Draytek 2910 Network Router User Manual
Contents
1. m 8 8 581 002 6 5 2 1 SI lt LON SVD 1108 1108 LON ONILNNOW TIVA L fe canter e ae lt Table of Contents General Installation Requirements 4 Installation Instructions I II III IV u s saa aaa ZO Operating Instructions 13 APPENDIX VI Low Water Cut O1Tf 27 I General Installation Requirements 1 N A 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 BOILER INSTALLATION must conform to the requirements of the authority having jurisdiction or in absence of such requirements to a National Fuel Gas Code ANSI Z223 1 obtainable from the American Gas Association 1515 Wilson Blvd Arlington Rosslyn VA 22209 b When required by the authority having jurisdiction the installation must conform to American Soci2. ou nb s peey 310 NOILVINOYIO LN3LLINY3LN 0313 NOI 1VH3dO LIOA 72 STOULNOD ALVYVd3S 11145 SNILOOHS 3718 0841 903 TWO Ot 1V1SOWH3HI 3340 5 SVS 0 0 LYVLS 20 1 Ql LSUld 28 3108 HOLIMS aunss3ud 39V1433 IM 49 TVILN 3334316 Si 8 SVH 3ATVA IHL LYHL ONY 3ATWA SYD JHL O1 ONY 5 LOTH LYHL GAZINDOIIH NOLLINDI O NOH1L2373 302995 IHL AVH1 SLVIIQNI SYD S3A 61 39Vd NIVAN S30G 302988 O1 44494 ON SVO DNLLOOHS G3N34O ATIWNALOY SVH 3ATVA AHL LVH1 ONY 3ATVA SVO IHL OL FINGON NOILINSI SINOH12313 302985 IHL LYHL SALVSHINI SVD LOTid SAA LO Nd 300 61 3Dvd Alddfs SVO NYNL ONILOOHS FTENOUL 904986 01 61 39Vd OMLOOHS IBM HO 318 NOLLINDI HiVd3H 83438 NOLLINOI ONY NOLLIN I 302888 38001 HOY
3. 7109 AYTAY 30 5395 H108 51704 2 SHH 31ON HOLIMS HOMMS 3unssatid NO 0 TVNIWS31 19 SLIOA 2 NOHO SJA S3A H31N32 2 AYTAY 8 300 53 T SNVH1 NO TVNIWH31 NO TVNIWH31L NO AVI3H 390V1d34 LY SLTOA FZ HOY ON 1V SLTOA FZ ON MOE 1934409 Z ALON JUNIN HIMO 40 3ENVD 3NIWH313q LS Z ILON NO SAYTI AVTAU SNVYL LSH 24 2108 2 ILON NO YOLVINDUIO FOV Ids AVISOWNAHL SSOHOV SLTOA O11 HOd NOHO ON 3ZIOH3N3 XO f NI OY31 TYH103N ONY YILNI AY TU BOUENO JOULNOD NO s300 AVTSY SNVHL SOYFI i AION Z HOT NOSES 1TVNINH31 1V1SOWH3HL SSOHOW SLTOA 011 SIA SLIOA FZ 804 ON S3A 1eu Jamod siojo uuoo 9500 40 S HM 40 YOOYD Z ZT a8eg 8 ajqnosy sold
4. 3NHVdS 617302985 NO ON AMS 3HVd4S ONY NOILINOI SINTON 193NNO28IG NO 9a APZ TVNIWH3 L H LIAS iY SLIOA FZ LINJA OSH AWTS INUL GN0238 09 08 YILJY HOSNAS HOLIND 10718 HOLMS 8 NHYVdS SI NO ON SLIOA W HO3 NOFHD ON 21 22 CHECK PILOT FLAME Flame should be a blue medium hard flame enveloping approximately 3 8 of the end of the sensing probe see Figure 14 CHECK THERMOSTAT OPERATION Raise and lower thermostat setting as required to start and stop burners CHECK HIGH LIMIT CONTROL Allow boiler to operate until burners are shut down by limit control approximately 235 F If burners are not shut down by limit control determine cause of malfunction Replace control if necessary and check its operation CHECK IGNITION SYSTEM SAFETY SHUTOFF DEVICE Remove pilot ground lead from electrical junction block If burners are not shut down by module determine cause of malfunction Replace module or gas valve if necessary COMBINATION PROBE PRIMARY AIR OPENING IGNITION ELECTRODE SENSING 10 11 12 Figure 14 TYPICAL PILOT FLAME MAIN BURNER FLAMES should have a clearly defined inner cone see Figure 15 with no yellow tipping Orange yellow streaks caused by dust should not be confused with true yellow
5. SUPPLY CHECK OR BACK FLOW PREVENTION VALVE ZONE 1 BALANCING VALVE OR ZONE VALVE SUPPLY TO SYSTEM TO ADDITIONAL ZONES FOR MULTIPLE ZONE OR CIRCUIT OPERATION VALVE SYSTEM RETURN If it is required to perform a long term pressure test of the hydronic system the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler To perform a long term pressure test including the boiler ALL trapped air must first be removed from the boiler A loss of pressure during such a test with no visible water leakage is an indication that the boiler contained trapped air INSTALL BOILER FLUSH JACKET See Figure 9 a Open jacket carton and locate side panels Note that jacket left side panel is not insulated and right side panel is insulated b Position the rear flange on jacket left side panel behind the boiler back plate Position flange support notches over jacket support hooks on back panel and engage jacket on both support hooks to keep the panel from moving front to rear c Position rear flange on jacket right side panel behind upper and lower jacket support brackets Engage jacket with jacket support hooks in similar manner as left side panel to provide proper positioning and support d Take jacket top and bottom panel from carton Top panel can be identified by the front channel used to IPE SAFETY RELIEF VALVE DISCHARGE TO IN 4 OF FL
6. T C O FLAME ROLL OUT SWITCH i HIGH LIMIT 2M2 SWITCH SENSOR COIL o IGNITOR RELAY NC HHE FAN DIFFERENTIAL Ai PRESSURE N al IGNITION MODULE A GAS VALVE PV W LADDER DIAGRAM LEGEND O R8285D CONTROL CENTER TERMINAL 24V EXTERNAL WIRING C FAN RELAY TERMINAL 24V INTERNAL WIRING DJ S8670E IGNITION MODULE TERMINAL 120V EXTERNAL WIRING A GAS VALVE TERMINAL 120V INTERNAL WIRING Figure 12 LADDER WIRING DIAGRAM 16 SEQUENCE OF OPERATION 1 When the thermostat calls for heat relay coil 1M is energized closing two sets of NO contacts One set 1M2 energizes the 24 volt limit circuit and the other set 1 1 completes the 120 volt circulator circuit With the thermal cutout switch on the burner access panel the high limit switch and the suction pressure switch in their normally closed positions the fan relay coil 2M is energized closing two sets of NO contacts One set 2M1 completes the 120 volt fan circuit and the other set 2M2 energizes the 24V suction pressure check circuit With the fan operating the suction pressure switch closes its NO contacts The check circuit contacts 2M2 keep power on the fan relay 2M during the heating cycle When the suction pressure switch pro
7. furnished in system piping 10 e Ahot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation If a low water cut off is required it must be mounted in the system piping above the boiler 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 f 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 temperature may be encountered 1 converted gravity circulation system etc The bypass should be the same size as the supply and return lines with valves located in the by pass and supply outlet as illustrated in order to regulate water flow for maintenance of higher boiler water temperatures See Figure 6 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 SUPPLY THERMOMETER FLOW CONTROL VALVE AIR VENT AIR ELIMINATOR PRESSURE REDUCING OR MANUAL FILL VALVE SYSTEM SUPPLY SIDE CIRCULATOR PREFERRED LOCATION WATER
8. immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 25 V Repair Parts All Spacemaster 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 Burnham Customer Service at 717 481 8400 or Fax 717 481 8408 Any parts not listed can be ordered by description or part number on the item Part No 1 Gas Valve Honeywell VR8204C3007 81660145U 2 Ignition Module Honeywell S8670E1007 80160108 3 Differential Pressure Switch 60160880 4 High Limit Honeywell L4189B2012 80160460 4a Honeywell 45900409 003B Immersion Well 12 NP T 80160461 5 Circulator TACO 005 T1 8056054 6 Pilot Honeywell Q362A1037 8236068 7 Ignition Sensor Cable Honeywell 394799 36 8236085 8a Main Gas Burner with Pilot Bracket and Orifice AB24040 3 section 8236070 8b Main Gas Burner with Pilot Bracket and Orifice AB24042 4 section 8236074 9 Induced Draft Fan Replacement Assem
