting bracket and wiring harness to allow mounting in the Series 3 and adjust the IQ Boiler Control and connected plastic hood above the front door. For installation, IQ Option Cards.

  • Page 16: Perform Startup Checks And Adjustments

    10. PERFORM STARTUP CHECkS AND ADjUSTMENTS FAILURE TO PERFORM THESE CHECKS of the boiler's combustion and safety systems may result in serious property damage, injury, or death. IF YOU SMELL GAS, STOP and repair the leak. Lighting the boiler when gas is leaking may cause explosion or fire.

  • Page 17: Annual Maintenance Checklist

    ANNUAL MAINTENANCE CHECkLIST WARNINGS personal injury or death, and extensive property THE BOILER CONTAINS REFRACTORY damage. CERAMIC FIBER, a possible human carcinogen Use a NIOSH approved respirator when servicing TURN OFF ALL GAS AND ELECTRIC power high-temperature insulation and gasket materials. supplies to the boiler before servicing.

  • Page 18: Troubleshooting

    TROUBLESHOOTING When a problem occurs with the boiler operation, the Burnham IQ Control System easily provides specific, valuable information to help resolve the issue quickly. The display on the IQ Boiler control should be the first place to check. If "Err" IS Not displayed on the IQ Boiler Control: Use the following table to determine the problem and possible causes.
  • Page 19 tRoUBLeShootING (continued) "Err" IQ Boiler Control Status Codes (when is not displayed) - continued Display Status Boiler / Control Action(s) Damper Failed The damper end switch has not closed (damper end switch is open) at the beginning of Open the heat cycle. An alarm message is sent but the control is not in lockout. The damper end switch has not opened (damper end switch is closed) at the Damper Failed Closed...
  • Page 20 tRoUBLeShootING (continued) If IQ Boiler Control Shows Status Code “STA 15": The IQ Boiler Control is “Waiting for Limit to Close” and the display on the IQ Option Panel should be the first place to check. The IQ Option Panel display (lower display) will show one of the following status codes: IQ Option Panel Display Shows “ERR"...

  • Page 21: Repair Parts List

    REPAIR PARTS LIST [Quantity] Part Number Description Block Assembly 102287-03 102287-04 102287-05 102287-06 102287-07 102287-08 102287-09 Canopy Gasket Kit 6206001 Canopy Assembly 102554-03 102554-04 102554-05 102554-06 102554-07 102554-08 102554-09 Blocked Vent Switch 80160157 (not shown)
  • Page 22 RePAIR PARtS LISt (continued) [Quantity] Part Number Description Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 Base Tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091 Base Front Panel 71807035 71807045 71807055 71807065...
  • Page 23 RePAIR PARtS LISt (continued) [Quantity] Part Number Description Gas Valve (Natural Gas), 81660282 Honeywell VR8204P1171 Gas Valve (Natural Gas), 81660283 Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell 81660146 VR8204C3015 Gas Valve (LP Gas), Honeywell 81660160 VR8304P4314 ½" Gas Manifold 82207031 82207041 82207051 82207061 ¾"...
  • Page 24 RePAIR PARtS LISt (continued) [Quantity] Part Number Description IQ Boiler Control 102289-01 IQ Option Panel 102291-01 Transformer 102516-01 Temperature Sensor 102411-01...
  • Page 25 RePAIR PARtS LISt (continued) [Quantity] Part Number Description Jacket Left Side Panel 102566-01 Jacket Right Side Panel 102567-01 Jacket Rear Panel 102569-03 102569-04 102569-05 102569-06 102569-07 102569-08 102569-09 Jacket Vestibule Panel 102565-03 102565-04 102565-05 102565-06 102565-07 102565-08 102565-09 Jacket Top Panel 102568-03 102568-04 102568-05...
  • Page 26 RePAIR PARtS LISt (continued) [Quantity] Part Number Description Supply Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 Circulator Wiring Harness 6130701 30 PSI Relief Valve 81660363 Drain Valve 102802-01 Vent Damper 102284-01 102284-02 102284-03 102284-04 102284-05 Circulator (not shown): Taco 007-2 8056170 Grundfos UP-15 102805-01 B &...

