-
8141775R23-10/05 Price - $3.00
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DNAGNITAREPO,NOITALLATSNIROFSNOITCURTSNIECIVRES
VP2SEIRESTNEVREWOP
RELIOBDERIF-SAG
-
2The following terms are used throughout this manual to bring
attention to the presence of hazards of various risk levels, or to
important information concerning product life.
Table of Contents
REGNADsuodrazahyltnenimminasetacidnI
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.egamadytreporp
GNINRAWsuodrazahyllaitnetopasetacidnI
dluoc,dediovatonfi,hcihwnoitautisroyrujnisuoires,htaednitluser
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.sdrazahyrujnilanosrep
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This Series 2PV Boiler has been approved by the Massachusetts
Board of Plumbers and Gas Fitters: Approval No. G3-1200-28.The
Commonwealth of Massachusetts requires this product to be installed
by a licensed Plumber or Gas Fitter.
I. Pre-Installation ........................4
II. Unpack Boiler ..........................5
III. Water Piping ............................6
IV. Gas Piping ................................8
V. Venting ......................................9
VI. Electrical ................................15
VII. System Start-up .....................16
VIII. Service ....................................24
IX. Repair Parts ...........................26
X. Appendix Low Water Cut Off ................35
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tluseryam,dediovatonfi,hcihwnoitautisytreporproyrujnironimroetaredomni
.egamad
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-
4I. Pre-Installation
D. Provide clearance between boiler jacket and combustible
material in accordance with local fi re ordinance. See Figure 2 for
minimum clearance from combustible material for closet
installation. For alcove installation provide top clearance of 27
inches and right side clearance of 6 inches. Recommended service
clearance is 24 inches from left side, right side and front.
Service clearances may be reduced to minimum clearances to
combustible materials.
E. Install on level fl oor. For basement installation provide
solid base, such as concrete, if fl oor is not level or if water
may be encountered on fl oor around boiler.
F. Install near outside wall for through wall venting. Refer to
Section V: Venting, for vent length limitations.
GNINRAWllatsnI.ecnailppaIIIyrogetaCsadeifitreC
noitceShtiwecnadroccanimetsystnevyrnosamgnisutnevtonoD.gnitneV:V
rehtoro,tnevsagBepyT,yenmihc.metsysgnitnevIyrogetaC
G. Protect gas ignition system components from water (dripping,
spraying, rain, etc.) during boiler operation and service
(circulator replacement, condensate trap, control replacement,
etc.).
H. Provide combustion and ventilation air in accordance with
applicable provisions of local building codes, or National Fuel Gas
Code, NFPA 54/ANSI Z223.1, Section 5.3, Air for Combustion and
Ventilation, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149
Installation Codes.
GNINRAWrianoitalitnevdnanoitsubmocetauqedA
reporperussaotdedivorpebtsum.noitsubmoc
The following guideline is based on the National Fuel Gas Code,
NFPA 54/ANSI Z223.1.1. Determine volume of space (boiler room).
Rooms
communicating directly with space (through openings not
furnished with doors) are considered part of space.
Volume [ft] = Length [ft] x Width [ft] x Height [ft]2. Determine
Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total Input.
GNINRAWerofebsnoitcurtsnilladaerylluferaCllawollofoteruliaF.reliobgnillatsni
esuacnacredroreporpnisnoitcurtsni.htaedroyrujnilanosrep
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 carrier in good
condition. Any claim for damage or shortage in shipment must be fi
led immediately against carrier by consignee. No claims for
variances or shortages will be allowed by Boiler Manufacturer,
unless presented within sixty (60) days after receipt of
equipment.
B. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such requirements,
installation must conform to National Fuel Gas Code, NFPA 54/ANSI
Z223.1, and/or CAN/CGA B149 Installation Codes. Where required by
the authority having jurisdiction, the installation must conform to
the Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1.
Figure 2: Minimum Clearances to Combustible Construction for
Closet Installation
C. Appliance is design certifi ed for installation on
combustible fl ooring. The boiler must not be installed on
carpeting.
-
5a. If result is greater than or equal to 50 ft per 1,000 Btuh,
space is considered an unconfi ned space.
b. If result is less than 50 ft per 1,000 Btuh, space is
considered a confi ned space.
4. Determine building type. A building of unusually tight
construction has the following characteristics:a. Walls and ceiling
exposed to outside atmosphere
have a continuous water vapor retarder with a rating of 1 perm
or less with openings gasketed and sealed, and;
b. Weather-stripping has been added on openable windows and
doors, and;
c. Caulking or sealants applied in joints around window and door
frames, between sole plates and fl oors, between wall-ceiling
joints, between wall panels, at plumbing and electrical
penetrations, and at other openings.
5. For boiler located in an unconfi ned space in a building of
other than unusually tight construction, adequate combustion and
ventilation air is normally provided by fresh air infi ltration
through cracks around windows and doors.
6. For boiler located within unconfi ned space in building of
unusually tight construction or within confi ned space, provide
outdoor air through two permanent openings which communicate
directly or by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one opening within
12 inches of top of space. Locate remaining opening within 12
inches of bottom of space. Minimum dimension of air opening is 3
inches. Size each opening per following:a. Direct communication
with outdoors. Minimum
free area of 1 square inch per 4,000 Btu per hour input of all
equipment in space.
b. Vertical ducts. Minimum free area of 1 square inch per 4,000
Btu per hour input of all equipment in space. Duct cross-sectional
area shall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1 square inch per
2,000 Btu per hour input of all equipment in space. Duct
cross-sectional area shall be same as opening free area.
Alternate method for boiler located within confi ned space. Use
indoor air if two permanent openings communicate directly with
additional space(s) of suffi cient volume such that combined volume
of all spaces meet criteria for unconfi ned space. Size each
opening for minimum free area of 1 square inch per 1,000 Btu per
hour input of all equipment in spaces, but not less than 100 square
inches.
7. Ventilation Duct Louvers and Grilles. Equip outside openings
with louvers to prevent entrance of rain and snow, and screens to
prevent entrance of insects and rodents. Louvers and grilles must
be fi xed in open position or interlocked with equipment to open
automatically before burner operation. Screens must not be smaller
than inch mesh.
