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20-PV-I

Burnham 20-PV-I User Manual

INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
SERIES 2PV
GAS BOILER
Price - $3.00
Boiler Model Number
20_ PV_I- _ _ _ _
Heating Contractor Phone Number
Address
8141775R9-11/99
Boiler Serial Number
6 _ _ _ _ _ _ _
1
Installation Date
The 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.
CAUTION
DANGER
Indicates an imminently hazardous situation which, if not avoide d, will result in death, ser i ous i nj ur y or sub s t anti a l prope rty dam a ge.
Indicates a potentially hazardous situation w hic h, if n o t avo id ed , m ay re sult in mod erate o r m inor injury or property damage.
WARNING
Indicates a potentially hazardous situation which, if not avoide d, could result in death, serious injury or substantial property damage.

T able of Contents

I. Pre-Installation ..................................... 4
II. Unpack Boiler ....................................... 5
III. Water Piping ......................................... 6
IV. Gas Piping ............................................ 8
V. Venting ................................................. 9
VI. Electrical ............................................. 12
VII. System Start-up .................................. 13
NO TI CE
Indicates spec ial ins tructions on installation, operation, or maintenance which are important but not related to personal injury hazards.
VIII. Service Instructions ............................ 20
IX. Repair Parts ........................................ 23
2
NOTICE
USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orifice sizing is indicated on th e rating label. High altitude b oiler models are identifiable by the second digit in the model number suffix on the rating label:
20_PV_I-__2: Less than 2000 ft. elevation 20_PV_I-__4: 2000 ft. and high er elevation, C anada 20_P V_I-__5: 2000 ft. and higher elevation , USA
Figure 1: Elevation Views
Boiler Model
Dimensions [in inches]
ABCD
203PV 20‰ 14‰ 10-1/16 15-5/8 3.2 265 204PV 23 17 11 15-5/8 4 309 205PV 27 21 13‰ 15… 4.7 357 206PV 30… 24… 15-1/8 15… 5.5 419
Water Content
[Gallons]
Approx. Shippin g
3
Weight (lb.)
I. Pre-Installation
WARNING
Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death.
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 filed 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.
C. Appliance is design certified for installation on
combustible flooring. The boiler must not be installed on carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local fire 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 floor. For basement installation
provide solid base, such as concrete, if floor is not level or if water may be encountered on floor around boiler.
F. Install near outside wall for through wall venting.
Refer to Section V: Venting. Certified for minimum vent length of 2 feet with one (1) elbow and maximum vent length of 15 feet with one (1) or two (2) elbows.
WARNING
Certified as Category III appliance. Install vent system in accordance with Section V: Venting. Do not vent using masonry chimney, Type B gas vent, or other Category I venting system.
Figure 2: Minimum Clearances to Combustible
Construction for Closet Installation
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.
WARNING
Adequate combustion and ventilation air must be provided to assure proper combustion.
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.
4
Volume [ft³] = 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.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconfined space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a confined 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 floors, between wall-ceiling joints, between wall panels, at plumbing and electrical penetrations, and at other openings.
5. For boiler located in an unconfined space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors.
6. For boiler located within unconfined space in
building of unusually tight construction or within confined 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 confined space. Use indoor air if two permanent openings
communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined 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 fixed in open position or interlocked with equipment to open automatically before burner operation. Screens must not be smaller than ¼ 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
flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket against floor.
A. 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 Steps 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.
5
III. Water Piping and Trim
CAUTION
Failure to properly pipe boiler may result in improper operation and damage to boiler or building.
A. Design and install boiler and system piping to prevent
oxygen contamination of boiler water.
CAUTION
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham’s standard warranty does not cover problems caused by oxygen contamination of boiler water.
Oxygen contamination sources are system leaks requiring addition of makeup water, fittings, and oxygen permeable materials in distribution system. Eliminate oxygen contamination by repairing system leaks, repairing fittings, and using nonpermeable materials in distribution system.
B. Connect system supply and return piping to boiler. See