9. 16 Remove any obstructions Replace all deteriorated parts CLEANING BOILER FLUES See Figure 16 Flue passageways in the boiler sections should be checked annually for any blockage or accumulation of soot To obtain access to flueways a Remove jacket front panel b Remove sheet metal screws securing combustion area enclosure cover and remove cover Exercise care when removing to prevent damage to enclosure gasket c Remove fan assembly after disconnecting electrical leads and vent tube Care should be exercised to avoid damage to gaskets d Remove four 4 bolts securing canopy and remove canopy flueways are now exposed Using a flashlight examine all flue passageways If passageways are free of soot and obstruction replace canopy secure and seal using kit available from Burnham distributors e Replace fan connect vent tube and electrical wiring f Reinstall and secure enclosure cover and jacket front panel 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 boilers as illustrated in Figure 16 Replace canopy and seal BURNERS AND FIREBOX SHOULD BE CLEANED ANNUALLY a Remove jacket front panel b Remove sheet metal screws securing enclosure cover and remove cover exercising care with gasket c Remove TCO leads from TCO and remove burner access panel d Brush to
10. 24 from left side and front jacket panel is recommended for servicing In utility room installations the door must be wide enough to allow boiler to enter or to permit replacement of another appliance in this room VENTILATION AND COMBUSTION AIR Provide provisions for combustion and ventilation air in accordance with Section 5 3 Air for combustion and ventilation of the National Fuel Gas Code ANSI Z223 1 or applicable provisions of local building codes This boiler is equipped with a fan which produces an induced draft through the unit Combustion air is pulled in from outdoors and the flue gases are exhausted to the outdoors through the intake air vent system See Figure 4 a Combustion air is provided 100 from the outdoors Air is pulled in on all four sides of vent terminal cover through the air intake duct and to the combustion area enclosure The vent terminal must be mounted on a flat surface which is flush or protrudes outward from the exterior wall Avoid recesses niches or areas which might have reduced fresh air circulation b Ventilation When the boiler is installed in an unconfined space in a building of normal or unusually tight construction there is no additional provision required to insure adequate air for ventilation of the jacket or control compartment When the boiler is installed in a confined space two openings in a wall or door to an adjoining interior area which has adequate air supply sh
11. and the boiler Gas supply piping should be sized in accordance with Tables I II and III The following shall be taken into account a Allowable loss of pressure to assure a burner manifold pressure of 32 water Supply of gas to be provided in cubic feet Length of piping and number of fittings Specific gravity of gas Correction factor for specific gravity TABLE Maximum Piping in Cubic Feet of Gas Per Hour Based on a Pressure Drop of 0 3 Water and 0 6 Specific Gravity Nominal Iron Pipe Size Length in Feet 1 2 3 4 1 10 132 278 520 20 92 190 350 30 73 152 285 40 63 130 245 50 56 115 215 60 50 105 195 70 46 96 180 80 43 90 170 90 40 84 160 100 38 79 150 TABLE Il Maximum Capacity of Piping in Cubic Feet of Gas Per Hour Based on a Pressure Drop of 0 5 Water and 0 6 Specific Gravity Length in Nominal Iron Pipe Size FERI 1 2 3 4 1 10 175 360 680 20 120 250 465 30 97 200 375 40 82 170 320 50 73 151 285 60 66 138 260 70 61 125 240 80 57 118 220 90 53 110 205 100 50 103 195 125 44 93 175 150 40 84 160 175 37 77 145 NOTE For all practical purposes each 90 elbow can be considered as the following equivalent in length of straight pipe VY 1 6 ft 1 2 6 ft 347 211 TABLE Ill Multipliers to be used with Tables and Il for Specific Gravity Other Than 0 60 Specific Gravity Correction Factors 50 1 10 55 1 04 6
12. bottom panel up to bottom of side panels with front channel forward and ventilation louvers to the left Secure bottom panel with four 4 8 x long sheet metal screws provided f Install jacket removable door Hold door parallel with top of door slightly above flat top panel Insert door between side panels Lower door engaging top panel reverse bend and lower panel flange in the mating door flanges Door is now locked into position g Reverse procedure to remove door INSTALL 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 at 4 ELECTRIC WIRING INSTALLATION See Figures 11 and 12 for applicable wiring diagram A separate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions The circuit should be run to the junction box mounted on the front of the boiler back plate in the control compartment See Figure 1 and connected to the proper leads therein Wires from the low voltage thermostat should be run to terminals R and G on the transformer I
13. expiration of the one year limited warranty on residential grade water boilers all boiler components manufactured by others but furnished by U S Boiler Co Inc such as oil burner circulator and controls will be subject only to the manufacturer s warranty if any 3 Proper Installation The warranties extended by U S Boiler Co Inc are conditioned upon the installation of the residential grade water boiler in strict compliance with U S Boiler Co Inc installation instructions U S Boiler Co Inc specifically disclaims liability of any kind caused by or relating to improper installation 4 Proper Use and Maintenance The warranties extended by U S Boiler Co Inc conditioned upon the use of the residential grade water 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 modification or is damaged as a result of being otherwise improperly operated or serviced including but not limited to damage from any of the following operation with insufficient water allowing the boiler to freeze subjecting the boiler to flood conditions and operation with unapproved water or fuel additives which cause deposits or corrosion 5 Removal and Installation These warranties do not cover expenses of
14. location of heating supply and return lines gas supply line cold water piping and expansion tank in selecting boiler location d Exterior wall surface must be flat to ensure that wall flange can be mounted without being distorted and also provide a positive weather tight seal to prevent water damage If exterior wall surface is not flat i e uneven masonry stucco aluminum siding etc a flat surface must be provided of equal size or larger than the exterior wall flange and vent terminal cover e Locate the vent terminal in relation to adjacent public walkways adjacent buildings operable windows and buildings consistent with the National Fuel Gas Code Z223 1 Minimum clearance of 4 feet horizontally from and in no case above or below unless four 4 foot horizontal distance is maintained electric meters gas meters regulators and relay equipment At least 12 from any door window or other building opening A minimum of 12 above grade 7 from any overhang 18 from any side obstruction or wall and 3 away from any adjacent building Increase minimum height above grade to maintain adequate clearance above average snow fall for geographical area in which unit is installed If the unit is to be vented over a public walkway it must be at least 7 above grade If the vent terminal is to be within 10 of a building fresh air intake it must be at least 3 above the opening In addition avoid venting the unit in