  • Page 27: Internal Wiring

    INTERNAL WIRING Figure IW-1: Wiring Diagram...
  • Page 28 INteRNAL WIRING (continued) Figure IW-2: Wiring Schematic...
  • Page 29 INteRNAL WIRING (continued) Figure IW-3: Single Zone System with Domestic Hot Water Tank Figure IW-: Multiple Zone System with Zone Circulators...
  • Page 30 INteRNAL WIRING (continued) Figure IW-5: Multiple Zone System with Zone Valves Figure IW-6: Multiple Zone System with Zone Circulator Panel...
  • Page 31 INteRNAL WIRING (continued) DHW AQUASTAT (L4006, L4080) POWER (SUPPLIED BY OTHERS) SUPPLY 120/60/1 THERMOSTAT THERMOSTAT THERMOSTAT TRANSFORMER DOMESTIC HOT WATER PRIORITY IS SELECTED USING ZONE PANEL SWITCH MODE ZONE 4 PRIORITY NORMAL RESET IQ OPTION PANEL POWER IN ZONE 1 ZONE 2 ZONE 3 ZONE 4...

  • Page 32: Appendices: A - Combustion Air

    APPENDIX A – COMBUSTION AIR If the Floorspace from Step 1 is less than the PROVIDE ENOUGH AIR to ventilate the Minimum Floorspace from Step 3, then you boiler room, dilute the flue gases, and must provide outdoor air to the boiler room. sustain combustion.

  • Page 33: B - Venting

    APPeNDIX B – VeNtING VENT THIS BOILER according to the instructions. Failure to do so may cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Install this boiler according to this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA 54, the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
  • Page 34 APPeNDIX B – Venting (continued) être prises pour chaque appareil toujours Une fois qu’il a été déterminé, selon raccordé au système d’evacuation la méthode indiquée ci-dessus, que commun et qui fonctionne alors que chaque appareil raccordé au système d’autres appareils toujours raccordés au d’évacuation est mis à...
  • Page 35 APPENDIX B1 – AtMoSPheRIC VeNtING GeNeRAL WARNINGS foR AtMoSPheRIC VeNtING SYSteMS USE ATMOSPHERIC VENTING only with DO NOT REDUCE THE DIAMETER of the vent boilers approved for atmospheric venting as connector between the boiler and the chimney. noted in the Specifications Section of this It must not be smaller than the outlet on the manual.
  • Page 36 APPENDICE B1 – SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPHÈRE AVeRtISSeMeNtS GÉNÉRAUX PoUR LeS SYStÈMeS D’ÉVACUAtIoN DeS PRoDUItS De LA CoMBUStIoN DU GAZ DANS L’AtMoSPhÈRe N’ÉVACUEZ LES PRODUITS DE LA NE PAS RÉDUIRE LE DIAMÈTRE du conduit COMBUSTION DU GAZ DANS L’ATMOSPHÈRE d’évacuation des produits de la combustion du gaz que dans le cas de chaudières approuvées pour...

  • Page 37: C - Gas Piping

    APPENDIX C – GAS PIPING Table C-3: Specific Gravity Correction Factors For ASSURE GAS PIPING IS LEAK FREE Natural Gas AND OF PROPER SIZE and type for the connected load. Specific Correction Specific Correction Gravity Factor Gravity Factor SHUT OFF MAIN GAS SUPPLY prior to installing or servicing boiler gas piping.

