8141775R23-10/05 Price - $3.00

nonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorp,reliob

rebmuNledoMrelioB____-I_VP_02

rebmuNlaireSrelioB_______6

etaDnoitallatsnI

rotcartnoCgnitaeH rebmuNenohP

sserddA

DNAGNITAREPO,NOITALLATSNIROFSNOITCURTSNIECIVRES

VP2SEIRESTNEVREWOP

RELIOBDERIF-SAG

2The 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

REGNADsuodrazahyltnenimminasetacidnI

tluserlliw,dediovatonfi,hcihwnoitautislaitnatsbusroyrujnisuoires,htaedni

.egamadytreporp

GNINRAWsuodrazahyllaitnetopasetacidnI

dluoc,dediovatonfi,hcihwnoitautisroyrujnisuoires,htaednitluser

.egamadytreporplaitnatsbus

ECITONnosnoitcurtsnilaicepssetacidnI

ecnanetniamro,noitarepo,noitallatsniotdetalertontubtnatropmierahcihw

.sdrazahyrujnilanosrep

ECITONevahlevelaesevobateef000,2nahtretaergsedutitlatanoitallatsniroftliubsreliobASUlevelaesevobateef000,1reptnecrep4etartupnisagecuderotdecifiroyllaicepsneeb

.FxidneppAdna2.1.8noitceS,1.322ZISNA/45APFN,edoCsaGleuFlanoitaNehtrepreliobedutitlahgiH.lebalgnitarehtnodetacidnisignizisecifiro'sreliobnaidanaCgnitarehtnoxiffusrebmunledomehtnitigiddnocesehtybelbaifitnedierasledom

:lebal2__-I_VP_02 noitavele.tf0002nahtsseL:

adanaC,noitavelerehgihdna.tf0002:4__-I_VP_02ASU,noitavelerehgihdna.tf0002:5__-I_VP_02

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.

I. Pre-Installation ........................4

II. Unpack Boiler ..........................5

III. Water Piping ............................6

IV. Gas Piping ................................8

V. Venting ......................................9

VI. Electrical ................................15

VII. System Start-up .....................16

VIII. Service ....................................24

IX. Repair Parts ...........................26

X. Appendix Low Water Cut Off ................35

NOITUACsuodrazahyllaitnetopasetacidnI

tluseryam,dediovatonfi,hcihwnoitautisytreporproyrujnironimroetaredomni

.egamad

3Figu

re 1

: Ele

vatio

n Vi

ews

led

oM

reli

oB

]sehc

nini[

sn

oisn

emi

Dt

net

no

Cr

eta

W]s

noll

aG[

gnippihS

.xorpp

A)

.bl(thgie

WA

BC

DV

P30202

4161/1

-018/5

-512

.3562

VP402

3271

118/5

-514

903

VP502

7212

3151

7.4

753

VP602

0342

8/1-51

515

.5914

4I. Pre-Installation

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.

GNINRAWllatsnI.ecnailppaIIIyrogetaCsadeifitreC

noitceShtiwecnadroccanimetsystnevyrnosamgnisutnevtonoD.gnitneV:V

rehtoro,tnevsagBepyT,yenmihc.metsysgnitnevIyrogetaC

G. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.).

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.

GNINRAWrianoitalitnevdnanoitsubmocetauqedA

reporperussaotdedivorpebtsum.noitsubmoc

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 [ft] = 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.

GNINRAWerofebsnoitcurtsnilladaerylluferaCllawollofoteruliaF.reliobgnillatsni

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.

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.

5a. If result is greater than or equal to 50 ft per 1,000 Btuh, space is considered an unconfi ned space.

b. If result is less than 50 ft 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 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.

NOITUACtnemnorivnenanireliobsihtgnitarepodiovA

yrd,srebifnoitalusniesool,tsudwaserehwsireliobfI.tneserpera.cte,tsudllaw

renrubeht,snoitidnocesehtrednudetarepodnadenaelcebtsumstropdnaroiretni

.noitareporeporperusniotyliaddetcepsni

II. Unpack Boiler

NOITUACreliobpmubtonoD.reliobpordtonoD

.roolftsniagatekcajA. 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.