15. pressure on manometer Should be 0 6 we or greater example 0 7 we d Stop boiler remove manometer and reconnect black silicone tubing to duct CHECK GAS INPUT RATE TO BOILER 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 Water manometer or water column gauge should be connected to a shutoff valve installed in the 1 8 pipe tapping in the gas valve boiler off By installing gas valve up stream of manometer gas pressure can be introduced gradually without shutoff valve 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 Approximate input Adjust pressure regulator on combination gas control so that manifold pressure is equal to that shown on rating label Determine what CONNECTOR TO FAN CONNECTING DUCT flow cu ft should be in 3 minutes using formula below cu ft per Btuh Input from Rating Label 3 min 20000 Clock gas meter for three 3 minutes using second hand or stop watch For minor input changes readjust pressure regulator on combination gas control Increase or decrease manifold pressure to obtain corresponding increase
16. tipping CHECK LWCO OPERATION 1 so equipped Drain boiler water below LWCO set point Burners should shutdown If burners do not shut down determine cause of malfunction and repair WARNING BEFORE INSTALLATION OF THE BOILER IS CONSIDERED COMPLETE THE OPERATION OF THE BOILER CONTROLS SHOULD ALL BE CHECKED PARTICULARLY THE WATER CUT OFF AND THE HIGH LIMIT CONTROL PILOT FLAME oO 8 GROUND STRAP INCANDESCENT OUTER MANTEL _ OUTER DARKER BLUE INNER CONE Figure 15 MAIN BURNER FLAME BLUE BURNER BLADE INNER CONE UNBURNED MIXTURE IV Service GENERAL 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 Wiring errors can cause improper and dangerous operation Verify proper operation after servicing VENT SYSTEM Vent system see Figure 4 for typical 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 attachment of vent cap and sealant around wall penetration e Remove vent cap and clean accumulations of soot and dirt with wire brush and vacuum See Figure
17. venting clearances of 1 minimum top clearance of 6 minium system front clearance of 2 minimum rear and flue system b Visually inspect the venting system for proper clearances of 0 and minimum floor clearance of 6 size and horizontal pitch and determine there is no between boiler surfaces and any combustible materials blockage or restriction leakage corrosion and other See Figure 3 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 Boiler must also be positioned to provide minimum clearances between edge of vent terminal and exterior obstructions Provide minimum overhang clearance of 7 minimum above grade clearance of 12 and minimum side obstruction clearance of 18 See Figure 2 In all cases clearance between boiler jacket and vent system surfaces and combustible materials must comply with the National Fuel Gas Code ANSI 2223 1 and local jurisdictions 2 Place in operation the appliance being inspected Follow the light
18. 0 1 00 65 96 70 93 Installation Instructions DETERMINE BEST MOUNTING LOCATION for boiler which meets site requirements outlined in Section L pages 4 through 6 1 INSTALLING BOILER MOUNTING WALL BRACKET See Figure 5 a Locate wall bracket packed in miscellaneous parts carton Hold wall bracket in desired location On studded walls mounting bracket must be secured directly to main vertical support studs Interior wall coverings such as paneling plaster and drywall are not suitable to support the unit s weight Place a 24 level across top corners adjust wall bracket until level Using the wall bracket as a template mark the eight 8 securing holes along the sides and the 442 x 5 rectangular opening at the top Remove wall bracket from wall NOTE The boiler mounting wall bracket is suitable for two main methods of wall construction Masonry built walls and stud framed walls where the main vertical support studs are on 16 centers or alternately where adequate supports are added between existing studs Drill eight 8 pilot holes properly sized for the fastener determined suitable for the type of wall construction in the area where the boiler is to be mounted 1 e lag screw for wood machine screw with toggle for cinder block etc Before cutting rectangular opening on interior wall use a straight edge to draw an X inside the box using the four 4 corners Drill a h
19. CO and the boiler to allow for servicing This will allow probe removal for inspection without draining the heating system Many probe LWCO manufacturers recommend an annual inspection of the probe How to Wire LWCO s are available in either 120 VAC or 24 VAC configurations The 120 VAC configuration can be universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler after the service switch if so equipped The presence of water in a properly installed LWCO will cause the normally open contact of the LWCO to close thus providing continuity of the 120 VAC service to the boiler It is recommended to supply power to the probe LWCO with the same line voltage boiler service as shown below LINE VOLTAGE Wiring of Typical LWCO A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler However a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application How to Test Shut off fuel supply Lower water level until water level is BELOW the LWCO Generate a boiler demand by turning up thermostat Boiler should not attempt to operate Increase the water level by filling the system The boiler should attempt to operate once the water level is above the LWCO 27 Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS Subject to the terms and co
20. D WITH A HONEYWELL VR8204 OR VR8304 GAS VALVE PLEASE FOLLOW THESE OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand 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 will settle on the floor WHAT TO DO IF YOU SMELL GAS gt Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life gt If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety informati
21. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR SPACEMASTER DIRECT VENT NATURAL GAS FIRED BOILER 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 Heating Contractor Phone Number Address 8140312R13 6 06 Price 3 00 IMPORTANT INFORMATION PLEASE READ THIS PAGE CAREFULLY This boiler has a limited warranty a copy of which is Post instructions near boiler for reference by owner and printed on the back page of this manual serviceman All heating systems should be designed by competent Maintain instructions in legible condition contractors and only persons knowledgeable in the layout and installation of hydronic heating systems WARNING should attempt installation of any boiler wan Ee When an existing boiler is removed from a This 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 common venting system the common venting system is likely to be too large for proper venting of the appliances remaining connected to it Boiler should be positioned to provide minimum side a Seal any unused openings in the common