Figure 3. Also consult I=B=R Installation and Piping Guides. Maintain minimum ½ inch clearance from hot water piping to combustible materials.
C. Install Circulator with flanges, 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.
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 4. 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 flow 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 encountered (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 5. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figure 5 in order to regulate water flow 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 200°F supply water temperature. Opening the boiler supply valve will raise system temperature, while opening the by-pass valve will lower system supply temperature.
D. Install Safety Relief Valve. See Figure 3. Safety Relief
Valve must be installed with spindle in vertical position. Installation of the relief valve must be consistant with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
WARNING
Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves.
E. Install Drain Valve in ¾" NPT connection in tee
provided. See Figure 1.
J. A hot water boiler installed above radiation level must be
provided with a low water cutoff device as part of installation.
K. 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 flushed. A qualified water treatment chemical specialist should be consulted for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations.
L. After the boiler and system have been cleaned and
flushed, and before refilling the entire system add
appropriate water treatment chemicals, if necessary, to bring the pH between 7 and 11.
6
Figure 3: Recommended Boiler Piping For Series - Loop Hot Water Heating Systems
Figure 4: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
Figure 5: Recommended Bypass Piping
7
IV. Gas Piping
A. 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 ½ 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
Boiler
Model
Number
203PV 62 24 ‰ 204PV 96 38‰ ‰ 205PV 130 52 ‰ 206PV 164 65 ‰
Natural Gas LP/Propane
Input Rate
[cubic feet per hour]
Gas
Connection
Size
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 ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler's individual manual shutoff valve.
2. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. Do not use matches, candles, open flames, or other ignition source.
3. Length of piping and number of fittings. Refer to Table 2 for maximum capacity of Schedule 40 pipe. Table 3 lists equivalent pipe length for standard fittings.
4. Specific gravity of gas. Gas piping systems for gas with a specific gravity of 0.70 or less can be sized directly from Table 2, unless authority having jurisdiction specifies a gravity factor be applied. For specific gravity greater than 0.70, apply gravity factor from Table 4. If exact specific 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 liquefied petroleum gas.
Figure 6: Recommended Gas Piping
8
Table 2: Maximum Capacity of Schedule 40 Pipe in CFH For Gas Pressures of 0.5 psig or Less
Length
[Feet]
10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 118 220 460 90 40 84 160 320 53 110 205 430
100 38 79 150 305 50 103 195 400
0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop
‰ 1 1… ‰ 1 1…
Table 3: Fitting Equivalent Lengths Table 4: Specific Gravity Correction Factors
Fitting
Nominal Pipe Size
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
‰ 1 1…
45 Ell 0.7 1 1.2 1.6 90 Ell 1.6 2.1 2.6 3.5
Tee (As Elbow) 3.1 4.1 5.2 6.9
0.50 1.10 1.30 1.07
0.55 1.04 1.40 1.04
0.60 1.00 1.50 1.00
0.65 0.96 1.6 0.97
0.7 0.93 1.7 0.94
0.75 0.9
0.8 0.87
V. Venting
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 fire officials 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.
WARNING
Do not use this appliance with nonmetallic vent systems such as Hart & Cooley Ultravent, Plexco Plexvent, or Selkirk-Metalbestos Sel-Vent.
9
Table 5: Burnham Vent System Components
Burn ham
Vent System
Component
*Car to ned
Part
Numbe r
3" Dia. Pipe x 1 Ft 61160112 8116135 3" Dia. Pipe x 3 Ft 61160101 8116058 3" Dia. Pipe x 4 Ft ** 8116176 3" Dia. Pipe x 5 Ft 61160111 8116059
3" Dia. 90 E lbow 61160121 8116060 3" Dia. 45 E lbow 61160131 8116061
Com plete with Locking Band(s)
*
61160 33 Contains (4) 4 ft. lengths
* *
6116040 Contains (2) 4 ft. lengths
Burn ham
Component
Part
Numbe r
3. Minimum vent length requirement is 2 feet of pipe and one (1) elbow. Maximum vent length is 15 feet with one (1) or two (2) elbows.
4. Do not install venting system components on the exterior of the building except as specifically required by these instructions.
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:
(a) Seal any unused openings in the common venting
system.
(b) Visually inspect the venting system for proper size
and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other 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.
(d) Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate
continuously.
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
(f) After it has been determined that each appliance
remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use.
(g) 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, orifice plate and hardware from blower outlet flange.
3. Assemble orifice plate gaskets, orifice plate, and vent connector. See Figure 7.
4. Secure vent connector with washers and locknuts.
Figure 7: Vent Connector Installation
10
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