Consider the blocking effect of louvers, grilles and screens
when calculating the opening size to provide the required free
area. If free area of louver or grille is not known, assume wood
louvers have 20-25 percent free area and metal louvers and grilles
have 60-75 percent free area.
I. Do not install boiler where gasoline or other fl ammable
vapors or liquids, or sources of hydrocarbons (i.e. bleaches,
cleaners, chemicals, sprays, paint removers, fabric softeners,
etc.) are used or stored.
NOITUACtnemnorivnenanireliobsihtgnitarepodiovA
yrd,srebifnoitalusniesool,tsudwaserehwsireliobfI.tneserpera.cte,tsudllaw
renrubeht,snoitidnocesehtrednudetarepodnadenaelcebtsumstropdnaroiretni
.noitareporeporperusniotyliaddetcepsni
II. Unpack Boiler
NOITUACreliobpmubtonoD.reliobpordtonoD
.roolftsniagatekcajA. Move boiler to approximate installed
position.
B. Remove all crate fasteners.
C. Lift outside container and remove with all other inside
protective spacers and bracing. Save two of the wooden slats from
the container sleeve for use in Paragraphs E and F.
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under the
two raised feet.
F. Tilt the boiler to the other side and slide another wooden
slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using the
two wooden slats as runners.
H. Move boiler to its permanent location.
-
6III. Water Piping and Trim
F. Space heating and domestic water heating with Alliance water
heater. Install Alliance water heater as a separate heating zone.
Refer to Alliance Installation, Operating and Service Instructions
for additional information.
G. If boiler is used in connection with refrigeration systems,
boiler must be installed with chilled medium piped in parallel with
the heating boiler using appropriate valves to prevent chilled
medium from entering boiler, see Figure 3. Also consult I=B=R
Installation and Piping Guides.
H. If boiler is connected to heating coils located in air
handling units where they may be exposed to refrigerated air,
boiler piping must be equipped with fl ow control valves to prevent
gravity circulation of boiler water during operation of cooling
system.
I. 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 temperatures may be encoun-tered (i.e. converted
gravity circulation system, etc.).
Install pipe tee between circulator and boiler return along with
second tee in supply piping as shown in Figure 4A or 4B. Bypass
should be same size as the supply and return lines with valves
located in bypass and supply outlet as illustrated in Figure 4A or
4B in order to regulate water fl ow to maintain higher boiler water
temperatures.
After the boiler is operational (reference Section VII. System
Start-Up) set by-pass and boiler supply valves to half throttle
position to start. Operate boiler until system water temperature
reaches normal operating range.
Adjust valves to provide 180 to 200F supply water temperature.
Opening the boiler supply valve will raise system temperature,
while opening the by-pass valve will lower system supply
temperature.
J. A hot water boiler installed above radiation level must be
provided with a low water cut-off device as part of
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.
Refer to Section X for low water cut-off piping and wiring
instructions.
K. If it is required to perform a long term pressure test of the
hydronic system, the boiler should fi rst be isolated to avoid a
pressure loss due to the escape of air trapped in the boiler.
NOITUACnitluseryamreliobepipylreporpoteruliaFroreliobotegamaddnanoitareporeporpmi
.gnidliub
A. Design and install boiler and system piping to prevent oxygen
contamination of boiler water.
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reliobleetsdnanorifonoisorrocesuac.eruliafreliobotdaelnacdna,stnenopmoc
tonseodytnarrawdradnatss'mahnruBnegyxoybdesuacsmelborprevoc
.retawreliobfonoitanimatnoc
Oxygen contamination sources are system leaks requiring addition
of makeup water, fi ttings, and oxygen permeable materials in
distribution system. Eliminate oxygen contamination by repairing
system leaks, repairing fi ttings, and using nonpermeable materials
in distribution system.
B. Connect system supply and return piping to boiler. See Figure
4A or 4B. Also consult I=B=R Installation and Piping Guides.
Maintain minimum inch clearance from hot water piping to
combustible materials.
C. Install Circulator with fl anges, gaskets and bolts provided.
Five foot circulator harness allows circulator to be mounted on
supply or return. Connect harness to circulator and secure any
excess conduit.
D. Install Safety Relief Valve. See Figure 4A or 4B. Safety
Relief Valve must be installed with spindle in vertical position.
Installation of the relief valve must be consistent with the
ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
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folaitnetopetanimileotroolfraendepipaeraynaniepiptonoD.snrubereves
llatsnitonoD.ruccodluocgnizeerferehw.sevlavffo-tuhsyna
E. Install Drain Valve in " NPT connection in tee provided. See
Figure 1.
-
7Figure 4A: Boiler Piping for Circulator Zoned Heating
System
Figure 3: Recommended Piping for Combination Heating &
Cooling (Refrigeration) Systems
To perform a long term pressure test including the boiler, ALL
trapped air must fi rst 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.
L. Oil, grease, and other foreign materials which accumulate in
new hot water boilers and a new or reworked system should be boiled
out, and then thoroughly fl ushed. A qualifi ed water treatment
chemical specialist should be consulted for recommendations
regarding appropriate chemical compounds and concentrations which
are compatible with local environmental regulations.
M. After the boiler and system have been cleaned and fl ushed,
and before refi lling the entire system add appropriate water
treatment chemicals, if necessary, to bring the pH between 7 and
11.
-
8IV. Gas PipingA. Size gas piping. Design system to provide
adequate gas
supply to boiler. Consider these factors:
1. Allowable pressure drop from point of delivery to boiler.
Maximum allowable system pressure is psig. Actual point of delivery
pressure may be less; contact gas supplier for additional
information. Minimum gas valve inlet pressure is listed on rating
label.
2. Maximum gas demand. Table 1 lists boiler input rate. Also
consider existing and expected future gas utilization equipment
(i.e. water heater, cooking equipment).
Table 1: Rated Input
3. Length of piping and number of fi ttings. Refer to Table 2
for maximum capacity of Schedule 40 pipe. Table 3 lists equivalent
pipe length for standard fi ttings.