22. OOR OR TO DRAIN FRONT OF BOILER DRAIN VALVE SYSTEM RETURN ON SINGLE CIRCUIT APPLICATIONS SIDE CIRCULATOR BALANCING VALVES AND ZONE VALVES ALTERNATE LOCATION ARE NOT NEEDED ON MULTIPLE CIRCUITS SHUT OFF Figure 6 WITHOUT ZONE VALVES A BALANCING VALVE SHOULD BE USED WITH EACH ZONE IF ZONE VALVES ARE NOT USED INSTALL FLOW CONTROL VALVE IF BOILER IS CONNECTED TO INDIRECT WATER HEATER RECOMMENDED BOILER PIPING K a WATER _ CHILLER HEATING SHUT OFF BOILER SHUT OFF J N VALVES VALVES N by Q 5 F z AIR CUSHION TANK CIRCULATOR SUPPLY MAIN RETURN MAIN COMBINED HEATING COMBINED HEATING amp COOLING SYSTEM amp COOLING SYSTEM Figure 7 RECOMMENDED PIPING FOR COMBINATION HEATING amp COOLING REFRIGERATION SYSTEMS 8 SHEET METAL JACKET TOP PANEL SCREW TYPICAL JACKET SUPPORT HOOKS AT FOUR CORNERS OF BACK PLATE 4 RIGHT V N Z SIDE PANEL SIDE VIEW ENLARGED JACKET LEFT SIDE PANEL FRONT REMOVABLE DOOR JACKET PANEL Figure 9 EXPLODED JACKET ASSEMBLY 11 12 support the removable door See Figure 9 Place Jacket top panel over top side panels with ventilation louvers to the left Secure top panel with four 4 8 x 1 2 long sheet metal screws provided e Lift jacket
23. Y INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the owner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler although failure to comply with this request will void the owner s rights under these warranties Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the owner should write to U S Boiler Co Inc Burnham Hydronics at P O Box 3079 Lancaster PA 17604 giving full particulars in support of the claim The owner is required to make available for inspection by U S Boiler Co Inc or its representative the parts claimed to be defective and if requested by U S Boiler Co Inc to ship these parts prepaid to U S Boiler Co Inc at the above
24. above its setting the TCO switch will open to de energize the ignition module and fan relay coil 2M causing the gas valves to close and the fan to stop The circulator will continue to operate as long as the thermostat is calling for heat Since the TCO switch is a one time fusible link the reason for over heating must be determined and the switch replaced in order for the boiler to function again In the event the fan is inoperative or fails to provide sufficient air flow the suction pressure switch connected at the inlet of the fan will not activate the NO contacts will not close the ignition module will not be energized and hence the gas valves cannot be opened 12 If the contacts in the suction pressure switch were to weld together during the heating cycle COM to NO the ignition module could not be energized on the next call for heat due to the fact the fan relay coil 2M could not be energized through either the suction pressure switch or the now open check circuit contacts 17 TROUBLE SHOOTING 18 Use the Trouble Shooting Guide pages 19 to 21 to assist in locating where malfunction in the control system is occurring PROCEDURE FOR MEASURING FAN DIFFERENTIAL PRESSURE See Figure 13 a With boiler off remove black silicone tubing from low side of pressure switch b With tee and 14 aluminum stubs connect manometer as shown with additional tubing c Start boiler and read differential
25. address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Burnham Hydronics 03 03
26. all be provided One opening should be near the floor and the other near the ceiling Each shall have a free area of not less than one 1 square inch for each thousand 1000 BTU input to all appliances in the boiler room See Figure 3 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 1 2 control assembly connection especially if run from meter is long or includes several elbows This piping is to be supplied by the installer and must include a trap a ground joint union and a manual shut off 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 must be isolated from the gas supply piping system by closing the manual shut off during any pressure testing at pressures equal to or less than 1 2 psig The boiler and shut off valve must be disconnected from the gas supply piping system during any pressure testing at pressures greater than 1 2 psig RECOMMENDED SIZING OF GAS SUPPLY PIPING TO BOILER shall be such as to provide the required supply of gas without undue loss of pressure between meter
27. assembly gasket first orifice plate second and remaining gasket last See Figures 4 and 5 e Insert the vent tube flange first through the intake air duct and secure to fan outlet flange with four 4 14 flat washers 14 lock washers and 47 20 brass hex nuts provided f Position vent terminal cover over exterior intake air duct Insert end of vent tube into collar on rear of vent terminal cover Align four 4 holes on cover with 1 2 long threaded aluminum spacers Secure vent terminal cover with four 4 10 32 x 4 long stainless steel machine screws provided DO NOT REPLACE ENCLOSURE COVER until boiler piping is completed and system is filled vented and checked for water leaks 6 CONNECT SUPPLY AND RETURN PIPING TO heating system 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 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 b
28. bly Includes Fan 8116055 6110303 Canopy Outlet Gasket Fan Inlet Gasket and two 2 Fan Outlet Gaskets 10 Fan Inlet Casting 8116056 11 Temperature Pressure Gauge 8056235 12a Lower Circulator Return Piping Assembly 3 section 8060301 12b Lower Circulator Return Piping Assembly 4 section 8060305 13a Supply Piping Assembly 3 section 8060302 13b Supply Piping Assembly 4 section 8060304 14 Upper Circulator Return Piping Assembly 8060303 15 Enclosure Gasket 8200301 16 Canopy Outlet Gasket 8206034 17 Fan Inlet Gasket 8206011 18 Fan Outlet Orifice Plate Gasket 2 required 8200306 19 Transformer Relay Combination Honeywell R8285D5001 80160156U 20 Relay Honeywell R8222U1006 80160096U 21 Misc Parts Carton 5 to 9 thick walls 6050301 22 Misc Parts Carton 9 to 15 thick walls 6050302 23 Vent Tube 2 O D x 24 Lg 8110301 24 Vent Tube Mounting Flange 7110311 25a Orifice Plate 3 section 61103036 25b Orifice Plate 4 section 61103046 26 Air Inlet Duct Gasket 8200307 27 Flame Roll Out Switch 80160044 WARNING The Honeywell 58670 Ignition Module incorporates a prepurge feature that is necessary for the safe operation of this boiler Do not substitute any other Ignition Module 26 Low Water Cut Off LWCO WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut LWCO Only use connections specifically identified for Low Water Cut Off In all cases follow t