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.

6III. Water Piping and Trim

F. Space heating and domestic water heating with Alliance water heater. Install Alliance water heater as a 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 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 encoun-tered (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 200F 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 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.

NOITUACnitluseryamreliobepipylreporpoteruliaFroreliobotegamaddnanoitareporeporpmi

.gnidliub

A. Design and install boiler and system piping to prevent oxygen contamination of boiler water.

NOITUAClliwretawreliobfonoitanimatnocnegyxO

reliobleetsdnanorifonoisorrocesuac.eruliafreliobotdaelnacdna,stnenopmoc

tonseodytnarrawdradnatss'mahnruBnegyxoybdesuacsmelborprevoc

.retawreliobfonoitanimatnoc

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 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.

GNINRAWebtsumgnipipegrahcsidevlavfeilerytefaS

folaitnetopetanimileotroolfraendepipaeraynaniepiptonoD.snrubereves

llatsnitonoD.ruccodluocgnizeerferehw.sevlavffo-tuhsyna

E. Install Drain Valve in " NPT connection in tee provided. See Figure 1.

7Figure 4A: Boiler Piping for Circulator Zoned Heating System

Figure 3: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems

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.

8IV. Gas PipingA. 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 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

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.

relioBledoMrebmuN

etaRtupnI]ruohrepteefcibuc[ saG noitcennoC

eziSsaGlarutaN enaporP/PL

VP302 26 42

VP402 69 83

VP502 031 25

VP602 461 56

Figure 4B: Boiler Piping for Zone Valve Zoned Heating Systems

9Table 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: Specifi c Gravity Correction Factors

htgneL]teeF[

porDerusserP.c.whcni3.0 porDerusserP.c.whcni5.0 1 1 1 1

01 231 872 025 050,1 571 063 086 004,1

02 29 091 053 037 021 052 564 059

03 37 251 582 095 79 002 573 077

04 36 031 542 005 28 071 023 066

05 65 511 512 044 37 151 582 085

06 05 501 591 004 66 831 062 035

07 64 69 081 073 16 521 042 094

08 34 09 071 053 75 811 022 064

09 04 48 061 023 35 011 502 034

001 83 97 051 503 05 301 591 004

gnittiFeziSepiPlanimoN

1 1

llE54 7.0 1 2.1 6.1

llE09 6.1 1.2 6.2 5.3

)woblEsA(eeT 1.3 1.4 2.5 9.6

cificepSytivarG

noitcerroCrotcaF

cificepSytivarG

noitcerroCrotcaF

05.0 01.1 03.1 70.155.0 40.1 04.1 40.106.0 00.1 05.1 00.156.0 69.0 06.1 79.007.0 39.0 07.1 49.057.0 09.008.0 78.0

Figure 6: Recommended Gas Piping

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 psig, boiler and its individual shut-off valve must be disconnected from gas supply piping. For testing at 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.

10

Table 5: Burnham Vent System Components

V. Venting

Figure A: Burnham Vent

ECITONhcaednanidesahpgnieberaAerugiFniwolebderutcipstnenopmocmetsystnevdeteksagehT

gnitnevssel-teksagdeilppusylsuoiverpehthtiwelbaegnahcretnisitnenopmoctnevodyehtsa,niojotreisaednarekciuqyllarenegerastnenopmoctnevrewenehT.stnenopmoc

.dehcattaerasdnabpmalcriehtdnanoitacilppatnalaesehteriuqerton

adnatnenopmoctnevdeteksagatneveehtnI-nocretniebtsumtnenopmoctnevssel-teksaghtiwdetaicossasnoitcurtsniehtwollof,detcenfoselpicnirpgnidiugowtehT.C8roB8erugiF

:swollofsaerasnoitcurtsnieseht

stnenopmoctnevfogniniojynA)1enotsaeltasevlovnitaht

tnenopmoctnevssel-teksagtnalaesehtseriuqersyawla

.noitacilppassel-teksagafodneelamefehT)2seriuqersyawlatnenopmoctnev

ehtfosseldrager,dnabpmalcatnevelamgnitamehtfongised

.tnenopmoc

.tnalaesdnadnabpmalcahtiwdeilppussitnenopmoctnevssel-teksaghcaE3enodnadnabpmalcenosniatnoctahtelbaliavasi,2036116rebmuntrap,tiKnoitisnarTtneVA