4. Specifi c gravity of gas. Gas piping systems for gas with a
specifi c gravity of 0.70 or less can be sized directly from Table
2, unless authority having jurisdiction specifi es a gravity factor
be applied. For specifi c gravity greater than 0.70, apply gravity
factor from Table 4. If exact specifi c gravity is not shown choose
next higher value.
For materials or conditions other than those listed above, refer
to National Fuel Gas Code, NFPA 54/ANSI Z223.1, or size system
using standard engineering methods acceptable to authority having
jurisdiction.
B. Connect boiler gas valve to gas supply system.1. Use methods
and materials in accordance with local
plumbing codes and requirements of gas supplier. In absence of
such requirements, follow National Fuel Gas Code, NFPA 54/ANSI
Z223.1 and/or CAN/CGA B149 Installation Codes.
2. Use thread (joint) compounds (pipe dope) resistant to action
of liquefi ed petroleum gas.
relioBledoMrebmuN
etaRtupnI]ruohrepteefcibuc[ saG noitcennoC
eziSsaGlarutaN enaporP/PL
VP302 26 42
VP402 69 83
VP502 031 25
VP602 461 56
Figure 4B: Boiler Piping for Zone Valve Zoned Heating
Systems
-
9Table 2: Maximum Capacity of Schedule 40 Pipe in CFH For Gas
Pressures of 0.5 psig or Less
Table 3: Fitting Equivalent Lengths Table 4: Specifi c Gravity
Correction Factors
htgneL]teeF[
porDerusserP.c.whcni3.0 porDerusserP.c.whcni5.0 1 1 1 1
01 231 872 025 050,1 571 063 086 004,1
02 29 091 053 037 021 052 564 059
03 37 251 582 095 79 002 573 077
04 36 031 542 005 28 071 023 066
05 65 511 512 044 37 151 582 085
06 05 501 591 004 66 831 062 035
07 64 69 081 073 16 521 042 094
08 34 09 071 053 75 811 022 064
09 04 48 061 023 35 011 502 034
001 83 97 051 503 05 301 591 004
gnittiFeziSepiPlanimoN
1 1
llE54 7.0 1 2.1 6.1
llE09 6.1 1.2 6.2 5.3
)woblEsA(eeT 1.3 1.4 2.5 9.6
cificepSytivarG
noitcerroCrotcaF
cificepSytivarG
noitcerroCrotcaF
05.0 01.1 03.1 70.155.0 40.1 04.1 40.106.0 00.1 05.1 00.156.0
69.0 06.1 79.007.0 39.0 07.1 49.057.0 09.008.0 78.0
Figure 6: Recommended Gas Piping
3. Install sediment trap, ground-joint union and manual shut-off
valve upstream of boiler gas control valve and outside jacket. See
Figure 6.
4. All above ground gas piping upstream from manual shut-off
valve must be electrically continuous and bonded to a grounding
electrode. Do not use gas piping as grounding electrode. Refer to
National Electrical Code, ANSI/NFPA 70 and/or CSA C22 Electrical
Code.
C. Pressure test. The boiler and its gas connection must be leak
tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over psig,
boiler and its individual shut-off valve must be disconnected from
gas supply piping. For testing at psig or less, isolate boiler from
gas supply piping by closing boiler's individual manual shut-off
valve.
2. Locate leaks using approved combustible gas detector, soap
and water, or similar nonfl ammable solution. Do not use matches,
candles, open fl ames, or other ignition source.
-
10
Table 5: Burnham Vent System Components
V. Venting
Figure A: Burnham Vent
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gnitnevssel-teksagdeilppusylsuoiverpehthtiwelbaegnahcretnisitnenopmoctnevodyehtsa,niojotreisaednarekciuqyllarenegerastnenopmoctnevrewenehT.stnenopmoc
.dehcattaerasdnabpmalcriehtdnanoitacilppatnalaesehteriuqerton
adnatnenopmoctnevdeteksagatneveehtnI-nocretniebtsumtnenopmoctnevssel-teksaghtiwdetaicossasnoitcurtsniehtwollof,detcenfoselpicnirpgnidiugowtehT.C8roB8erugiF
:swollofsaerasnoitcurtsnieseht
stnenopmoctnevfogniniojynA)1enotsaeltasevlovnitaht
tnenopmoctnevssel-teksagtnalaesehtseriuqersyawla
.noitacilppassel-teksagafodneelamefehT)2seriuqersyawlatnenopmoctnev
ehtfosseldrager,dnabpmalcatnevelamgnitamehtfongised
.tnenopmoc
.tnalaesdnadnabpmalcahtiwdeilppussitnenopmoctnevssel-teksaghcaE3enodnadnabpmalcenosniatnoctahtelbaliavasi,2036116rebmuntrap,tiKnoitisnarTtneVA
.tnalaesfoebutecnuo
GNINRAWrocillatemnon,leetssselniats613epyTro403epyT,dezinavlaghtiwreliobsihtesutonoD
C4-92LAnonrehtoyna .smetsystnevdesab
.reliobsihthtiwdoohtfardrorepmadcirtemorabaesutonoD
.reliobsihthtiwsrepmadtnevesutonoD
,noitaroiretedtneverpoT.noitanimretdnuorasecafrusnomrofyamecidnaerutsioM.).cte,detniap,delaes(riaperdoogniebdluohssecafrus
snoisivorperaerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenreliobsihT.rianoitalitnevdnanoitsubmocetauqedarof
fosecruosro,sdiuqilrosropavelbammalfrehtoroenilosagerehwreliobetarepotonoD,srenetfoscirbaf,srevomertniap,syarps,slacimehc,srenaelc,sehcaelb.e.i(snobracordyh
.riaehtnitneserpro/dnaderots,desuera).cte.teeftnelaviuqe52fohtgneltnevmumixamdeecxetonoD
mahnruBmetsyStneVtnenopmoC
mahnruBrebmuNtraP
tF1xepiP.aiD"3 U6926118tF3xepiP.aiD"3 U8926118tF5xepiP.aiD"3
U0036118
elbatsujdAxepiP.aiD"3 U9136118woblE09.aiD"3
U4926118woblE54.aiD"3 U2926118
eeTniarDlatnoziroH.aiD"3 U2036118eeTniarDlacitreV.aiD"3
U4036118
-
11
A. General Guidelines.1. Vent system installation must be in
accordance with
National Fuel Gas Code, NFPA 54/ANSI Z221.3, Part 7, Venting of
Equipment; and/or CAN/CGA B149 Installation Codes, Section 7,
Venting Systems and Air Supply for Appliances; or applicable
provisions of local building codes. Contact local building or fi re
offi cials about restrictions and installation inspection in your
area.
