Boiler Company SERIES 3 Specifications

102998-01R1-7/10INSTALLATION, OPERATING ANDSERVICE INSTRUCTIONS FORSERIES 3™Gas - Fired BoilerFor service or repairs to boiler, call your heating cont

102. Screw the water supply manifold into the boiler outlet tapping “O.”3. Orient the manifold with the relief valve on top.4. Screw the relief val

117. Screw an installer-supplied 1¼” pipe or nipple into the water return tapping “R”.8. Screw the supplied drain valve into tapping “D”.6. CONNECT

12 DISCONNECT ELECTRICAL POWER to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock ele

13Using IQ Boiler Control Display8. PROGRAM THE CONTROLSViewing the Operating Mode OptionsIn operating mode the user may view (but not change) boiler

14Unit DisplayORSample Display1 sec1 sec1 sec Please note that in operating mode to hold the display on the value the user can press and hold either t

159. CHECK FOR GAS AND WATER LEAKS GAS LEAKS may result in re or explosion. WATER LEAKS may cause extensive property dam

1610-b10. PERFORM STARTUP CHECKS AND ADJUSTMENTS FAILURE TO PERFORM THESE CHECKS of the boiler's combustion and safety systems may

17ANNUAL MAINTENANCE CHECKLIST WARNINGSTHE BOILER CONTAINS REFRACTORY CERAMIC FIBER, a possible human carcinogen Use a NIOSH approved respirator whe

18TROUBLESHOOTINGIQ Boiler Control Status Codes (when "Err" is not displayed)Display Status Boiler / Control Action(s)BlankBoiler and Circul

19If "Err" IS displayed on the IQ Boiler Control: "Err" ashes on the IQ Boiler control display followed by a number. Use the fo

2FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler.INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efcie

20TROUBLESHOOTING (continued)If IQ Boiler Control Shows Status Code “STA 15": The IQ Boiler Control is “Waiting for Limit to Close” and the dis

21Key No.Description[Quantity] Part Number 303 304 305 306 307 308 3091A Block Assembly 102287-03 102287-04 102287-05 102287-06 102287-07 102287-08 10

22REPAIR PARTS LIST (continued)Key No.Description[Quantity] Part Number 303 304 305 306 307 308 3092A Base Wrapper 71807031 71807041 71807051 71807061

23REPAIR PARTS LIST (continued)Key No.Description[Quantity] Part Number 303 304 305 306 307 308 3093AGas Valve (Natural Gas), Honeywell VR8204P1171816

24REPAIR PARTS LIST (continued)Key No.Description[Quantity] Part Number 303 304 305 306 307 308 3094A IQ Boiler Control 102289-014B IQ Option Panel 10

25Key No.Description[Quantity] Part Number 303 304 305 306 307 308 3095A Jacket Left Side Panel 102566-015B Jacket Right Side Panel 102567-015C Jacket

26REPAIR PARTS LIST (continued)Key No.Description[Quantity] Part Number 303 304 305 306 307 308 3096A Supply Water Manifold 806070016B Temperature/Pre

27INTERNAL WIRING Figure IW-1: Wiring Diagram

28INTERNAL WIRING (continued)Figure IW-2: Wiring Schematic

29Figure IW-3: Single Zone System with Domestic Hot Water TankFigure IW-4: Multiple Zone System with Zone CirculatorsINTERNAL WIRING (continued)

352134Congratulations on your purchase of a new Burnham® boiler—designed and constructed to provide you with years of reliable service. • Cast iron

30Figure IW-5: Multiple Zone System with Zone ValvesFigure IW-6: Multiple Zone System with Zone Circulator PanelINTERNAL WIRING (continued)

31T STAT 1VALVE 1T STAT 2VALVE 2T STAT 3OFFONZONE 4 PRIORITYTACO ZVC 404 (OR EQIV.)FOUR ZONE ZONE VALVE CONTROLWITH OPTIONAL PRIORITYTHERMOSTATBOILER