.tnalaesfoebutecnuo

GNINRAWrocillatemnon,leetssselniats613epyTro403epyT,dezinavlaghtiwreliobsihtesutonoD

C4-92LAnonrehtoyna .smetsystnevdesab

.reliobsihthtiwdoohtfardrorepmadcirtemorabaesutonoD

.reliobsihthtiwsrepmadtnevesutonoD

,noitaroiretedtneverpoT.noitanimretdnuorasecafrusnomrofyamecidnaerutsioM.).cte,detniap,delaes(riaperdoogniebdluohssecafrus

snoisivorperaerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenreliobsihT.rianoitalitnevdnanoitsubmocetauqedarof

fosecruosro,sdiuqilrosropavelbammalfrehtoroenilosagerehwreliobetarepotonoD,srenetfoscirbaf,srevomertniap,syarps,slacimehc,srenaelc,sehcaelb.e.i(snobracordyh

.riaehtnitneserpro/dnaderots,desuera).cte.teeftnelaviuqe52fohtgneltnevmumixamdeecxetonoD

mahnruBmetsyStneVtnenopmoC

mahnruBrebmuNtraP

tF1xepiP.aiD"3 U6926118tF3xepiP.aiD"3 U8926118tF5xepiP.aiD"3 U0036118

elbatsujdAxepiP.aiD"3 U9136118woblE09.aiD"3 U4926118woblE54.aiD"3 U2926118

eeTniarDlatnoziroH.aiD"3 U2036118eeTniarDlacitreV.aiD"3 U4036118

11

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

12

D. Install Vent Pipe, General.1. Plan venting system to avoid possible contact with

plumbing or electrical wires. Start venting system at vent connector and work toward the vent terminal.

2. Use non-combustible inch pipe strap to support horizontal runs, maintain vent location and slope, while preventing sags in pipe. Do not restrict thermal expansion or movement of vent system. Maximum support spacing is 5 feet. Do not penetrate any part of the vent system with fasteners.

3. Provide and maintain vent pipe minimum clearance to combustible materials. Vent pipe minimum clearance to combustible material is fi ve (5) inches when vent is installed in a fully enclosed (chase) application or four (4) inches when vent is installed with at least one side open, similar to a joist bay application. Use thimble when penetrating combustible wall.a. 203PV and 204PV Single wall thimble,

Burnham Part No. 8116116. Other wall thimble manufac-turers are American Metal Products, Hart & Cooley, and Metal Fab.

b. 205PV and 206PV Double wall thimble, Burnham Part No. 8116115 (accommodates 5 inch to 8-3/4 inch wall thickness). Another wall thimble manufacturer is Hart & Cooley.

4. Once a vent pipe manufacturer and system is chosen never mix and match vent systems.

5. If a non-standard length pipe is required:Gasketed Vent System: The use of the adjustable length

pipe (P/N 8116319U) is recommended to complete a non-standard pipe length. This pipe requires a minimum installed length of 12 inch and can adjust across a 7 inch gap up to a maximum of 19 inch long. (Note for the adjustable pipe the installed length should be measured from the centerline of the bead on the male end of the fi rst pipe to the end of the female pipe excluding the locking band of the second pipe with a single gasket.) Only in the event the adjustable length pipe is not suffi cient a standard length pipe may be cut using the procedure outlined below for the Gasket-Less Vent System.

GNINRAWfohtgneldellatsnimumixamdeecxereveN

.epiphtgnelelbatsujdarofsehcni91.elbissopsiegakaelsageulffoksiR

Gasket-Less Vent System: Carefully cut pipe to length using a hacksaw with minimum 32 teeth per inch or circular saw with metal abrasive wheel. Remove male (bead) end only female (bell) end accepts next fi tting or pipe.