2. This appliance requires a Special Gas Vent. Use Vent
Connector and Vent Terminal in Vent Accessory Carton provided with
boiler (See Repair Parts, Key No. 8). The product is designed to
use Burnham supplied AL 29-4C Stainless Steel vent system
components. The following manufacturers offer similar AL 29-4C
components and are approved for use with this product: Heat-Fab
Inc. - Saf-T-Vent, Flex-L International Inc., - Star-34, Protech
Systems, Inc. - FasNSeal, and Z-Flex U. S., Inc. - Z-Vent. The use
of these alternate manufacturer's venting systems will require
adapters to connect to the Burnham supplied vent connector and vent
terminal. These adapters are not supplied with this unit and should
be obtained from the supplier of the alternate manufacturer's
venting system. See Table 5 for complete list of Burnham Vent
System Components.
3. Vent length restrictions are based on equivalent feet of vent
pipe (total length of straight pipe in feet plus 5 equivalent feet
for each 45 or 90 elbow). Do not exceed the maximum certifi ed vent
length of 25 equivalent feet. The minimum certifi ed vent length is
7 equivalent feet. Do not include vent terminal or vent connector
in equivalent feet calculations.
4. Do not install venting system components on the exterior of
the building except as specifi cally required by these
instructions.
5. This 2PV boiler may only be sidewall vented; it may not be
vertically vented, as through a roof.
B. Removal of Existing Boiler. For installations not involving
the replacement of an existing boiler, proceed to Step C.
When an existing boiler is removed from a common venting system,
the common venting system is likely to be too large for proper
venting of the remaining appliances. At the time of removal of an
existing boiler, the following steps shall be followed with each
appliance remaining connected to the common venting system placed
in operation, while the other appliances remaining connected to the
common venting system are not in operation:1. Seal any unused
openings in the common venting
system.2. Visually inspect the venting system for proper
size
and horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion, and other defi ciencies which
could cause an unsafe condition.
3. 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
maxi mum speed. Do not operate a summer exhaust fan. Close fi
replace dampers.
4. Place in operation the appliance being inspected. Follow the
Lighting (or Operating) Instructions. Adjust thermo stat so
appliance will operate continuously.
5. Test for spillage at the drafthood relief opening after 5
minutes of main burner operation. Use the fl ame of a match or
candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remain ing
connected to the common venting system properly vents when tested
as outlined above, return doors, win dows, exhaust fans, fi replace
dampers and any other gas burning appliance to their previous
conditions of use.
7. Any improper operation of the common venting system should be
corrected so the installation conforms with the National Fuel Gas
Code, NFPA 54/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 II in the National Fuel Gas Code, NFPA 54/ANSI
Z223.1.
C. Install Vent Connector.1. Remove vent connector from vent
accessory carton.2. Remove gaskets, orifi ce plate and hardware
from
blower outlet fl ange.3. Assemble orifi ce plate gaskets, orifi
ce plate, and
vent connector. See Figure 7.4. Secure vent connector with
washers and locknuts.
Figure 7: Vent Connector Installation
-
12
D. Install Vent Pipe, General.1. Plan venting system to avoid
possible contact with
plumbing or electrical wires. Start venting system at vent
connector and work toward the vent terminal.
2. Use non-combustible inch pipe strap to support horizontal
runs, maintain vent location and slope, while preventing sags in
pipe. Do not restrict thermal expansion or movement of vent system.
Maximum support spacing is 5 feet. Do not penetrate any part of the
vent system with fasteners.
3. Provide and maintain vent pipe minimum clearance to
combustible materials. Vent pipe minimum clearance to combustible
material is fi ve (5) inches when vent is installed in a fully
enclosed (chase) application or four (4) inches when vent is
installed with at least one side open, similar to a joist bay
application. Use thimble when penetrating combustible wall.a. 203PV
and 204PV Single wall thimble,
Burnham Part No. 8116116. Other wall thimble manufac-turers are
American Metal Products, Hart & Cooley, and Metal Fab.
b. 205PV and 206PV Double wall thimble, Burnham Part No. 8116115
(accommodates 5 inch to 8-3/4 inch wall thickness). Another wall
thimble manufacturer is Hart & Cooley.
4. Once a vent pipe manufacturer and system is chosen never mix
and match vent systems.
5. If a non-standard length pipe is required:Gasketed Vent
System: The use of the adjustable length
pipe (P/N 8116319U) is recommended to complete a non-standard
pipe length. This pipe requires a minimum installed length of 12
inch and can adjust across a 7 inch gap up to a maximum of 19 inch
long. (Note for the adjustable pipe the installed length should be
measured from the centerline of the bead on the male end of the fi
rst pipe to the end of the female pipe excluding the locking band
of the second pipe with a single gasket.) Only in the event the
adjustable length pipe is not suffi cient a standard length pipe
may be cut using the procedure outlined below for the Gasket-Less
Vent System.
GNINRAWfohtgneldellatsnimumixamdeecxereveN
.epiphtgnelelbatsujdarofsehcni91.elbissopsiegakaelsageulffoksiR
Gasket-Less Vent System: Carefully cut pipe to length using a
hacksaw with minimum 32 teeth per inch or circular saw with metal
abrasive wheel. Remove male (bead) end only female (bell) end
accepts next fi tting or pipe.