29. corners niches or areas which might have reduced fresh air circulation See Figure 2 ik SIDE OBSTRUCTION TOP OBSTRUCTION 2 BOTTOM OBSTRUCTION Figure 2 f If boiler is to be installed above the level of the radiation a low water cutoff must be installed PROVIDE CLEARANCE between boiler jacket mounting bracket and vent system and combustible material in accordance with local fire ordinance VENT TERMINAL OUTSIDE MIN SEE NOTE 4 TOP VIEW M OF 24 FROM LEFT 15 CLOSET j WALL BOILER N ies I OUTLINE I Zee 2 Z SEE NOTE 3 2 l 3 FLOOR 6 l 8 Rs 31 FRONT VIEW RIGHT SIDE VIEW Figure 3 A minimum of 24 from left side and front jacket panel is recommended for servicing MINIMUM CLEARANCE TO COMBUSTIBLE SURFACES Minimum listed clearances from combustible materials for non closet installation or closet installation See Figure 3 Top 6 Left Side 1 Rear 0 Right Side 1 Front 2 Flue 0 Floor 6 Since the above dimensions are measured between boiler jacket and combustible walls or ceiling practical service clearances for all external adjoining equipment must be considered see Figure 1 A minimum of
30. duct forward until duct and weld studs are engaged through 4 x 5 rectangular opening and holes in back plate Make sure gasket is in place and flat against back plate Attach duct with four 4 7 20 brass hex nuts lockwashers and flat washers INSTALLING EXTERIOR TELESCOPING INTAKE AIR DUCT See Figures 4 and 5 a Position the exterior telescoping intake air duct into wall penetration and insert duct inside interior duct already in place Push duct inward until wall flange is against the wall check for level and mark the four 4 4 diameter clearance holes for securing wall flange to exterior wall Remove duct from wall VENT TERMINAL TELESCOPING INTAKE AIR DUCT EXTERIOR HALF BOILER MOUNTING WALL BRACKET LOWER JACKET MOUNTING BRACKET FASTENER REQUIREMENTS 1 8 SHEET METAL SCREW 2 10 32 ST STEEL MACHINE SCREW _ 3 10 32 X 1 2 ALUMINUM SPACER 4 1 47 20 HEAD CAP SCREW 5 1 4 FLAT WASHER 6 1 4 20 BRASS NUT 7 1 4 LOCKWASHER _ 8 SUITABLE FOR WALL CONSTRUCTION 9 SUITABLE FOR WALL CONSTRUCTION NON CORROSIVE NOT FURNISHED BY MANUFACTURER Figure 5 EXPLODED BOILER ASSEMBLY b Drill four 4 pilot holes properly sized for the non corrosive fasteners stainless steel brass or aluminum to be used to secure the wall flange to wall Attach four 4 1 2 long threaded aluminum spacers to the outer flanges of the ext
31. e 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 a For heating only see Figure 6 Consult I B R Installation Guides Clearance between hot water pipes and combustible material must not be less than 1 2 b If this boiler is used in connection with refrigeration systems the boiler must be installed so that the chilled medium is piped parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler see Figure 7 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 c Pipe safety relief valve to suitable drain CAUTION Safety relief valve should be piped to an open drain full size of discharge outlet on relief valve without any provision of shut off between the relief valve and discharge into drain d Install diaphragm type expansion tank not
32. earings are factory sealed VENT TUBE VENT TERMINAL INTAKE DUCT ASSEMBLY CAST IRON SECTION ASSEMBLY BASE ASSEMBLY WIRE FLUE BRUSH Figure 16 CLEANING OF VENT SYSTEM BOILER FLUES AND BURNERS Warning This product contains refractory ceramic fibers has been classified as a possible human carcinogen After this product is fired RCF may when exposed to extremely high temperature gt 1800F change into a known human carcinogen When disturbed as a result of servicing or repair RCF becomes airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace previously fired RCF combustion chamber insulation target walls canopy gasket flue cover gasket etc or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an air tight plastic bag First Aid Procedures e If contact with eyes Flush with water for at least 15 minutes Seek
33. erior telescoping intake air duct wall flange with four 4 10 32 x long stainless steel machine screws provided See Figure 5 d Apply 4 thick continuous bead of silicone rubber type caulking to the rear of the exterior telescoping intake air duct wall flange approximately 1 from duct e Re install exterior telescoping intake air duct and secure to wall NOTE Non corrosive stainless steel brass or aluminum fasteners must be used f Apply a bead of silicone rubber caulking to perimeter of wall flange where the wall and flange join Use a tool or your finger and apply pressure while smoothing caulking to provide a weather tight seal INSTALLING VENT TUBE ORIFICE PLATE AND VENT TERMINAL COVER See Figures 4 and 5 a The vent tube furnished has a standard length of 24 This length is suitable for a wall thickness from 5 to 15 b To determine the proper length required place a 24 level horizontally across the exterior wall flange just below the aluminum spacers measure the distance between the outlet flange on the fan and the level Add 1 to this measurement for the total length of the vent tube c Measuring from the flange end of the vent tube mark the total length required Cut off and discard the remaining piece d IMPORTANT Before connecting vent tube to fan install the orifice plate and two 2 cerafibre gaskets on the fan outlet flange weld studs in the proper order of
34. ety of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired boilers No CSD 1 c The boiler must be electrically grounded in accordance with requirements of the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA No 70 THESE GAS BOILERS ARE DESIGN CERTIFIED FOR INSTALLATION on an exterior wall of buildings constructed with combustible materials wood framed walls with paneling drywall plaster etc or masonry walls brick stone stucco or cinder block DO NOT INSTALL ON CARPETING These gas boilers may be installed above carpeted areas Note Protect carpeting or flooring to avoid possible damage during installation and maintenance procedures BOILER LOCATION MUST MEET THE FOLLOWING SITE REQUIREMENTS a The boiler must be mounted on a flat wall sufficiently strong enough to carry the weight of the unit See Figure 1 Minimum acceptable wall construction would consist of 2 x 4 studding on 24 centers Unit is designed for installation on 16 centers Therefore adequate supports must be added between existing studding b Asuggested mounting height where practical is five feet six inches from floor to center line of intake air duct opening See Figure 1 NOTE depending on ceiling height 6 combustible clearance height from jacket top panel to ceiling must be maintained See Figure 3 c Consider
35. excessive temperatures TURN GAS SUPPLY ON PILOT BURNER LIGHTS YES Check that all manual gas cocks are open supply tubing and pressures are good and pilot burner orifice is not blocked Check electrical connections between module and pilot operator on gas control Check for 24 Vac across amp PV terminals on module if voltage is okay re place gas control if no voltage replace Ignition Module NOTE If Ignition module goes into lockout reset system Check continuity of ignition cable and ground wire Clean flame Check electrical connections between flame rod and medule Check for cracked ceramic flame rod insulator Check that pilot flame covers flame rod and is steady and blue Adjust pilot flame If checks are okay replace Ignition Module SPARK STOPS WHEN PILOT IS LIT YES Check for 24 nominal across amp terminats if no voltage replace tgnition Module Check electrical connections between Ignition module and gas control If okay replace gas control or gas control operator MAIN BURNER LIGHTS YES NOTE If ignition module goes into lockout five or six minutes after lockout the ignition moduie starts the ignition sequence automatically Check continuity of ignition cable and ground wire SYSTEM RUNS UNTIL CALL FOR HEAT ENDS YES NOTE If ground is poor or erratic shutdowns may occ