  • Page 38: D - System Piping

    APPeNDIX C – Gas Piping (continued) When testing at ½ psig or less, isolate Bond all above-ground gas piping to a boiler from gas supply piping by closing grounding electrode and ensure the piping is boiler’s individual manual shut-off valve. electrically continuous.
  • Page 39 APPeNDIX D – System Piping (continued) Comply with the boiler’s specific or radiator. Also add a low-water water quality requirements. See the cutoff when required by local code Specifications Section of this manual. requirements. Comply with the boiler’s specific Thermal shock requirements for minimum water flow through the boiler, installing a system Do not over-pump.
  • Page 40 APPeNDIX D – System Piping (continued) Figure D-0: Piping Schematic Symbols...
  • Page 41 APPeNDIX D – System Piping (continued) Figure D-W1: Water Boiler, Series Loop Figure D-W2: Water Boiler, Two or More Zones...
  • Page 42 APPeNDIX D – System Piping (continued) Figure D-W3: Water Boiler, Tankless Coil, Two or More Zones Figure D-W: Water Boiler, Indirect Water Heater, Two or More Zones...
  • Page 43 APPeNDIX D – System Piping (continued) Figure D-W5: Water Boiler, Indirect Water Heater Figure D-W6: Multiple Water Boilers, Indirect Water Heater, Two or More Zones...

  • Page 44: E - Filling The System And Checking For Leaks

    APPENDIX E – FILLING THE SYSTEM AND CHECkING FOR LEAkS fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling. Close full port ball valve located between Open the zone valve or shut-off valve vertical hose bib and air scoop in boiler...

  • Page 45: F - Adjusting Gas Input Rate

    Then, turn “on” both gas valves reduce more than 0.3” w.c. Instead, contact and adjust the gas valve without pilot control. Burnham for an orifice replacement kit. Clock gas meter for at least two (2) If input is below 98% of Rating Label input, revolutions of the dial typically labeled ½...
  • Page 46 APPeNDIX f – Adjusting Gas Input Rate (continued) Table F-1: Gas Flow Rate in Cu. Ft. / Hr. Recheck Main Burner Flame. Size of Gas Meter Dial Return other gas-fired appliances to Seconds for Two previous condition of use. One-Half (2) Revolutions Cu.

  • Page 47: G - Checking Draft And Combustion

    APPENDIX G – CHECkING DRAFT AND COMBUSTION CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) After 5 minutes of main burner operation, Insofar as is practical, close all doors and test for spillage at the draft hood relief windows in the building. opening, using a lighted match, candle, Turn on all appliances not connected to the cigarette, etc.

  • Page 48: H - Iq Control System

    • Efficiently operates the entire boiler system to save energy. IQ Boiler Control: The heart of Burnham’s IQ Control System is the When the optional Outdoor Air Reset Card is IQ Boiler Control. The IQ Boiler Control replaces installed in the IQ Option Panel, the Operating...
  • Page 49 APPeNDIX h – IQ Control System (continued) IQ option Cards: A variety of IQ Option Cards are For example, if additional safety limits are required, available to enhance the features of select Manual or Automatic Reset Aquastat or a standard boiler. Low Water Cutoff IQ Option Cards.
  • Page 50 APPeNDIX h – IQ Control System (continued) IQ Display Kit: The LCD Display is an easy to use touch screen The LCD Display kit includes a mounting type display that allows a technician to monitor bracket and wiring harness to allow simple and adjust the IQ Boiler Control and connected IQ physical installation and “plug-in”...
  • Page 51 APPeNDIX h – IQ Control System (continued) stem Parts List Factory Mounted Components Burnham Part Item Description Number IQ Boiler Control, Vent Damper, 24 Vac Ignition Control, with Prepurge, Continuous Retry, 90 Second Ignition 102289-01 Trail, Aquastat Limit Control, 130-220 Deg F, 15 Deg F Adjustable Differential, Auto Reset, less Well, less Sensor, 120 Vac Circulator Control Relay IQ Option Panel with three slots “plug-in”...

  • Page 52: Warranty

    Boiler Company, Inc. with respect to any defect in a residential grade boiler, parts, ® date of original installation. In the event that any cast iron section of a Burnham or accessories and U.S. Boiler Company, Inc. shall have no express obligations, ™...

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