ECITONrodelifdnaepiphtiwerauqsebtsumtuC
ylluferaC.gniniojerofebhtoomsdednashtiwdnahybepiptucfossendnuorerusne
VTRhtiwtniojlaeS.gnillatsnierofebsevolg.launamsihtnideificeps
6. Seal all Burnham Gasket-Less vent, Burnham mixed vent
(Gasket-Less and Gasketed) and fi eld cut joints using Dow Corning
Silastic 732 RTV, Dow Corning Silastic 736 RTV, GE RTV106, Polybac
#500 RTV, Sil-bond RTV 4500 (Acetoxy) and Sil-bond RTV 6500. Do not
use other adhesives or sealants.
E. Install Vent Pipe, Burnham Gasket-Less Vent System.1.
Procedure for Joining Burnham Gasket-Less Vent
Pipe and Fittings. See Figure 8A.
Figure 8A: Burnham Gasket-Less Vent Joint Detail
a. Clean joints of pipe or fi ttings using an alcohol pad to
remove any dirt and grease.
b. Slip a locking band over female (bell) end of pipe/fi
tting.
c. Apply a continuous 1/4 inch bead of sealant around male end
of joint no more than 1/8 inch from end.
d. Align weld seams and use a slight twisting motion to FULLY
insert male end into female end of joint. Ensure bead in male end
rest against the end of the female pipe.
e. Smooth sealant around joint for a continuous seal. Reapply
sealant if necessary.
f. Slip the locking band over joint and align closest bead in
locking band with bead in male end of pipe.
g. Tighten locking band by HAND with a 5/16" nut driver until
snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP
RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
-
13
h. Once the installation is complete, operate appliance and
inspect all joints to ensure that fl ue gases and/or liquid
condensate will not escape.
F. Install Vent Pipe, Burnham Gasketed Vent System.1. Procedure
for Joining Burnham Gasketed Vent Pipe
and Fittings. See Figure 8B.
a. Wipe the male end of each joint using an alcohol pad to
remove any dirt and grease.
b. Align weld seams in pipes and use a slight twisting motion to
FULLY insert male end into female end of joint. Ensure bead in male
end of pipe is below locking band and rest against the end of the
female pipe. Verify the factory-installed gasket is not dislodged
or cut
c. Tighten locking band by HAND with a 5/16" nut driver until
snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP
RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
d. Once the installation is complete, operate appliance and
inspect all joints to ensure that fl ue gases and/or liquid
condensate will not escape.
G. Install Vent Pipe, Burnham Gasket-Less & Gasketed Vent
System.1. Procedure for joining the male end of Burnham
Gasket-Less Vent with the female end of Burnham Gasketed Vent.
See Figure 8C.
Figure 8B: Burnham Gasketed Vent Joint Detail
Figure 8C: Burnham Gasket-Less Male and Gasketed Female Vent
Joint Detail
c. Align weld seams in pipes and use a slight twisting motion to
FULLY insert male end into female end of joint. Ensure bead in male
end of pipe is below locking band and rest against the end of the
female pipe. Verify the factory-installed gasket is not dislodged
or cut.
d. Smooth sealant around joint for a continuous seal. Reapply
sealant if necessary.
e. Tighten locking band by HAND with a 5/16" nut driver until
snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP
RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
f. Once the installation is complete, operate appliance and
inspect all joints to ensure that fl ue gases and/or liquid
condensate will not escape.
2. Procedure for joining the female end of Burnham Gasket-Less
Vent with the male end of Burnham Gasketed Vent. See Figure 8D.
Figure 8D: Burnham Gasket-Less Female and Gasketed Male Vent
Joint Detail
a. Clean joints of pipe or fi ttings using an alcohol pad to
remove any dirt and grease.
b. Slip a locking band over female (bell) end of pipe/fi
tting.
c. Apply a continuous inch bead of sealant around male end of
joint no more than 1/8 inch from end.
d. Align weld seams in pipes and use a slight twisting motion to
FULLY insert male end into female end of joint.
e. Smooth sealant around joint for a continuous seal. Reapply
sealant if necessary.
f. Slip the locking band over joint and align closest bead in
locking band with bead in male end of pipe.
g. Tighten locking band by HAND with a 5/16" nut driver until
snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP
RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
a. Clean the male end of each joint using an alcohol pad to
remove any dirt and grease.
b. Apply a continuous inch bead of sealant around male end of
joint no more than 1/8 inch from end.
-
14
Figure 9: Recommendations for Thimble and Wall Penetration
h. Once the installation is complete, operate appliance and
inspect all joints to ensure that fl ue gases and/or liquid
condensate will not escape.
H. Horizontal (Through Wall) Vent Installation.1. Maintain
minimum inch per foot slope in
horizontal runs. Slope pipe down toward vent terminal. Position
weld seams in vent pipes in all horizontal runs at the top to avoid
condensate from lying on the seams.
2. Vent terminal location restricted per following: a. Minimum
12 inches above grade plus normally
expected snow accumulation level, or 7 feet above grade if
located adjacent to public walkway. Do not install over public
walkway where local experience indicates condensate or vapor from
Category III appliances creates a nuisance or hazard.
b. Minimum 3 feet above any forced air inlet located within 10
feet.
c. Minimum 4 foot below, 4 foot horizontally from, or 1 foot
above any door, window, or gravity air inlet.
d. Minimum 4 feet (6 feet in Canada) horizontally from, and in
no case above or below, unless a
4-foot horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment.
e. Minimum 12 inches from overhang or corner.
3. Use wall thimble when passing through combustible outside
wall (thimble use optional for noncombustible wall). Insert thimble
through wall from outside. Secure outside fl ange to wall with
nails or screws, and seal with adhesive material. Install inside fl
ange to inside wall, secure with nails or screws, and seal with
adhesive material.
4. For noncombustible wall when thimble is not used size opening
such that female (bell) end with locking band attached cannot pass
through.
5. Join vent terminal to vent pipe. Locate vent terminal 3
inches (minimum) and 6 inches (recommended) from wall when joined
to inside vent piping. See Figure 9. Vent terminal clearance to
vinyl wall surfaces is 6 inches.
6. Insert vent pipe through thimble/opening from outside and
join to vent system. Apply sealant between vent pipe and
opening/thimble to provide weathertight seal.
-
15
VI. Electrical
A. General. Install 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,
and/or the CSA C22.1 Electric Code.
