Burnham PVG manual

8140708R8-8/08 As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that the PVG Series meets the ENERGY ST AR ® guidelines for energy efciency established by the United States Environmental Protection Agency (EP A). Price - $5.00 n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r[...]

2 IMPOR T ANT INFORMA TION - READ CAREFULL Y NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on b[...]

3 W ARNING This boiler requires regular maintenance and service to operate safely . Follow the instructions contained in this manual. Improper insta llation, adjust ment, alteratio n, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up oper[...]

4 T able of Contents Figure 1: Minimum Clearances to Combustibles I. P re-Installation ............................... 6 II. U npack Boiler ................................ 7 III. V enting ........................................... 8 IV . W ater Piping and T rim ................. 20 V . Gas Piping .................................... 25 VI. Electr[...]

5 Figure 2: Dimensions[...]

6 W ARNING If you do not follow these instructions exactly , a re or explosion may result causing property damage or personal injury . DANGER Do not install boiler where gasoline or other ammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or store[...]

7 space(s) of sufcient volume such that combined volume of all spaces meet criteria for unconned space. Size each opening for minimum free area of one (1) square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches. 7. Combustion Air/V entilation Duct Louvers and Grilles. Equip outside openings wit[...]

8 III. V enting T able 1: V ent System Options T able 2: V ent System Components Included with Boiler W ARNING Do not use this boiler with galvanized, T ype 304 or T ype 316 stainless steel, non metallic or any other non AL29-4C ® based vent systems. Do not use a barometric damper or drafthood with this appliance. Do not use vent dampers with this[...]

9 T able 3: Burnham V ent System Components T able 4: V ent Length V ent System Component Part Number Equivalent Feet of Pipe 3” Dia. Pipe x 1 Ft 81 16296U 1 4” Dia. Pipe x 1 Ft 100176-01 3” Dia. Pipe x 3 Ft 81 16298U 3 4” Dia. Pipe x 3 Ft 100177-01 3” Dia. Pipe x 5 Ft 81 16300U 5 4” Dia. Pipe x 5 Ft 100178-01 3” Dia. Pipe x Adjustabl[...]

10 A. V ent Guidelines Due to Removal of an Existing Boiler For installations not involving the replacement of an existing boiler , proceed to Step B. 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 exist[...]

1 1 a. Minimum twelve (12) inches above grade plus normally expected snow accumulation level, or seven (7) feet above grade if located adjacent to public walkway . Do not install over public walkway where local experience indicates appliance ue gas vapor or condensate creates a nuisance or hazard. b. Minimum three (3) feet above any forced air i[...]

12 c. T ighten locking band by HAND with a 5/16” nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH SHEET MET AL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM! d. Once the installation is complete, operate appliance and inspect all joints to ensure that ue gases and/or liquid condensate will not escape. D. Horizontal V entin[...]

13 Figure 4: Recommended Horizontal – V ent Installation[...]

14 Figure 4A: Alternate Horizontal – V ent Installation[...]

15 Figure 5: Horizontal – V ent T erminal Conguration (3” or 4” V ent)[...]

16 V ent Piping – 1. Do not exceed maximum vent lengths. Refer to T able 4. 2. Installation of a vertical vent tee 8116304U is required on all vertical vent applications. See Figures 6 and 7. Attach vertical vent drain tee directly to elbow or horizontal pipe from an elbow immediately after vent connector . 3. Slope horizontal runs minimum ¼ inc[...]

17 Figure 7: Attic Offset Figure 6: V ertical V ent Installation[...]

18 Figure 8: V ertical V ent T ermination Extend V ent Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof sur - face. Allow additional vertical (“X”) distance for expected snow accumulation.[...]

19 1. Do not exceed maximum vent lengths. Refer to T able 4. 2. This installation will allow a maximum of seven (7) feet vertical exterior run of the vent piping to be installed . NOTICE Exterior run to be included in equivalent vent lengths. 3. Install vent piping. a. Install vent piping for desired venting system. Refer to specic section for d[...]

20 A. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system leaks. b. Absorption through open tanks and ttings. c. Oxygen permeable materials in the di[...]