36. he Low Water Cut manufacturer s instructions When A low water cutoff is required to protect a hot water boiler when any connected heat distributor radiation is installed below the top of the hot water boiler i e baseboard on the same floor level as the boiler In addition some jurisdictions require the use of a LWCO with a hot water boiler Where The universal location for a LWCO on both gas and oil hot water boilers is above the boiler in either the supply or return piping 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 What Kind Typically in residential applications a probe type LWCO is used instead of a float type due to their relative costs and the simplicity of piping for a probe LWCO How to Pipe A tee is commonly used to connect the probe LWCO to the supply or return piping as shown below SYSTEM SYSTEM SUPPLY RETURN MINIMUM SAFE WATER LINE LWCO Location Select the appropriate size tee using the LWCO manufacturer s Instructions Often the branch connection must have a minimum diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee Ideally manual shutoff valves should be located above the LW
37. ing instructions Adjust thermostat so appliance will operate continuously Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids e Test for spillage at the draft hood relief opening after Do not place any obstruction in the boiler room that 5 minutes of main burner operation Use the flame will hinder the flow of ventilating air of a match or candle or smoke from a cigarette Boiler must be installed with the vent intake air system cigar or pipe supplied as part of the unit without alteration f After it has been determined that each appliance The wall thickness through which the unit may be remaining connected to the common venting system installed must not exceed a minimum of 5 or a properly vents when tested as outlined above return maximum of 15 doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous a Misc Parts Carton Part No 6050301 D conditions of use 5 to 9 thick walls Standard b Misc Parts Carton Part No 6050302 8 9 to 15 thick walls Optional 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 Any improper operation of the common venting system should be corrected so the installation conforms with the Na
38. l the regulator on the gas valve will permit full flow through the main gas valve high fire Should a loss of flame occur the main valve closes and the spark reoccurs within 0 8 second The ignition module has an internal 100 lockout function to completely shutdown the system should the pilot gas fail to ignite with approx 90 seconds Five to six minutes after shutdown the Ignition Module restarts the ignition sequence The ignition trial shutdown and wait sequence continues until either the pilot lights or the Thermostat is set below room temperature to end the call for heat The ignition sequence can be reset by setting down the Thermostat for one minute Burners circulator and fan will continue to operate until the thermostat is satisfied If the high limit setting is reached before the thermostat is satisfied the switch in the high limit will open to de energize the ignition module and fan relay coil 2M causing the gas valves to close and the fan to stop The circulator will continue to operate as long as the thermostat is calling for heat When the boiler water temperature drops to a point where the high limit switch closes the fan will restart via 2M and the ignition module will be energized to repeat the sequence in Steps 4 through 7 above 10 If for any reason such as flame roll out into the 1 vestibule the thermal cutoff switch located on the burner access panel is subjected to temperatures
39. ndard telescoping intake air duct part No 6110301 is for wall thickness from 5 to 9 NOTE 2 Optional telescoping intake air duct part No 6110302 is for wall thickness from 9 to 15 Insert interior half of duct into rectangular opening and push it all the way back against wall plate Place 6 x 7 rectangular gasket on interior duct flange and weld studs Remove boiler from packaging 1 Remove surrounding packaging material from boiler and skid 2 Remove screws holding enclosure cover 3 Remove enclosure cover 4 Locate and remove two 2 lag screws which secure back plate of boiler to skid One is located in the upper left corner of the controls area and the second one is located in the lower right corner under the gas burner 5 Remove boiler from skid and set unit upright on floor in front of installation site NOTE On the back plate of the boiler is Z bracket approximately 10 long When the boiler is lifted into place this bracket must be lowered into the 1 2 wide x 11 long slot at the top of the boiler mounting wall bracket See Figures 4 and 5 Attach upper RS jacket mounting bracket to the upper corner of back plate Loosen the two 2 corner screws position bracket with flange facing forward and engage slots over screws Re tighten screws to secure bracket IMPORTANT Bracket must be installed before lifting boiler into position Lift boiler
40. nditions set forth below U S Boiler Co Inc Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1 1991 ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS U S Boiler Co Inc warrants to the original owner that its residential grade water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation If any part of a water boiler is found to be defective in material or workmanship during this one year period U S Boiler Co Inc will at its option repair or replace the defective part LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER U S Boiler Co Inc warrants to the original owner that the heat exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation If a claim is made under this warranty during the first ten years from the date of original installation U S Boiler Co Inc will at its option repair or replace the heat exchanger If a claim is made under this warranty after the expiration of ten years from the date of original installation U S Boiler Co Inc will a
41. nstall wiring and ground boiler in accordance with requirements of authority having jurisdiction or in absence of such requirements the National Electrical Code ANSI NFPA 70 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 ANSI Z21 13 1 INSPECTINSTALLATION BEFORE STARTING 2 INITIAL START a FILL ENTIRE HEATING SYSTEM WITH WATER and vent air from system Vent air from all heat distributing units and all high points in the piping of the system When venting air from system keep fill valve in open position to maintain water pressure Make certain pressure reducing valve is installed between the fill valve and the boiler See Figure 7 Use the following procedure on a series loop system equipped with zone valves 1 Close all but one zone valve 2 Attach a hose to drain valve on purge fitting and extend hose to drain Open drain valve on purge fitting Close purge valve Open relief valve on boiler Open fill valve When water discharges from relief valve release the lever on top of the relief valve allowing it to close 8 Allow water to run out of drain valve until zone has been purged of air and filled with water 9 Open zone valve to the second zone to be purged then close the first Repeat this step until all zones have been pu