B. Install thermostat. Locate on inside wall approximately 4
feet above fl oor. Do not install on outside wall, near fi replace,
or where infl uenced by drafts or restricted air fl ow, hot or cold
water pipes, lighting fi xtures, television, or sunlight. Allow
free air movement by avoiding placement of furniture near
thermostat.
C. Wire thermostat. Provide Class II circuit between thermostat
and boiler. Run wires through grommet in Jacket Left Side Panel.
Set thermostat heat anticipator to 0.6 amps. See Figure 10.
D. Wire boiler. Boiler is rated for 120 VAC, 60 hertz, less than
12 amperes. 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. Connect to black and white wires and
green ground screw. See Figure 10.
E. Alliance water heater (if used). See Figure 10. Also refer to
Alliance Installation, Operating and Service Instructions.
F. For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve manufacturer
for assistance.
Figure 10: Wiring Diagram
-
16
Figure 12: Gas Valve Pressure Tap
3. For natural gas fi red boiler, temporarily turn off all other
gas-fi red appliances.
E. Follow Operating Instructions to place boiler in operation.
See Figure 17.
F. Sequence of Operation. See Figure 14. If boiler fails to
operate properly, see Troubleshooting Tree on pages 20-22.
G. Check gas piping and connections between Gas Valve and
Manifold, Orifi ces and Pilot Tubing. Use soap solution or other
approved method. See Figure 13.
Figure 13: Schematic Pilot and Gas PipingFigure 11: Main Burner
Installation
VII. System Start-up
A. Safe operation and other performance criteria were met with
gas manifold and control assembly provided on boiler when boiler
underwent tests specifi ed in American National Standard for
Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI
Z21.13.
B. Fill heating system with water and vent air from system. Use
the following procedure on a Series Loop System equipped with zone
valves. See Figure 3.1. Close isolation valve in boiler supply
piping.2. Isolate all circuits by closing zone valves or
balancing valves.3. Attach hose to hose bib located just below
isolation
valve in boiler supply piping. Terminate hose in fi ve gallon
bucket at a suitable fl oor drain or outdoor area).
4. Starting with one circuit, open zone valve.5. Open hose
bib.6. Open fi ll valve. Makeup water line should be
located directly above isolation valve in boiler supply
piping.
7. Allow water to overfl ow from bucket until discharge from
hose is bubble free for 30 seconds.
8. Open zone valve to second zone to be purged, then close fi
rst. Repeat this step until all zones have been purged, but always
have one zone open. At completion, open all zone valves.
9. Close hose bib, continue fi lling system until pressure gauge
reads 12 psi. Close fi ll valve.
Note: If makeup water line is equipped with pressure reducing
valve, system will automatically fi ll to 12 psi. Leave globe valve
open.
10. Open isolation valve in boiler supply piping.11. Remove hose
from hose bib.
C. Check main burners. See Figure 11. Rear of burner must be in
vertical slot in rear of burner tray. Front of burner must be
seated on orifi ce.
D. Prepare to check operation.1. Obtain gas heating value (in
Btu per cubic foot)
from gas supplier.2. Connect manometer to pressure tap on gas
valve.
See Figure 12.
-
17
Figure 15: Pilot Burner Flame
Figure 14: Sequence of Operation
H. Check pilot burner fl ame. See Figure 15. Flame should be
steady, medium hard blue enveloping 3/8 to inch of sensing
probe.
I. Check main burner fl ame. See Figure 16. Flame should have
clearly defi ned inner cone with no yellow tipping. Orange-yellow
streaks should not be confused with true yellow tipping.
Figure 16: Main Burner Flame
J. Check thermostat operation. Raise and lower temperature
setting to start and stop boiler operation.
K. Check ignition control module shut-off. Disconnect
igniter/sensor cable from Terminal 9 (SPARK). Gas valve should
close and pilot and main burners should extinguish.
-
18
L. Check low water cut-off (if used). Drain boiler water below
LWCO set point. Burners should extinguish.
M. Check limit.1. Adjust thermostat to highest setting.2.
Observe temperature gauge. When temperature is
indicated, adjust limit to setting below observed temperature.
Main burners and pilot burner should extinguish and blower
stop.
3. Adjust limit to setting above observed temperature. Ignition
sequence should begin.
4. Adjust thermostat to lowest setting. Adjust limit to desired
setting.
N. Adjust gas input rate to boiler (Natural Gas).1. Adjust
thermostat to highest setting.2. Check manifold gas pressure.
Manifold pressure is
listed on rating label. Adjust gas valve pressure regulator as
necessary (turn adjustment screw counterclockwise to decrease
manifold pressure, or clockwise to increase manifold pressure). If
pressure can not be attained, check gas valve inlet pressure. If
less than minimum gas supply pressure listed on rating label,
contact gas supplier for assistance.
3. Clock gas meter for at least 30 seconds. Use Table 6 to
determine gas fl ow rate in Cubic Feet per Hour.
4. Determine Input Rate. Multiply gas fl ow rate by gas heating
value.
Table 6: Gas Flow Rate in Cubic Feet per Hour
sdnoceSenOrof
noituloveR
laiDreteMsaGfoeziS
flaH-enO.tF.uC
enO.tF.uC
owT.tF.uC
03 06 021 042
23 65 311 522
43 35 601 212
63 05 001 002
83 74 59 981
04 54 09 081
24 34 68 271
44 14 28 461
64 93 87 751
84 73 57 051
05 63 27 441
25 53 96 831
45 33 76 331
65 23 46 921
85 13 26 421
06 03 06 021
5. Compare measured input rate to input rate listed on rating
label. a. Boiler must not be overfi red. Reduce input rate
by decreasing manifold pressure. Do not reduce more than 0.3
inch w.c. If boiler is still overfi red, contact your Burnham
distributor or Regional Offi ce for replacement Gas Orifi ce.
b. Increase input rate if less than 98% of rating label input.
Increase manifold gas pressure no more than 0.3 inch w.c. If
measured input rate is still less than 98% of rated input:i. Remove
Main Burners per procedure in
Section VIII: Service.ii. Remove gas orifi ces. Drill one (1)
drill size
larger (drill size is stamped on orifi ce, or see Key No.