ECITONrodelifdnaepiphtiwerauqsebtsumtuC

ylluferaC.gniniojerofebhtoomsdednashtiwdnahybepiptucfossendnuorerusne

VTRhtiwtniojlaeS.gnillatsnierofebsevolg.launamsihtnideificeps

6. Seal all Burnham Gasket-Less vent, Burnham mixed vent (Gasket-Less and Gasketed) and fi eld cut joints using Dow Corning Silastic 732 RTV, Dow Corning Silastic 736 RTV, GE RTV106, Polybac #500 RTV, Sil-bond RTV 4500 (Acetoxy) and Sil-bond RTV 6500. Do not use other adhesives or sealants.

E. Install Vent Pipe, Burnham Gasket-Less Vent System.1. Procedure for Joining Burnham Gasket-Less Vent

Pipe and Fittings. See Figure 8A.

Figure 8A: Burnham Gasket-Less Vent Joint Detail

a. Clean joints of pipe or fi ttings using an alcohol pad to remove any dirt and grease.

b. Slip a locking band over female (bell) end of pipe/fi tting.

c. Apply a continuous 1/4 inch bead of sealant around male end of joint no more than 1/8 inch from end.

d. Align weld seams and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure bead in male end rest against the end of the female pipe.

e. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary.

f. Slip the locking band over joint and align closest bead in locking band with bead in male end of pipe.

g. Tighten locking band by HAND with a 5/16" nut driver until snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!

13

h. Once the installation is complete, operate appliance and inspect all joints to ensure that fl ue gases and/or liquid condensate will not escape.

F. Install Vent Pipe, Burnham Gasketed Vent System.1. Procedure for Joining Burnham Gasketed Vent Pipe

and Fittings. See Figure 8B.

a. Wipe the male end of each joint using an alcohol pad to remove any dirt and grease.

b. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure bead in male end of pipe is below locking band and rest against the end of the female pipe. Verify the factory-installed gasket is not dislodged or cut

c. Tighten locking band by HAND with a 5/16" nut driver until snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL 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 fl ue gases and/or liquid condensate will not escape.

G. Install Vent Pipe, Burnham Gasket-Less & Gasketed Vent System.1. Procedure for joining the male end of Burnham

Gasket-Less Vent with the female end of Burnham Gasketed Vent. See Figure 8C.

Figure 8B: Burnham Gasketed Vent Joint Detail

Figure 8C: Burnham Gasket-Less Male and Gasketed Female Vent Joint Detail

c. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure bead in male end of pipe is below locking band and rest against the end of the female pipe. Verify the factory-installed gasket is not dislodged or cut.

d. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary.

e. Tighten locking band by HAND with a 5/16" nut driver until snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!

f. Once the installation is complete, operate appliance and inspect all joints to ensure that fl ue gases and/or liquid condensate will not escape.

2. Procedure for joining the female end of Burnham Gasket-Less Vent with the male end of Burnham Gasketed Vent. See Figure 8D.

Figure 8D: Burnham Gasket-Less Female and Gasketed Male Vent Joint Detail

a. Clean joints of pipe or fi ttings using an alcohol pad to remove any dirt and grease.

b. Slip a locking band over female (bell) end of pipe/fi tting.

c. Apply a continuous inch bead of sealant around male end of joint no more than 1/8 inch from end.

d. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint.

e. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary.

f. Slip the locking band over joint and align closest bead in locking band with bead in male end of pipe.

g. Tighten locking band by HAND with a 5/16" nut driver until snug plus turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!

a. Clean the male end of each joint using an alcohol pad to remove any dirt and grease.

b. Apply a continuous inch bead of sealant around male end of joint no more than 1/8 inch from end.

14

Figure 9: Recommendations for Thimble and Wall Penetration

h. Once the installation is complete, operate appliance and inspect all joints to ensure that fl ue gases and/or liquid condensate will not escape.

H. Horizontal (Through Wall) Vent Installation.1. Maintain minimum inch per foot slope in

horizontal runs. Slope pipe down toward vent terminal. Position weld seams in vent pipes in all horizontal runs at the top to avoid condensate from lying on the seams.