42. ole in the center of the X straight through the wall to the outside On the exterior wall draw a 4 x 514 rectangular box centered around the reference hole which matches the rectangular box on the interior wall Cut along outside edge of lines on interior and exterior surfaces of the wall and remove all material within the rectangular box Check the wall penetration by inserting one half of the telescoping intake air duct through the opening Remove any jagged edges or webbing that prevents the duct from penetrating through the wall or from being level Remove duct from wall penetration Lay the wall bracket face down Apply a 4 thick bead of silicone rubber type caulking around the rectangular opening approximately 1 from the edge Reposition boiler mounting wall bracket on wall using a 24 level across top corners level wall bracket and secure to wall with suitable fasteners Attach lower R S jacket mounting bracket to right side of boiler mounting wall bracket with sheet metal screws provided See Figure 5 INSTALLING BOILER AND INTERIOR TELESCOPING INTAKE AIR DUCT See Figure 5 a Separate two halves of telescoping intake air duct Interior half of duct has a 1 wide rectangular gasket flange with four 4 weld studs for attaching to back plate of boiler Exterior half of duct has the 9 square stainless steel wall flange for securing to exterior wall See Figure 5 NOTE 1 Sta
43. on above on this label Set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device Remove front door which automatically lights the pilot Do not try to light the pilot by hand GAS CONTROL KNOB Locate the gas control valve at the end of the gas supply pipe going into the boiler The gas control knob is the brown or blue plastic knob located on top of the gas control valve Set the thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed Remove front door 14 7 Rotate gas control knob clockwise Cy from ON position to OFF Make sure knob rests against stop Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step Rotate gas control knob counterclockwise from OFF to ON Make sure knob rest against stop Do not force Replace front door Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier 4 Rotate gas control knob clockwise from position to OFF Make sure knob res
44. or decrease in gas input Turning regulator adjusting screw clockwise increases pressure Counterclockwise rotation decreases pressure 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 DIFFERENTIAL PRESSURE SWITCH BLACK TUBING 1 BULKHEAD 8 Z BULKHEAD CONNECTOR TO CANOPY N COMBUSTION AREA ENCLOSURE N GRAY TUBING FITTING SENSITIVE MANOMETER Figure 13 PROCEDURE FOR MEASURING FAN DIFFERENTIAL PRESSURE IGNITION SYSTEM TROUBLESHOOTING GUIDE HONEYWELL S8670E IGNITION MODULE Boiler Troubleshooting Guide Begins on Page 20 NOTE Before troubleshooting familiarize yourself with the Sequence of Operation START on Page 17 TURN GAS SUPPLY OFF TURN THERMOSTAT CALL FOR HEAT POWER TO MODULE NOMINAL YES Check line veltage power low voltage transformer limit controlier thermostat controller and wiring Also check air proving switch on combustion air blower system SPARK ACROSS IGNITERVSENSOR GAP Pull ignition lead and check spark at S8670E module ignition stud Check ignition cable ground wiring ceramic insulator and gap and correct Check boot of the ignition cable for signs of melting or buckling Take protec tive action to shield cable and boot from
45. p of burner with a soft bristle brush and vacuum burner see Figure 16 Check orifice to see that drilled passageway is free of lint and dirt e Vacuum tips of pilot burner f Clean firebox by vacuuming Exercise care not to disturb insulation inside base REMOVAL OF BURNER ASSEMBLY a Disconnect pilot tubing coupling ignition cable and ground wire from pilot assembly b Disconnect gas valve at union between valve and bulkhead penetration c Remove two fasteners attaching burner to bulkhead and single fastener for burner end support d Grasp burner tilt upward and remove from unit e INSTALL BURNER by reversing procedure used to remove REMOVAL OR REPLACEMENT OF PILOT ASSEMBLY OR PILOT ASSEMBLY PARTS a If pilot assembly sensor or pilot orifice need replacement remove jacket front panel enclosure cover and burner access panel using procedure described in paragraph 4 above b Disconnect pilot tubing ground wire and ignition sensor cable c Remove two machine screws holding pilot burner to pilot bracket d Reinstall pilot burner by reversing above procedure e Check pilot and main burner flames refer to Figures 14 amp 15 CHECK MAIN BURNER AND PILOT FLAMES refer to Section paragraphs 6 and 10 CHECK ALL CONTROLS ANNUALLY see procedure in Section paragraphs 7 8 9 11 and 12 MAINTENANCE OF LOW WATER CUTOFF During the heating season if an external float type low water cutoff is on
46. removal or reinstallation The owner is responsible for the cost of removing and reinstalling any defective part and its replacements and all labor and material connected therewith 6 Exclusive Remedy U S Boiler Co Inc obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall U S Boiler Co Inc be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time U S Boiler Co Inc liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade water boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 8 Limitation of Warranties These warranties set forth the entire obligation of U S Boiler Co Inc with respect to any defect residential grade water boiler and U S Boiler Co Inc shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set forth herein These warranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF AN
47. rged but always have one zone open At completion open all zone valves 10 Close drain valve on purge fitting 11 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 the set pressure of valve normally 12 psi Leave globe valve open 12 Open purge valve b Set ROOM THERMOSTAT below room temperature c Be sure that gas to pilot and main burners has been off for at least five minutes d Open valve on main gas line at meter e PURGE AIR FROM GAS PIPING During the purge adequate ventilation must be provided and no smoking or open flame permitted See Figure 10 1 Open manual shutoff valve upstream of combination gas valve 2 Loosen or remove inlet pressure tap plug in combination gas valve and when purging is complete tighten or replace plug 3 Check pipe and fittings from meter to combination gas valve using soap solution or other approved methods f TEST GAS PIPING Test gas piping and connections between combination gas valve and manifold manifold orifices and pilot piping for leaks after boiler is operating Use soap solution or other approved method g Install enclosure cover and secure with 8 1 2 long sheet metal screws 3 OPERATING INSTRUCTIONS See page 14 PILOT Figure 10 SCHEMATIC PILOT AND GAS PIPING 13 NOTE YOUR BOILER IS EQUIPPE