4D).
iii. Reinstall gas orifi ces and main burners. Measure input
rate.
6. Recheck Main Burner Flame.7. Adjust thermostat to normal
setting.8. Return other gas-fi red appliances to previous
conditions of use.
O. Adjust gas input rate to boiler (LP/Propane).1. Adjust
thermostat to highest setting.2. Check manifold pressure. Adjust
gas valve pressure
regulator to obtain 10 inches w.c. manifold pressure. Adjust gas
valve pressure regulator as necessary (turn adjustment screw
counterclockwise to decrease manifold pressure, or clockwise to
increase manifold pressure). If pressure can not be attained, check
gas valve inlet pressure. If less than minimum gas supply pressure
listed on rating label, contact gas supplier for assistance.
3. Recheck Main Burner Flame4. Adjust thermostat to normal
setting.
P. COMBUSTION CHAMBER BURN-OFF1. The mineral wool combustion
chamber panels
contain a cornstarch based binder that must be burned out at
installation to prevent odors during subsequent boiler
operation.
2. Ventilate the boiler room, set the high limit to its maximum
setting, set the thermostat to call for heat. Allow the boiler to
fi re for at least an hour or until the odor from the cornstarch
has dissipated.
3. Return the high limit and thermostat to their desired
settings.
Q. Review User's Information Manual and system operation with
owner or operator.
R. Post instructions near boiler for reference by owner and
service personnel. Maintain instructions in legible condition.
-
19
Figure 17: Operating Instructions
-
20
-
21
-
22
-
23
noitamrofnIytefaStcudorPtnatropmItcudorPrebiFcimareCyrotcarfeR
Warning:
This product contains refractory ceramic fi bers (RCF). RCF has
been classifi ed as a possible human carcinogen. After this product
is fi red, RCF may, when exposed to extremely high temperature
(>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 fi red RCF (combustion
chamber insulation, target walls, canopy gasket, fl ue 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 fi tting clothing3. Gloves4. 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:
If contact with eyes: Flush with water for at least 15 minutes.
Seek 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 diffi culty develops: Leave the area and move to a
location with clean fresh air. Seek immediate medical attention if
breathing diffi culties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
-
24
VIII. Service
A. General. Inspection and service should be conducted annually.
Turn off electrical power and gas supply while conducting service
or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE.
See Figure 17.
NOITUACnehwnoitcennocsidotroirpseriwllalebaLesuacnacsrorregniriW.slortnocgnicivres
yfireV.noitareposuoregnaddnareporpmi.gnicivresretfanoitareporeporp
B. Inspect Housekeeping. Boiler area must be clear and free from
combustible materials, gasoline and other fl ammable vapors and
liquids. Remove obstructions to the fl ow of combustion and
ventilation air.
C. Service Low water cut-off (if so equipped). Follow
instructions provided with low water cut-off
D. Inspect Vent System for obstructions in vent pipe, soot
accumulation, deterioration of pipe or joints, and proper
support:1. Remove vent connector and vent pipe. See Figure
19.2. Remove all obstructions. Check and clean vent
terminal screens.3. Remove soot accumulations with wire brush
and
vacuum.4. Replace deteriorated parts.5. Repair deteriorated
joints. See Section V: Venting.
E. Inspect Boiler Flue Passages for blockage or soot
accumulation. See Figure 19.
1. Disconnect vent connector from blower discharge fl ange.
2. Remove sheet metal screws securing Jacket Top Panel. Lift
panel and rotate about relief valve piping until top of boiler is
exposed. If piping or wall prevent full rotation of top panel for
access to canopy, cut slot into relief valve opening and remove top
panel.
3. Disconnect blower connection from wiring harness in
vestibule.
4. Remove bolts securing canopy to boiler sections. Cut silastic
sealant around base of canopy, pry canopy from boiler sections and
remove canopy/blower assembly from boiler.
5. Using fl ashlight, examine all fl ue passageways.a. If
passageways are free of soot and obstruction,
replace canopy, secure and seal using kit available from Burnham
Distributors, Part No. 6111716.
b. If passageways need cleaning, remove burners as described in
Paragraph F below. Using long handle wire or bristle fl ue brush
and vacuum, brush fl ueways thoroughly from top of boiler as
illustrated in Figure 19. Replace canopy and seal using kit
available from Burnham Distributors, Part No. 6111716.
GNINRAW237-VTRhtiwdelaeserebtsumyponaC
tnettimretnIF005(tnalaeSrebbuRenociliS.)ytuD
6. Reinstall jacket top panel, vent pipe and vent connector in
reverse manner. Reconnect electrical connector to blower.
F. Clean Main Burners and Firebox.1. To remove burners for
cleaning, changing orifi ce
plugs, or repairs:a. Remove jacket Front Panel.b. Disconnect
pilot tubing at gas valve.c. Disconnect igniter/sensor cable and
ground wire
at Ignition Module.d. Disconnect Flame Rollout Switch wires.e.
Remove Burner Access Panel.f. Mark Pilot Main Burner location on
Manifold.g. Hold burner on throat. Lift slightly to clear
orifi ce. Pull burner from combustion chamber. See Figure 11.
Pilot Main Burner can only be removed by lifting at 45 angle after
adjacent burner to right is removed.
2. Brush top of burners with a soft bristle brush. See Figure
19. Vacuum burners.
3. Check orifi ces. Drilled passageways must be free of lint or
dirt.
4. Vacuum tip of Pilot Burner.5. Clean fi rebox by vacuuming.
Exercise care not to
disturb insulation inside base.6. Install burners by reversing
procedure used to
remove burners. Burner with pilot assembly must be in same
location as original installation. See Table 7. Burners must be
properly located on support bracket at rear of burner. See Figure
11. Slide burner over orifi ce.
7. Reconnect pilot gas supply, igniter/sensor cable, and ground
wire. Reinstall Burner Access Panel. Reconnect Flame Rollout Switch
wires.
G. Check operation. Follow Paragraphs D through O from Section
VII: System Start-up.
