Burnham Care-Free E4 Installation, Operating And Service Instructions

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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 Specications

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

F. Install Electric Wiring in accordance with

NATIONAL ELECTRICAL CODE and Local
Regulations. The Burnham “CARE-FREE” Electric
Boilers may be used with 208 and 240 volt, 60 cycle,
single phase power and one 3 wire power supply. Since
the heaters are rated at 240 volts, however, any input
voltage less than this affects boiler capacity, see Figure

3.

To remove Front Door for access to terminal blocks and

controls:

1. CAUTION – make sure Electrical Service to Boiler
is disconnected.

2. Remove retaining screw at top of door.

3. Lower Door as far as possible, then push forward
until Hinge Pins in lower corners slide out of the
slots.

4. Raise one side of Door until Door will clear opening
– pull forward for removal.

Repeat above in reverse for replacing Door.

Provisions are provided in the right side of the boiler

jacket for power input, circulator, and thermostat
wiring, see Figure 1.

The power input legs are connected to the L1 and

L2 terminals on the terminal board on the control
compartment of the boiler. The neutral leg is connected
to the terminal marked N. Minimum recommended
wire sizes are shown in Figure 1. A separate grounding
conductor of at least #6AWG copper must be run to the

eld grounding lug on the control panel.

The Circulator is to be connected from its housing to

the terminals marked N and M on the Main Terminal
Block using Flexible Conduit, see Figures 2 and 4.
If the “QUICK CONNECT CIRCULATOR-PAK”
is ordered as Optional Equipment from the Boiler
Manufacturer, the Flexible Conduit for connecting the
circulator will be furnished.

G. A Prewired Low Voltage Control System is furnished

with every “CARE-FREE” boiler.

1. All controls are furnished in a compartment at the
front of the boiler for easy accessibility. In addition
to the Transformer used to power the system, are
the following: Circulator Relay, Heating Element
Sequencers (one per Heating Element), Dual High
Limit Control, Circulator Operation Selector Switch,
Circulator Fuse and Heating Element Relays.

2. If the Circulator Fuse is blown, power is interrupted
to the Transformer and hence, the control system
de-energized. This action prevents the Heating
Elements from coming on while the Circulator is
inoperative.

A Circulator Operation Selector Switch provides for

either Continuous or Intermittent Circulator operation.
With the switch in the “CONT.” position the Circulator
Delay Control will be bypassed and the Circulator will
operate continuously. The room Thermostat regulates
only the operation of the Heating Elements in the boiler.

With the Circulator Switch in the “INT.” position, the

Thermostat will operate both the Circulator and the
Heating Elements. Timing and wiring of the bimetal
heaters in the Circulator Relay and Sequencers assures
Circulator operation before and after Heating Elements
are energized and de-energized, respectively. The
Sequencers permit only one Heating Element at a time
(from bottom to top) to be energized thus preventing
a sudden inrush of electrical current. More detailed
operation is described in subsequent pages.

Wiring of a one zone system is shown in Figure 4.

Figures 5 and 6 show wiring for zoned systems, the
former when Zone Valves are used and the latter when
multiple Circulators are used.

Figure 3: Boiler Capacity at Various Voltages

4

SECTION II: OPERATING AND SERVICE INSTRUCTIONS

A. Intermittent Circulator Operation

1. ROOM TH ERMOSTAT CLOSES

2. CIRCULA TOR MOTOR ENERGIZE D

a. As the thermostat closes its contacts, a low

voltage circuit (24V.) is completed to the bimetal
heater in the circulator relay (24A51). After
a time delay of 15 seconds, the main contacts
(120V.) of the circulator relay close to start the
circulator.

3. HEA TING ELEM ENT #1 EN ERGIZED

a. Simultaneous with the completing of the circuit

for the circulator relay, two additional circuits
are completed.

b. The rst circuit is for the Heating Element

Relays which pull in immediately and the
second is for the bimetal heater in the #1 Heating
Element Sequencer (24A54).

c. These two circuits will be energized only if the

boiler is not “OFF” on limit.

d. After a time delay of 45 seconds (30 seconds

after the circulator has started) the main and
auxiliary contacts of the #1 Sequencer close;
the main contacts (240V.) energizing heating
element #1 and its pilot light (located at the
bottom of the side panel), the auxiliary contacts
(24V.) energizing the bimetal heater in the #2
Heating Element Sequencer.

4. HEA TING ELEM ENT #2 EN ERGIZED

a. 45 seconds after bimetal heater in #2 Heating

Element Sequencer is energized, its main
contacts (240V.) and auxiliary contacts close;
the main contacts energizing heating element #2
and its pilot light (3rd lowest in the boiler), the
auxiliary contacts (24V.) energizing the bimetal
heater in the #3 Heating Element Sequencer.