48. t its option and upon payment of the pro rated service charge set forth below repair or replace the heat exchanger The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows Years In Service Service Charge as of Retail Price Years 18 20 22 23 24 In Service Service Charge as of 40 45 50 55 60 65 70 75 Retail Price NOTE 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 ADDITIONAL TERMS AND CONDITIONS 1 Applicability The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to water boilers designated as residential grade by U S Boiler Co Inc and installed in a single or two family residence and do not apply to steam boilers of any kind or to commercial grade boilers 2 Components Manufactured by Others Upon
49. the boiler the blow off valve should be opened once a month use greater frequency 23 24 where conditions warrant to flush out the sediment chamber so the device will be free to function properly Low water fuel cutoffs and water feeders should be dismantled annually by qualified personnel to the extent necessary to insure freedom from obstructions and proper functioning of the working parts Inspect connecting lines to boiler for accumulation of mud scale etc and clean as required Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly Give special attention to solder joints on bellows and float when this type of control is used Check float for evidence of collapse and check mercury bulb where applicable for mercury separation or BLOWER ASSEMBLY CANOPY ASSEMBLY COMBUSTION AREA ENCLOSURE COVER BURNER ACCESS PANEL FRONT REMOVABLE DOOR MOUNTING discoloration Probe type low water cutoff should be removed once a year examined and cleaned of any dirt accumulations to assure proper operation Do not attempt to repair mechanisms in the field Complete replacement mechanisms including necessary gaskets and installation instructions are available from the manufacturer LUBRICATION There are no parts requiring lubrication on the part of the serviceman or the homeowner Circulator bearings are water lubricated Fan motor b
50. tional Fuel Gas Code 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 It is the responsibility of the installing contractor to the National Fuel Gas Code ANSI Z223 1 see that all controls are operating properly when the installation is completed Service on this boiler should be undertaken only by trained and skilled personnel IYNOISN NIA SVD GALNNOW TIVM YALSVASOVdS AINO H31VA St AHNSSAYd NDISAC NNNIXVW 3O013 MHIA ACIS MAIA ACIS LAAT SNOILO3S JAVA 5 9 3LON 335 NOY 1570 ONIdld 599 1 2 cm 558 o 55 om JNN Z a YILINIL 7VY3HL AVIAN OYO 2 YSNYOSSNVYL xog n AddnS TYM NA 43134 33S 38 1 INJA SS3NYOIHL HOLIMS VM OL f fez 3unss3ud NOILONS 2 401 43134 3 Lond SY3ANO1 HS333 1 3LON 335 aon ONILNNOW TYM 5 SL OL OL STIVM 3 39V3OVd 710395 581 OCZ 6 5 4 00 WON 2
51. ts against stop 5 Replace front door WVYDVIC SNIHIA OILVN3IHOS LL TEMEN 3ATyA SY9 JID RE 0 ak Pao 60 una HUM 38 LSNA FA H s Avz 38 ASN HUM A3NddNS SY 3HL 30 ANV 9 Ave 00 OMY 9 IZIS OO9XYS TVININUNOO OZ WWW ZYH 5 NOLUN9I TW3NOH SO WWW M3l ML SHIM OMY 8L IZIS INN M31N39 TOMINOO 098288 os 9 002 YO OMY 81 IZIS 009 T IN3NUN00 38W ANNOYS ML OMY 1 3215 901 389 YIMOd OMY 2 81 IZIS SO WMV NGL OMY 8 IZIS MOT AVAPVId z _ 1 09 02 wnaane M3TWISNI q3rlqans 38 OL SHAU 3S3HL 1NO TOY 3Y4 091 15 L1 L2 GND POWER SUPPLY 120 60 1 CIRCULATOR MOTOR 1M1 OVERCURRENT PROTECTION DISCONNECT SERVICE SWITCH OPTIONAL 24V TRANSFORMER THERMOSTAT CIRCULATOR RELAY 1M2 COIL
52. up into position Make sure that Z bracket is properly engaged into slot and is resting on wide flange in front of slot before releasing the weight of the boiler Move boiler slightly to the left or right to align the five 5 clearance holes in the back plate with the fasteners on boiler mounting wall bracket TELESCOPING INTAKE AIR DUCT ASSEMBLY COMBUSTION AREA ENCLOSURE 5 TO 97 WALL THICKNESS COMBUSTION AIR INTAKE EXHAUST GASES 3 1 0 1 d TE 54 FASTENER SECTION ASSEMBLY VENT TUBE VENT TERMINAL ASSEMBLY FAN ASSEMBLY 10 32 STAINLESS STEEL MACH SCREW W ALUMINUM HEX SPACER CANOPY SILICONE CAULKING ORIFICE PLATE VENT TUBE FAN FLANGE VENT TUBE COLLAR CERAFIBER GASKETS STANDARD AIR INTAKE DUCT FOR 5 TO 9 THICK EXTERIOR WALL SPECIAL VENTING PACKAGE REQUIRED FOR WALLS 10 TO 15 THICK Figure 4 VENT SYSTEM CROSS SECTION VENT TUBE MOUNTING FLANGE ALUMINUM VENT TUBE CERAFIBER GASKETS ORIFICE PLATE TELESCOPING INTAKE AIR DUCT INTERIOR HALF MOUNTING BRACKET ENCLOSURE COVER COMBUSTION AREA ENCLOSURE h Secure boiler to boiler mounting wall bracket with five 5 47 20 x 34 long machine screws and washers provided NOTE Tools required 7 16 socket extension bar s and drive ratchet i Secure interior telescoping intake air duct to back plate of boiler Pull
53. ur occassionally even though operaton is normal at the time of checkout Check that pilot flame covers flame rod and is steady and blue If checks are okay replace Ignition module CALL FOR HEAT ENDS SYSTEM SHUTS OFF YES TROUBLESHOOTING ENOS Minimum pilot signal should be 1 0 microamps Disconnect Pilot Ground wire from Module and connect DC microammeter between Ground Terminal and pilot Ground wire Check for proper thermostat controller operation Remove MV lead at module if valve closes recheck temperature controller and wiring not replace gas control Repeat procedure until troublefree operation is obtained 2 AVIY HOIH 39V A3 ON ON 1 qinons OLNI HOVE ONILENd 213 532290 3unssatid SYD INT SV HONS dPE11 8840 3 40 594 STVNINUSL 684 HOLIMS HLOG SLIOA p X93HS qat3suvs LIAN N3HA NOLLVH3dO STIVNIWH3L HiO8 SLIOA FZ 2ONILLAS JAQAY UFO SI SHA 7 ILON ILON Avay NO 8 1 SMH H108 SLTOA 041
54. ves fan operation the ignition module is energized beginning a 30 50 second prepurge During prepurge the module performs a safe start check that tests the internal components of the module for a flame simulating condition If a flame simulating condition is present in the module the heating system will not start After prepurge the module energizes the pilot gas valve operator The pilot gas valve opens allowing gas to flow to the pilot burner At the same time the electronic spark generator in the module generates a spark at the ignitor sensor to light the pilot If the pilot does not light within 90 seconds or pilot flame current is not at least 1 0 milliamps and steady the module will not energize the main gas valve and the main burner will not light Then the module goes into safety lockout de energizing the pilot gas valve operator causing the pilot gas valve to close Five to six minutes after shutdown the Ignition Module restarts the ignition sequence When the sensor senses pilot flame during the 90 second trial for ignition the module will shut off the spark generator reset the safety lockout timer and energize the main gas valve operator The main gas valve opens allowing gas to flow to the main burners where it is ignited by the pilot burner Since the main gas valve is a step opening valve a limited amount of gas will be admitted to main burners for ignition low fire After a short time interva
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