2. Vent terminal location restricted per following: a. Minimum 12 inches above grade plus normally

expected snow accumulation level, or 7 feet above grade if located adjacent to public walkway. Do not install over public walkway where local experience indicates condensate or vapor from Category III appliances creates a nuisance or hazard.

b. Minimum 3 feet above any forced air inlet located within 10 feet.

c. Minimum 4 foot below, 4 foot horizontally from, or 1 foot above any door, window, or gravity air inlet.

d. Minimum 4 feet (6 feet in Canada) horizontally from, and in no case above or below, unless a

4-foot horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

e. Minimum 12 inches from overhang or corner.

3. Use wall thimble when passing through combustible outside wall (thimble use optional for noncombustible wall). Insert thimble through wall from outside. Secure outside fl ange to wall with nails or screws, and seal with adhesive material. Install inside fl ange to inside wall, secure with nails or screws, and seal with adhesive material.

4. For noncombustible wall when thimble is not used size opening such that female (bell) end with locking band attached cannot pass through.

5. Join vent terminal to vent pipe. Locate vent terminal 3 inches (minimum) and 6 inches (recommended) from wall when joined to inside vent piping. See Figure 9. Vent terminal clearance to vinyl wall surfaces is 6 inches.

6. Insert vent pipe through thimble/opening from outside and join to vent system. Apply sealant between vent pipe and opening/thimble to provide weathertight seal.

15

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 approximately 4 feet above fl oor. Do not install on outside wall, near fi replace, or where infl uenced by drafts or restricted air fl ow, hot or cold water pipes, lighting fi xtures, television, or sunlight. Allow free air movement by avoiding placement of furniture near thermostat.

C. Wire thermostat. Provide Class II circuit between thermostat and boiler. Run wires through grommet in Jacket Left Side Panel. Set thermostat heat anticipator to 0.6 amps. See Figure 10.

D. Wire boiler. Boiler is rated for 120 VAC, 60 hertz, less than 12 amperes. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Connect to black and white wires and green ground screw. See Figure 10.

E. Alliance water heater (if used). See Figure 10. Also refer to Alliance Installation, Operating and Service Instructions.

F. For installations using zone valves provide separate transformer for zone valve wiring. Consult zone valve manufacturer for assistance.

Figure 10: Wiring Diagram

16

Figure 12: Gas Valve Pressure Tap

3. For natural gas fi red boiler, temporarily turn off all other gas-fi red appliances.

E. Follow Operating Instructions to place boiler in operation. See Figure 17.

F. Sequence of Operation. See Figure 14. If boiler fails to operate properly, see Troubleshooting Tree on pages 20-22.

G. Check gas piping and connections between Gas Valve and Manifold, Orifi ces and Pilot Tubing. Use soap solution or other approved method. See Figure 13.

Figure 13: Schematic Pilot and Gas PipingFigure 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 specifi ed in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13.

B. Fill heating system with water and vent air from system. Use the following procedure on a Series Loop System equipped with zone valves. See Figure 3.1. Close isolation valve in boiler supply piping.2. Isolate all circuits by closing zone valves or

balancing valves.3. Attach hose to hose bib located just below isolation

valve in boiler supply piping. Terminate hose in fi ve gallon bucket at a suitable fl oor drain or outdoor area).

4. Starting with one circuit, open zone valve.5. Open hose bib.6. Open fi ll valve. Makeup water line should be

located directly above isolation valve in boiler supply piping.

7. Allow water to overfl ow from bucket until discharge from hose is bubble free for 30 seconds.

8. Open zone valve to second zone to be purged, then close fi rst. Repeat this step until all zones have been purged, but always have one zone open. At completion, open all zone valves.

9. Close hose bib, continue fi lling system until pressure gauge reads 12 psi. Close fi ll valve.

Note: If makeup water line is equipped with pressure reducing valve, system will automatically fi ll to 12 psi. Leave globe valve open.

10. Open isolation valve in boiler supply piping.11. Remove hose from hose bib.

C. Check main burners. See Figure 11. Rear of burner must be in vertical slot in rear of burner tray. Front of burner must be seated on orifi ce.

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.