5. HEA TING ELEM ENT #3 EN ERGIZED

a. 45 seconds after bimetal heater in the #3 Heating

Element Sequencer is energized, its main
contacts and auxiliary contacts close; the main
contacts (240V.) energizing heating element #3
and its pilot light (2nd lowest in the boiler), the
auxiliary contacts (24V.) energizing the bimetal
heater in the #4 Heating Element Sequencer.

6. HEA TING ELEM ENT #4 EN ERGIZED

a. 45 seconds after bimetal heater in #4 Heating

Element Sequencer is energized, its main
contacts and auxiliary contacts close, the main
contacts (240V.) energizing heating element #4
and its pilot light (highest in the boiler) – nothing
is connected to the auxiliary contacts.

7. ROOM TH ERMOSTAT OPENS

8. HEATING ELEMENTS DE-ENERG IZED

When the thermostat is satised and opens its

contacts, the low voltage circuits to the Heating
Element Relay and the Heating Element Sequencers
are broken. The Heating Element Relays “drop-out”
immediately and totally de-energize the Heating
Elements and pilot lights. After a time delay of 45
seconds, the main contacts of all the Sequencers
“break” thus resetting the Heating Element Relays.

9. CIRCULA TOR MOTOR DE-ENERG IZED

Simultaneous with the breaking of the low voltage

circuit to the Heating Element Sequencers is the
breaking of the low voltage circuit to the Circulator
Relay by the opening of the thermostat contact.
After a time delay of 90 seconds after all Heating
Elements are “off” the bimetal heater opens the
main contacts in the Circulator Relay thus stopping
the circulator. When the boiler is zoned with
circulator and switching relays as illustrated in
Figure 6 on Page 8 the circulator switch must be in
the “constant” position; therefore the circulator will
not have any delay when the thermostat(s) closes or
opens its contacts.

B. Continuous Circulator Operation

If the Circulator Switch (located in the control portion

of the Boiler Jacket) is placed in the “CONT.” position,
the Circulator will run continuously and the Heating
Elements will sequence as in steps 3-6 and 8 above.

C. Dual Limit Operation

The Dual Limit Control consists of two independently

adjustable temperature limits. The left hand adjustment
is for the safety limit and should be set initially for
220°F. The lower right hand adjustment is for the
operating limit and should be set for 210°F with a
differential setting (upper right hand adjustment) of 10º.
These adjustments may be varied to suit the individual
installation, with minimum of 10° difference between
the limit settings. If the setting of the operating Limit
or the safety limit is reached, the Heating Elements only
will be de-energized; the Circulator will continue to
run. If the Circulator Switch is in the “INT.” position,

the Circulator runs until the thermostat is satised and

the main contacts on the Circulator Relay open.

WARNING

Before installation of the boiler is considered
complete, the operation of the boiler controls
should be checked, particularly the Operating &
Safety Limit Controls.

5

Figure 4: Wiring Diagram - Model E-4 Boilers

6

D. Indicator Lights

There is an indicator light for each heating element.

If an indicator light is “on” it indicates its respective
heating element is energized. If the light is “off” it
indicates:

1. The heating element has not been energized.

2. The heating element sequencer is malfunctioning.

E. Built-In Air Eliminator

An air eliminator has been built into the top of the

electric boiler and a 3/4" tapping is provided with

nipple and tee for connection of Relief Valve and a oat

type Air Vent. See Figure 1.

Figure 5: Wiring Diagram - 3 Zone System

White-Rodgers 2 Wire Zone Valves

Figure 6: Wiring Diagram - 2 Zone System

Multiple Circulators

7

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Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc.
Lancaster, Pennsylvania hereby extends the following limited warranties to the original
owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied
parts and/or accessories manufactured and shipped on or after July 1, 2008:

ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS
AND PARTS / ACCESSORIES SUPPLIED BY U.S. BOILER COMPANY, INC.

U.S. Boiler Company, Inc. warrants to the original owner that its residential grade
water and steam boilers and parts/accessories 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 residential grade boiler or
any part or accessory provided by U.S. Boiler Company, Inc. is found to be defective
in material or workmanship during this one year period, U.S. Boiler Company, Inc.
will, at its option, repair or replace the defective part.

HEAT EXCHANGER WARRANTIES

U.S. Boiler Company, Inc. warrants to the original owner that the heat exchanger of its
residential grade boilers will remain free from defects in material and workmanship
under normal usage for time period specified in the chart below of the original owner at
the original place of installation. If a claim is made under this warranty during the “No

Charge” period from the date of original installation, U.S. Boiler Company, Inc. will, at its

option, repair or replace the heat exchanger. If a claim is made under this warranty after
the expiration of the “No Charge” period from the date of original installation, U.S. Boiler
Company, 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 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

Repair Parts Pricing where the heat exchanger last

appeared or the current retail price of the then nearest equivalent heat exchanger.

