Burnham 20_PV_I manual

1 8141775R12-3/01 Price - $3.00 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 2PV POWER VENT GAS - FIRED BOILER For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number 20_PV_I -_ _ _ _ Boiler Serial N[...]

2 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. Table of Contents I. Pre-Installation .......................................... 4 II. Unpack Boiler ............................................. 5 III. Water Piping ......[...]

3 Figure 1: Elevation Views[...]

4 I. Pre-Installation 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 [...]

5 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 con[...]

6 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[...]

7 Figure 3: Recommended Boiler Piping For Series - Loop Hot Water Heating Systems Figure 4: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems[...]

8 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 pressu[...]

9 Table 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: Specific Gravity Correction Factors Length [Feet] 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950 30 73 152[...]

10 Table 5: Burnham Vent System Components Figure 7: Vent Connector Installation 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 remai[...]

11 D. Install Vent Pipe, General. 1. Start at vent connector. Work toward vent terminal. 2. Use ¾ inch pipe strap to support horizontal runs, maintain vent location and slope, and prevent sags. Do not restrict thermal expansion movement. Maximum support spacing is 5 feet. 3. Provide minimum 5 inch clearance to combustible materials. Use thimble wh[...]

12 Figure 9: Recommendations for Thimble and Wall Penetration 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 a[...]

13 Figure 10: Wiring Diagram Figure 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 specified in American National Standard for Gas-Fired Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13. B. Fill he[...]

14 Figure 12: Gas Valve Pressure Tap 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. 3. For natural gas fired boiler, temporarily turn off all other gas-fired appliances. E. Follow Operating Instructions to place boiler in operati[...]

15 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. L. Check low water cut-off (if used). Drain bo[...]

16 Figure 17: Operating Instructions 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 suppli[...]

17 TROUBLE SHOOTING GUIDE SPLIT (SEPARATE) CONTROLS, 24 VOLT OPERATION WITH ELECTRONIC IGNITION AND INTERMITTENT CIRCULATION NOTE: 1. Read Sequence of Operation prior to using Trouble Shooting Guide. See Page 14. 2. Prior to replacing a control, always check for broken wires or loose connectors that provide power to that control.[...]

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19 Note : Minimum pilot signal should be 1.0 microamps. Disconnect Pilot Ground wire from Module and connect DC microammeter between Ground Terminal and Pilot Ground wire.[...]

20 Important Product Safety Information Refractory Ceramic Fiber Product Warning : This product contains refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. After this product is fired, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a resu[...]

21 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. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous op[...]

22 Table 7: Pilot Burner Location Figure 18: Spark Gap Setting Figure 19: Flueway Cleaning at rear of burner. See Figure 11. Slide burner over orifice. 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 Sect[...]

23 Table 8: Minimum Suction Pressure Figure 20: Procedure for Measuring Fan Suction Pressure I. Lubrication. There are no parts requiring lubrication by service technician or owner. Circulator bearings are water lubricated. Blower motor bearings are factory sealed. Boiler Model Minimum Suction Pressure 203PV -0.50 inches w.c. 204PV -0.50 inches w.c[...]

24 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 your Burnham Regional Sales Office as listed below. Contact R[...]

25 Key No. Description [Quantity] Part Number 203PV 204PV 205PV 206PV 1. Section Assembly 617170321 617170421 617170521 617170621 2. Canopy/Blower Assembly 2A Canopy [1] 61117034 [1] 61117044 [1] 61117054 [1] 61117064 2B Carriage Bolt, ¼-20 x 1" [2] Common Hardware 2C Washer, ¼, SAE [10] Common Hardware 2D Nut,¼-20, Heavy Hex [2] Common Har[...]

26 Key No. Description [Quantity] Part Number 203PV 204PV 205PV 206PV 3. Base Assembly Group 3 Base Assembly, Complete [1] 618600391 [1] 618600491 [1] 618600591 [1] 618600691 3A Base Tray Assembly [1] 718600391 [1] 718600491 [1] 718600591 [1] 718600691 3B Base Wrapper [1] 718600311 [1] 718600411 [1] 718600511 [1] 718600611 3B1 Base End Insulation [[...]

27 Key No. Description [Quantity] Part Number 203PV 204PV 205PV 206PV 4. Manifold and Main Burners 4A Main Burner [2] 8236099 [4] 8236099 [6] 8236099 [8] 8236099 4B Main Burner with 60° Pilot Bracket [1] 8236098 4C Manifold [1] 82260033 [1] 82260043 [1] 82260053 [1] 82260063 4D (Natural Gas Only) Main Burner Orifice, #44, Orange [3] 822712 ----- -[...]

28 Key No. Description [Quantity] Part Number 203PV 204PV 205PV 206PV 5. Pilot Burner and Gas Valve 5A Pilot Assembly, Natural Gas, Honeywell Q348A1333 [1] 8236104 Pilot Assembly, LP Gas, Honeywell Q348A1341 [1] 8236107 5B Pilot Orifice, Natural Gas Honeywell 388146NE Included with Key No.5A Pilot Orifice, LP/Propane Honeywell 388146KP 5C Compressi[...]

29 Key No. Description [Quantity] Part Number 203PV 204PV 205PV 206PV 6. Jacket 6A Jacket Wrap-A-Round Panel (1) [1] 604170312 [1] 604170412 [1] 604170512 [1] 604170612 6B Jacket Upper Vestibule Panel (1) [1] 6041703221 [1] 6041704221 [1] 6041705221 [1] 6041706221 6C Jacket Lower Vestibule Panel [1] 6041703222 [1] 6041704222 [1] 6041705222 [1] 6041[...]

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31 Key No. Description [Quantity] Part Number 203PV 204PV 205PV 206PV 7. Miscellaneous Trim and Controls 7A Safety Relief Valve, 30 psi, ¾ NPT, Conbraco 10-408-05 [1] 81660319 7B Limit, Honeywell L4080D1036 [1] 80160156 7B1 Immersion Well, ½ NPT Included with 7B 7B2 Immersion Well, ¾ NPT, Honeywell 123870A (Dual Limit Only) [1] 80160426 7B3 Limi[...]

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