32APPENDIX A – COMBUSTION AIR PROVIDE ENOUGH AIR to ventilate the boiler room, dilute the ue gases, and sustain combustion. Ignition fail

33APPENDIX B – VENTING VENT THIS BOILER according to the instructions. Failure to do so may cause products of combustion to enter the buil

34être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés

35APPENDIX B1 – ATMOSPHERIC VENTINGFigure B-1: Typical Atmospheric Vent Installation GENERAL WARNINGS FOR ATMOSPHERIC VENTING SYSTEMSUSE ATMOSPHERI

36 AVERTISSEMENTS GÉNÉRAUX POUR LES SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPHÈREAPPENDICE B1 – SYSTÈMES D’ÉVAC

37APPENDIX C – GAS PIPING ASSURE GAS PIPING IS LEAK FREE AND OF PROPER SIZE and type for the connected load. SHUT OFF MAIN GAS SUPPLY

385. Bond all above-ground gas piping to a grounding electrode and ensure the piping is electrically continuous. DO NOT USE GAS PIPING AS A

39(2) Comply with the boiler’s specic water quality requirements. See the Specifications Section of this manual.(3) Comply with the boiler’s

4Series 3Boiler ModelInput (MBH) DOE Heating Capacity (MBH) Net I=B=R Rating (MBH) AFUE (%)303 70 59 51 84304 105 88 77 84305 140 117 102 84306 175 14

40Figure D-0: Piping Schematic SymbolsAPPENDIX D – System Piping (continued)

41Figure D-W1: Water Boiler, Series LoopAPPENDIX D – System Piping (continued)Figure D-W2: Water Boiler, Two or More Zones

42Figure D-W3: Water Boiler, Tankless Coil, Two or More ZonesAPPENDIX D – System Piping (continued)Figure D-W4: Water Boiler, Indirect Water Heater,

43APPENDIX D – System Piping (continued)Figure D-W5: Water Boiler, Indirect Water HeaterFigure D-W6: Multiple Water Boilers, Indirect Water Heater,

44APPENDIX E – FILLING THE SYSTEM AND CHECKING FOR LEAKSFill entire heating system with water and vent air from system. Use the following procedure o

45APPENDIX F – ADJUSTING GAS INPUT RATENatural Gas Boilers:1. Turn off gas supply to all appliances other than gas-red boiler.2. Note the rated man

46Seconds for Two (2) RevolutionsSize of Gas Meter DialOne-Half Cu. Ft.OneCu. Ft.TwoCu. Ft.24 150.0 300.0 450.026 138.4 276.9 415.328 128.5 257.1 385.

47APPENDIX G – CHECKING DRAFT AND COMBUSTIONCHECK DRAFT (GAS BOILERS WITH DRAFT HOODS)1. Insofar as is practical, close all doors and windows in the

48The IQ Boiler Control stores two boiler supply temperature setpoints in its memory; one setpoint is for the High Limit Setting and the second is for

49APPENDIX H – IQ Control System (continued)IQ Option Cards: For example, if additional safety limits are required, select Manual or Automatic Reset A

5Figure S-1: Minimum Clearances to Combustibles and Closet DimensionsSPECIFICATIONS (continued)

50The LCD Display kit includes a mounting bracket and wiring harness to allow simple physical installation and “plug-in” style electrical connection.

51APPENDIX H – IQ Control System (continued)Burnham Part NumberItem Description102723-01Outside Reset IQ Option Card, Domestic Hot Water Priority, for

52Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranti

6Installation: 1. Unpack the crate ... 7 2. Position t

7 THE BOILER IS TOP-HEAVY. Do not allow it to tip over.1. Remove the sleeve. 2. Remove the contents from the skid, except the boiler.

83. PROVIDE COMBUSTION AIR INSUFFICIENT COMBUSTION AIR SUPPLY may result in the production and release of deadly carbon monoxide (CO) i

94-a4. CONNECT VENTING IMPROPER VENTING may result in property damage and the release of ue gases which contain deadly c