Burnham Care-Free E4 Installation, Operating And Service Instructions
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8143606R9-2/10 Price - $3.00
IMPORTANT: READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE
INSTALLATION OF BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER
AND SERVICE TECHNICIAN. MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION.
NOTE: — The equipment shall be installed in accordance with those installation regulations in force in the area where the
installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before
installations are made.
All wiring shall be made in accordance with the National Electrical Code and/or local regulations.
SECTION I - INSTALLATION INSTRUCTIONS ...........................................................Page 3
SECTION II - OPERATING AND SERVICE INSTRUCTIONS .....................................Page 5
CLEARANCE REQUIREMENTS
For Service Accessibility
LEFT SIDE 18" 18"
RIGHT SIDE 6" 0"
TOP 9" 9"
BOTTOM 9" 15"
REAR 0" 0"
FRONT For Door Removal - 24"
* Closet Installation Requires Two Ventilation Openings, one located at top and one at bottom, each opening to have 25 sq. in. net free area.
Approved for Closet & Alcove Installation with minimum
clearance to combustible material*
2" Closet
18" Alcove
Water Flow Rate -
Recommended Power
Supply to Boiler
Min.*
Wire Size
#4 AWG 80 155 3½ 5.5 4.6 4.2
Max. Fuse
Size-Amps
Appx.
Wt. Full
(Lb.)
Water
Contents
(Gal.)
Boiler
Model
DOE HEATING
CAPACITY, BTU/HR
AFUE
KW
Amps
Rating
%
(240V)
(240V)
No. and Size
of Elements
240V 220V 208V
412 41,000 35,000 31,000 100 12 50 4-3KW #6 AWG 60 155 3½ 4.1 3.5 3.1
416 55,000 46,000 41,000 100 16 70
420 68,000 58,000 52,000 100 20 85 4-5KW #2 AWG 90 155 3½ 6.8 5.8 5.2
DOE Heating Capacities are shown. Where the boiler and piping are in the heated space, the boiler may be selected on the basis of the DOE Heating Capacity. Where
a piping loss and/or a pickup loss will exist, add this loss to the building loss to determine the total heating requirements. Where a piping loss only will exist but cannot be
calculated, multiply the calculated building loss by a 1.15 factor to determine the total heating requirement.
*For runs in excess of 50 ft. consult local or national electrical code.
Maximum Allowable Working Pressure: 30 PSI (Water Only)
2-3KW (top)
2-5KW (bottom)
(GPM) Based on 20°F
Temp. Rise and Boiler
Capacity At
240V 220V 208V
Figure 1: Dimensions and Specications
2
SECTION I: INSTALLATION INSTRUCTIONS
A. Inspect Shipment carefully for any signs of damage.
1. All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of Boiler to the carrier in good condition.
2. Any claims for damage or shortage in shipment
must be led immediately against the carrier by
the consignee. No claims for variances from,
or shortage in orders, will be allowed by Boiler
Manufacturer, unless presented within sixty (60)
days after receipt of goods.
B. Read These Instructions Carefully before proceeding
with installation and operation of the “CARE-FREE”
Electric Boiler.
1. The “CARE-FREE” is U.L. listed, constructed
and tested in accordance with the requirements of
the ASME Boiler and Pressure Vessel Code and
designed for use in any conventional hydronic
system except steam and gravity hot water.
2. The “CARE-FREE” Electric Boilers are shipped
completely assembled less circulator. All electrical
controls are mounted and wired in a compartment
immediately behind the Front Door of the Boiler
Jacket, see Figure 1.
C. Locate Boiler in or adjacent to the space to be heated
with consideration given to the location of the electrical
service. Although its compactness will allow the
“CARE-FREE” Electric Boiler to be mounted almost
anywhere – closet, alcove, or other small area, see
CLEARANCE REQUIREMENTS on Page 2.
D. Mount Boiler to wall using four 3/8" lag screws
or anchor bolts (depending upon wall construction)
passing through the holes provided in the wall
mounting channels. Figure 1 shows bolt center
dimensions. It is recommended that 1/2" plywood
be used as a base for mounting the boiler so that the
structure is adequate to carry the weight imposed upon
it – see Figure 1 for weight of boiler when full of water.
Boiler should be level for proper operation of BUILTIN AIR SEPARATOR.
E. Connect Supply and Return Piping to Heating
System using standard recognized practices. See Figure
2. Install an appropriate size expansion tank in system
as per Figure 2. Do not connect into the 3/4" tee on top
of the boiler; instead install an automatic oat type air
vent at this point. Water content of the boiler is given
in Figure 1.
The relief valve outlet should be piped full size to a
drain or near the oor.
The heating elements are NOT compatible with
ethylene glycol based antifreeze.
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.
If it is required to perform a long term pressure test of
the hydronic system, the boiler should rst e isolated to
avoid a pressure test including the boiler, ALL trapped
air must 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.
Figure 2: Recommended Boiler Piping
3
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