21 How to W ire Ensure power is turned off to boiler . Locate the L WCO jumper wire in the factory wiring harness. Remove the jumper wire and install the L WCO wiring from L WCO Model 1 100-H4 (P/N 100592-01) into the plug of the PVG factory wiring. How to T est Shut off fuel supply . Lower water level until water level is BELOW the L WCO. Generate[...]

22 Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in Figure 1 1 or 12. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figure 1 1 or 12 in order to regulate water ow to maintain higher boiler water temperatures. Afte[...]

23 Figure 1 1: Recommended Boiler Piping For Circulator Zoned Heating Systems[...]

24 Figure 12: Recommended W ater Piping for Zone V alve Zoned Heating Systems[...]

25 V . Gas Piping T able 5: Gas Ratings For materials or conditions other than those listed above, refer to National Fuel Gas Code , NFP A54/ANSI Z223.1, or size system using standard engineering methods acceptable to authority having jurisdiction. T able 6: Specic Gravity Correction Factors for Natural Gas W ARNING Failure to properly pipe gas [...]

26 T able 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Natural Gas Pressures of 0.5 psig or Less Figure 13: Recommended Gas Piping T able 8: Equivalent Lengths of Standard Pipe Fittings & V alves B. Connect boiler gas valve to gas supply system. W ARNING Failure to use proper thread compounds on all gas connectors may result in leaks of [...]

27 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 , NFP A 70. C. Pressur e test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect[...]

28 VI. Electrical A. General. Install wiring and electrically ground boiler in accordance with authority having jurisdiction or , in the absence of such requirements, follow the National Electrical Code , NFP A 70, and/or CSA C22.1 Electrical Code. B. A separate electrical circuit must be run from the main electrical service with an over-current de[...]

29 Figure 14: Internal Boiler Wiring Schematic Diagram[...]

30 Figure 15: Internal Boiler Wiring Ladder Diagram NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below .[...]

31 D. System Controls and Wiring 1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code. 2. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes. 3. Use armored cable (BX) over all exposed line voltage wiring. 4. If an Alliance™ indirect[...]

32 Figure 16: Single Heating Zone Only Wiring Schematic[...]

33 Figure 17: Single Zone System with Packaged Alliance™ Water Heater W iring Schematic NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below .[...]

34 Figure 18: Circulator Zoned System Wiring Schematic[...]

35 Figure 19: Zone V alve Zoned System Wiring Schematic[...]

36 Figure 20: Different Manufacturer ’ s Zone V alve Connections to Honeywell R8889[...]

37 A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual unless otherwise instructed in this section. 2. Consult Local Building Codes or National Fuel Gas Code, NFP A 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Modu[...]

38 Figure 21: Modular Boiler Piping[...]

39 A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specied in American National Standar d for Gas-Fired Low- Pr essure Steam and Hot W ater Boilers, ANSI Z21.13. B. V erify that the venting, water piping, gas piping and electrical system are installed[...]

40 Figure 22: Operating Instructions[...]

41 H. Operating Instructions 1. Follow Operating Instructions to place boiler in operation. See Figure 22. 2. Electronic Ignition Modules with LED indicators. T able 10 cross-references the ignition module terminal designations to the ignition terminal Figure 23: LED Locations Ignition Module T erminal Designation Wiring Ladder Diagram T erminal Nu[...]

42 T able 12: Green LED Status Codes Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None 2 5 minute Retry Delay- Pilot ame not detected during trial for ignition Initiate new trial for i[...]

43 Honeywell Electronic Ignition T roubleshooting Guide Figure 24: T roubleshooting Guide[...]

44 I. Sequence of Operation. See Figure 25. If boiler fails to operate properly , see T roubleshooting T ree in Section IX: Service. J. Check pilot burner ame. See Figure 27. Flame should be steady , medium hard blue enveloping 3/8 to ½ inch of sensing probe. K. Check main burner ame. See Figures 26. Flame should have clearly dened inner [...]

45 T able 13: Gas Flow Rate in Cubic Feet Per Hour temperature. Main burners and pilot burner should extinguish, and blower should stop. 3. Adjust limit to setting above observed temperature. Ignition sequence should begin. 4. Adjust thermostat to lowest setting. Adjust limit to desired setting. P . Adjust gas input rate to boiler . 1. Adjust therm[...]