*MegaSteam Waterside Corrosion Warranty: U.S. Boiler Company, Inc. warrants the
cast iron sections of the MegaSteam boiler to resist Temperature Induced Chloride
Activated Graphitic Corrosion for a period of five years from the date of original
installation. In the event that any cast iron section of a Mega Steam boiler fails due to
this corrosion mechanism during this period, U.S. Boiler Company, Inc. will repair or
replace, at its option, the cast iron section assembly.

LIFETIME NIPPLE LEAKAGE WARRANTY

U.S. Boiler Company, Inc. warrants the cast iron and steel nipples that join the cast iron
boiler sections to be free of defects in material and workmanship for the lifetime of the
original owner at the original place of installation. In the event that such nipples are
found to be defective in material and workmanship during this period, U.S. Boiler
Company, Inc. will repair or replace at its option, the cast iron section assembly.

ADDITIONAL TERMS AND CONDITIONS

1. 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 boilers, parts, or accessories
designated as residential grade by U.S. Boiler Company, Inc. and installed in a
single or two-family residence and do not apply to commercial grade products.

2. Components Manufactured by Others: Upon expiration of the one year limited
warranty on residential grade boilers, all boiler components manufactured by
others but furnished by U.S. Boiler Company, Inc. (such as oil burner, circulator
and controls) will be subject only to the manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by U.S. Boiler Company, Inc.
are conditioned upon the installation of the residential grade boiler, parts, and
accessories in strict compliance with U.S. Boiler Co., Inc. installation
instructions. U.S. Boiler Company, Inc. specifically disclaims liability of any
kind caused by or relating to improper installation.

4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Company,
Inc. conditioned upon the use of the residential grade boiler, parts, and
accessories for its intended purposes and its maintenance accordance with U. S.
Boiler Company, Inc. recommendations and hydronics industry standards. For
proper installation, use, and maintenance, see all applicable sections of the

Installation and Operating, and Service Instructions Manual furnished with the unit.

5. This warranty does not cover the following:
a. Expenses for removal or reinstallation. The homeowner will be responsible

for the cost of removing and reinstalling the alleged defective part or its
replacement and all labor and material connected therewith, and
transportation to and from U.S. Boiler Company, Inc.

b. Components that are part of the heating system but were not furnished by

U.S. Boiler Company, Inc. as part of the residential boiler.

c. Improper burner adjustment, control settings, care or maintenance.

d. This warranty cannot be considered as a guarantee of workmanship of an

installer connected with the installation of the U.S. Boiler Company, Inc.
boiler, or as imposing on U.S. Boiler Company, Inc. liability of any nature for
unsatisfactory performance as a result of faulty workmanship in the
installation, which liability is expressly disclaimed.

e. Boilers, parts, or accessories installed outside the 48 contiguous United

States, the State of Alaska and Canada.

f. Damage to the boiler and/or property due to installation or operation of the

boiler that is not in accordance with the boiler installation and operating
instruction manual.

g. Any damage or failure of the boiler resulting from hard water or scale

buildup in the heat exchanger.

h. Any damage caused by improper fuels, fuel additives or contaminated

combustion air that may cause fireside corrosion and/or clogging of the
burner or heat exchanger.

i. Any damage resulting from combustion air contaminated with particulate

which cause clogging of the burner or combustion chamber including but
not limited to sheetrock or plasterboard particles, dirt, and dust particulate.

j. Any damage, defects or malfunctions resulting from improper operation,

maintenance, misuse, abuse, accident, negligence including but not limited to
operation with insufficient water flow, improper water level, improper water
chemistry, or damage from freezing.

k. Any damage caused by water side clogging due to dirty systems or

corrosion products from the system.
l. Any damage resulting from natural disaster.
m. Damage or malfunction due to the lack of required maintenance outlined in

the Installation and Operating Manual furnished with the unit.

6. Exclusive Remedy: U.S. Boiler Company, 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 Company, 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 Company, Inc. liability under these warranties shall under no
circumstances exceed the purchase price paid by the owner for the residential
grade 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 Company, Inc. with respect to any defect in a residential grade boiler, parts,
or accessories and U.S. Boiler Company, 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 BOILER SHALL
EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE
HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE
OF INSTALLATION. SOME STATES DO NOT 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 Warranty Card provided with the product or register product online
at www.burnham.com within ten days after the installation of the boiler, although

failure to comply with this request will not void the owner’s 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
Company, Inc.,

C/O Burnham, 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 Company, Inc. or its representative the parts
claimed to be defective and, if requested by U.S. Boiler Company, Inc. to ship
these parts prepaid to U.S. Boiler Company, 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.

Years in Service 1-5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25+

Cast Iron Water 5 15 20 25 30 40 45 50 55 60 65 70 75

Cast Iron Steam*

Carbon Steel 5 15 20 25 30 40 45 50 55 60 65 70 75

Cast Aluminum 30 40 50 60 70
Stainless Steel 30 40 50 60 70

Service Charge as a % of Retail Price

No Charge 10

No Charge 10

No Charge 100

No Charge 100

No Charge 100