Burnham 2PV Series Installation, Operating And Service Instructions
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Price - $3.00
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.
REGNAD
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laitnatsbusroyrujnisuoires,htaedni
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GNINRAW
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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.
.egamadyt
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Table of Contents
tluseryam,dediovatonfi,hcihwnoitautis
I. Pre-Installation ........................4
II. Unpack Boiler ..........................5
III. Water Piping ............................6
IV. Gas Piping ................................8
V. Venting ......................................9
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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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Figure 1: Elevation Views
ABCD
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VP302½02½4161/1-018/5-512.3562
VP602¼03¼428/1-51¼515.5914
VP5027212½31¼517.4753
VP402¾32¾71118/5-514 903
3
I. Pre-Installation
GNINRAW
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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.
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.
GNINRAW
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G. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
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.
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.
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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 [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.
4
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconfi ned
space.
b. If result is less than 50 ft³ 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 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
fl ammable vapors or liquids, or sources of hydrocarbons
(i.e. bleaches, cleaners, chemicals, sprays, paint
removers, fabric softeners, etc.) are used or stored.
NOITUAC
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II. Unpack Boiler
NOITUAC
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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
Paragraphs E and F.
D. Remove all boiler hold-down fasteners.
reliobpmubtonoD.reliobpordtonoD
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
NOITUAC
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A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water.
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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 ½ 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.
GNINRAW
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E. Install Drain Valve in ¾" NPT connection in tee
provided. See Figure 1.
F. Space heating and domestic water heating with
Alliance water heater. Install Alliance water heater as a
nitluseryamreliobepipylreporpoteruliaF
roreliobotegamaddnanoitareporeporpmi
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
.eruliafreliobotdaelnacdna,stnenopmoc
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 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 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 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.
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
ebtsumgnipipegrahcsidevlavfeilerytefaS
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.
6
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.
Figure 3: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
Figure 4A: Boiler Piping for Circulator Zoned Heating System
7
IV. Gas Piping
Figure 4B: Boiler Piping for Zone Valve Zoned Heating Systems
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
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VP40269½83½
VP50203125½
VP602461¾56½
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.
8
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 shut-off 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 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.
Table 2: Maximum Capacity of Schedule 40 Pipe in CFH For Gas Pressures of 0.5 psig or Less
Figure 6: Recommended Gas Piping
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01231872025050,1571063086004,1
0229091053037021052564059
033725158209579002573077
043603154200528071023066
056551151204437151582085
060550159100466831062035
07646908107316521042094
08340907105375811022064
09044806102335011502034
001839705150305301591004
Table 3: Fitting Equivalent Lengths
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Table 4: Specifi c Gravity Correction Factors
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05.001.103.170.1
55.040.104.140.1
06.000.105.100.1
56.069.006.179.0
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07.039.007.149.0
57.009.0
08.078.0
9
V. Venting
GNINRAW
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tneserpro/dnaderots,desuera).cte
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Table 5: Burnham Vent System Components
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tF3xepiP.aiD"3U8926118
tF5xepiP.aiD"3U0036118
elbatsujdAxepiP.aiD"3U9136118
iD"3U4926118
woblE°09.a
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eeTniarDlatnoziroH.aiD"3U2036118
eeTniarDlacitreV.aiD"3U4036118
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10
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odyehtsa,niojotreisaednarekciuqyllarenegerastnenopmoctnevrewenehT.stnenopmoc
.dehcattaerasdnabpmalcriehtdnanoitacilppatnalaesehteriuqerton
deteksagatneveehtnI
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stnenopmoctnevfogniniojynA)1
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tnevelamgnitamehtfongised
.tnalaesfoebutecnuo
adnatnenopmoctnev
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htiwdetaicossasnoitcurtsniehtwollof,detcen
foselpicnirpgnidiugowtehT.C8roB8erugiF
Figure A: Burnham Vent
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3enodnadnabpmalcenosniatnoctahtelbaliavasi,2036116rebmuntrap,tiKnoitisnarTtneVA
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
11
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