46 IX. Service A. General. Inspection and service should be conducted annually . T urn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 22. B. Low water cutoff (if so equipped). Probe T ype (Annual Service). Probe type L WCO should be removed once a year , exam[...]

47 Figure 28: Silicone T ubing Assembly Figure 29: Blower V ent Connector Assembly e. Mark location of Main Burner with Pilot Bracket on gas manifold. f. Hold Main Burner on throat. Lift front of burners to clear orice. Burner which holds pilot can be removed by lifting the burner adjacent to its right rst. 2. Disconnect V ent Connector and V[...]

48 Figure 30: Flue and Burner Cleanout, 1” Burner[...]

49 T able 14: Pilot Burner Location 3. Start boiler and read Pressure on Manometer when boiler water temperature reaches operating temperature. Refer to T able 15 for minimum readings. NOTE: If switch drops-out before boiler reaches temperature or if pressure differential readings are below minimums shown in T able 15, check for cracks in hose or c[...]

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52 XI. Repair Parts All PVG 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 Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.[...]

53 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 1. CASTING ASSEMBL Y 1 Section Assembly 61707031 61707041 61707051 61707061 61707071 61707081 61707091 1A Left End Section 71707001 1B Center Section [1] 71707003 [2] 71707003 [3] 71707003 [4] 71707003 [5] 71707003 [6] 71707003 [7] 71707003 1C Right End Section [...]

54[...]

55 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 2. BASE ASSEMBL Y 2A Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 2B Base Tray 71807032 71807042 71807052 71807062 71807072 71807082 71807092 2C Burner T ray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091 2[...]

56 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 3. BASE ASSEMBL Y 3A Burner Cover (Natural Gas Only) 102033-03 1 02033-04 102033-05 102033-06 102033- 07 102033-08 102033-09 3B Manifold Support Bracket 718070001 3C Sheet Metal Screw , #8 x 1/2” [2] 80860000 3D Self T apping Screw , 10-32 x 3/8” [6] 8086070[...]

57 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 4. F AN/CANOPY ASSEMBL Y 4A Canopy Assembly - Sea Level 61 107031 61 107041 61 107051 61 107061 61 107071 61 107081 61 107091 Canopy Assembly - High Altitude 61 107032 61 107042 61 107052 61 107062 61 107072 61 107082 61 107092 4B Cerafelt 9206005 4C U-Clip [4] [...]

58[...]

59 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 5. BURNER ASSEMBL Y 5A Gas V alve (Natural Gas), Honeywell VR8204P1 171 81660282 N/A Gas V alve (Natural Gas), Honeywell VR8304P4496 N/A 81660283 Gas V alve (LP Gas), Honeywell VR8204C3015 81660146 N/A Gas V alve (LP Gas), Honeywell VR8304P4280 N/A 81660181 5B N[...]

60 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 6. CONTROL P ANEL ASSEMBL Y 6A Limit, Honeywell L4080D 100189-01 6B T ransformer/Relay , Honeywell R8285D 80160155U 6C Ignition Module, Honeywell S8670E3003 100959-01 6D Blower Relay , Honeywell R8222U1006 80160096U 6E Differential Pressure Switch Sea Level 0’[...]

61 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 7. JACKET P ARTS 7A Left Side Panel 60407002 7B Right Side Panel 60407001 7C Rear Panel 60407033 60407043 60407053 60407063 60407073 60407083 60407093 7D V estibule Panel 60407034 60407044 60407054 60407064 60407074 60407084 60407094 7E T op Panel 60407032 60407[...]

62 Key No. Description [Quantity] Part Number PVG-3 PVG-4 PVG-5 PVG-6 PVG-7 PVG-8 PVG-9 8. MISCELLANEOUS P ARTS CARTON 8A Water Manifold 80607001 8B T emperature/Pressure Gauge 8056169 8C Circulator Wiring Harness 6130701 8D Safety Relief V alve 81660363 8E Boiler Drain V alve 806603061 8F V ent T erminal 81 10701 81 10702 8G V ent Connector 81 107[...]

63 Important Produc t Safety Informat ion Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts that contain refracto ry ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, su ch as during direct flame contact, RCF changes into crystalline silica, a k[...]

64 for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthorized modication, or is damaged as a result of being otherwise im[...]