-
25
Table 7: Pilot Burner Location
Figure 18: Spark Gap Setting
Figure 19: Flueway Cleaning
H. Removal or replacement of pilot assembly or pilot assembly
parts. If pilot assembly, sensor or pilot orifi ce need replacing,
remove main burner with pilot using procedure described in
Paragraph F.1.1. To replace orifi ce.
a. Disconnect pilot tubing. Pilot orifi ces screw into Pilot
Burner. Replace with Honeywell 388146NE (Natural Gas) or Honeywell
388146KP (LP/Propane).
b. Reconnect pilot tubing and check for leaks.
2. To adjust or check spark gap between electrode and hood on
Honeywell Q348A intermittent pilot. See Figure 18.a. Use round wire
gauge to check spark
gap.b. Spark gap should be 1/8 inch for
optimum performance.
3. To replace complete pilot assembly.a. Remove two machine
screws holding
pilot burner to pilot bracket.b. Disconnect pilot tubing.c.
Disconnect all other leads to pilot.d. Select pilot assembly with
identical
model number, reconnect leads and pilot tubing. Resecure to
pilot bracket.
4. Reinstall main burner following procedure described in
Paragraph F.
I. Lubrication. There are no parts requiring lubrication by
service technician or owner. Circulator bearings are water
lubricated. Blower motor bearings are factory sealed.
J. Procedure for measuring blower inlet pressure. See Figure
20.1. With boiler off, remove hose at pressure
switch.2. With tee connect water manometer as shown
with additional tubing.
relioBledoM
htiwrenruBniaM*tekcarBtoliP06
detacoLrenruBtoliPniaMneewteB
*srenruB
VP302 1 2&1
VP402 2 3&2
VP502 3 4&3
VP602 4 5&4
morfdeweivsathgirottfelderebmunsrenrubniaM*.reliobfotnorf
-
26
IX. Repair Parts
All Series 2PV 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.
Table 8: Minimum Fan Pressure
Figure 20: Procedure for Measuring Fan Pressure
3. Start boiler and read pressure on manometer when boiler water
temperature reaches operating temperature. Refer to Table 8 for
minimum readings.
NOTE: If switch drops-out before boiler reaches temperature or
if pressure reading is below minimum shown in Table 8, check for
cracks in hose or contact your nearest Burnham representative.
4. Stop boiler, remove manometer and reconnect hose to pressure
switch.
ledoMrelioB rewolBmuminiMerusserPtelnI
VP302 .c.wsehcni04.0-
VP402 .c.wsehcni04.0-
VP502 .c.wsehcni07.0-
VP602 .c.wsehcni07.0-
-
27
yeK.oN noitpircseD
rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602
ylbmessAnoitceS.1 123071716 124071716 125071716 126071716
ylbmessArewolB/yponaC.2
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erawdraHnommoC]01[D2 xeHyvaeH,02-,tuN erawdraHnommoC]2[E2
]F2.oNyeKnidedulcnI[teksaGgnitnuoMrewolB 8406028]1[ 9406028]1[F2
rewolB 4171116]1[ 5171116]1[G2
]F2.oNyeKnidedulcnI)2([teksaGetalPecifirO 2406028]2[ 5306028]2[
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J2 803AreywD,gnittiFerusserP 756228]1[K2
]F2.oNyeKnidedulcnI)4([ssarB,02-4/1,tuNxeH 42406808]4[L2
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-
28
yeK.oN noitpircseD
rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602
puorGylbmessAesaB.33 etelpmoC,ylbmessAesaB 193006816]1[
194006816]1[ 195006816]1[ 196006816]1[A3 ylbmessAyarTesaB
193006817]1[ 194006817]1[ 195006817]1[ 196006817]1[B3 repparWesaB
113006817]1[ 114006817]1[ 115006817]1[ 116006817]1[1B3
noitalusnIdnEesaB 106027]2[2B3 noitalusnIraeResaB 53006027]1[
54006027]1[ 55006027]1[ 56006027]1[
C3 ylbmessAlenaPtnorFesaB 143006816]1[ 144006816]1[ 145006816]1[
146006816]1[D3 yarTrenruB 503006817]1[ 504006817]1[ 505006817]1[
506006817]1[E3 ylbmessAgeLesaB 1006816]4[1E3 geLesaB 12006817]4[2E3
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F3 lenaPsseccArenruB 163006817]1[ 164006817]1[ 165006817]1[
166006817]1[G3 tfeL,tekcarBtnemhcattAtekcaJ 11006407]1[H3
thgiR,tekcarBtnemhcattAtekcaJ 21006407]1[
J3 "2x",teksaGtlefareC 004-FRCellivsnaM-snhoJ 2006026]1[
K3 naPspillihP,FepyTgnippaT-fleS,wercS detalP,"x02-,daeH
00706808]02[
L3 "1x81-"61/5,gnippaTfleS,wercS 71706808]4[M3 "61/5,rehsaWtalF
erawdraHnommoC]4[N3 81-"61/5,tuNkcoLxeH 46406808]4[P3
"x8#,daeHspillihP,lateMteehS,wercS erawdraHnommoC]2[
-
29
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35
A 24 VAC LWCO is used primarily for gas fi red 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 fi lling the system. The boiler should attempt to
operate once the water level is above the LWCO.
X. Low Water Cut Off (LWCO) on Hot Water Boilers
Wiring of Typical LWCO
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 fl oor 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 fl oat 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.
LWCO Location
draining the heating system. Many probe LWCO manufacturers
recommend an annual inspection of the probe.
How to Wire LWCOs are available in either 120 VAC or 24 VAC
confi gurations. The 120 VAC confi guration 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.
Select the appropriate size tee using the LWCO manufacturers
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 LWCO
and the boiler to allow for servicing. This will allow probe
removal for inspection without
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36
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 modifi cation, 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
insuffi cient water, allowing the boiler to freeze, subjecting the
boiler to fl ood 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 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 in a 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 ANY, 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 not void the owners 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 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.
Limited WarrantyFOR RESIDENTIAL CAST IRON WATER BOILERS
03/03
Subject to the terms and conditions 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 fi rst 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, at 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:
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 CONDITIONS1. 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 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 manufacturers 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. specifi cally 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
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