17

Figure 15: Pilot Burner Flame

Figure 14: Sequence of Operation

H. Check pilot burner fl ame. See Figure 15. Flame should be steady, medium hard blue enveloping 3/8 to inch of sensing probe.

I. Check main burner fl ame. See Figure 16. Flame should have clearly defi ned inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping.

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.

18

L. Check low water cut-off (if used). Drain boiler water below LWCO set point. Burners should extinguish.

M. Check limit.1. Adjust thermostat to highest setting.2. Observe temperature gauge. When temperature is

indicated, adjust limit to setting below observed temperature. Main burners and pilot burner should extinguish and blower stop.

3. Adjust limit to setting above observed temperature. Ignition sequence should begin.

4. Adjust thermostat to lowest setting. Adjust limit to desired setting.

N. Adjust gas input rate to boiler (Natural Gas).1. Adjust thermostat to highest setting.2. Check manifold gas pressure. Manifold pressure is

listed on rating label. 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 supplier for assistance.

3. Clock gas meter for at least 30 seconds. Use Table 6 to determine gas fl ow rate in Cubic Feet per Hour.

4. Determine Input Rate. Multiply gas fl ow rate by gas heating value.

Table 6: Gas Flow Rate in Cubic Feet per Hour

sdnoceSenOrof

noituloveR

laiDreteMsaGfoeziS

flaH-enO.tF.uC

enO.tF.uC

owT.tF.uC

03 06 021 042

23 65 311 522

43 35 601 212

63 05 001 002

83 74 59 981

04 54 09 081

24 34 68 271

44 14 28 461

64 93 87 751

84 73 57 051

05 63 27 441

25 53 96 831

45 33 76 331

65 23 46 921

85 13 26 421

06 03 06 021

5. Compare measured input rate to input rate listed on rating label. a. Boiler must not be overfi red. Reduce input rate

by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still overfi red, contact your Burnham distributor or Regional Offi ce for replacement Gas Orifi ce.

b. Increase input rate if less than 98% of rating label input. Increase manifold gas pressure no more than 0.3 inch w.c. If measured input rate is still less than 98% of rated input:i. Remove Main Burners per procedure in

Section VIII: Service.ii. Remove gas orifi ces. Drill one (1) drill size

larger (drill size is stamped on orifi ce, or see Key No. 4D).

iii. Reinstall gas orifi ces and main burners. Measure input rate.

6. Recheck Main Burner Flame.7. Adjust thermostat to normal setting.8. Return other gas-fi red appliances to previous

conditions of use.

O. Adjust gas input rate to boiler (LP/Propane).1. Adjust thermostat to highest setting.2. Check manifold pressure. Adjust gas valve pressure

regulator to obtain 10 inches w.c. manifold pressure. 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 supplier for assistance.

3. Recheck Main Burner Flame4. Adjust thermostat to normal setting.

P. COMBUSTION CHAMBER BURN-OFF1. The mineral wool combustion chamber panels

contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation.

2. Ventilate the boiler room, set the high limit to its maximum setting, set the thermostat to call for heat. Allow the boiler to fi re for at least an hour or until the odor from the cornstarch has dissipated.

3. Return the high limit and thermostat to their desired settings.

Q. Review User's Information Manual and system operation with owner or operator.

R. Post instructions near boiler for reference by owner and service personnel. Maintain instructions in legible condition.

19

Figure 17: Operating Instructions

20

21

22

23

noitamrofnIytefaStcudorPtnatropmItcudorPrebiFcimareCyrotcarfeR

Warning:

This product contains refractory ceramic fi bers (RCF). RCF has been classifi ed as a possible human carcinogen. After this product is fi red, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace previously fi red RCF (combustion chamber insulation, target walls, canopy gasket, fl ue cover gasket, etc.) or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fi tting clothing3. Gloves4. Eye Protection

Take steps to assure adequate ventilation. Wash all exposed body areas gently with soap and water after contact. Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes. Discard used RCF components by sealing in an air tight plastic bag.

First Aid Procedures:

If contact with eyes: Flush with water for at least 15 minutes. Seek immediate medical attention if irritation persists.

If contact with skin: Wash affected area gently with soap and water. Seek immediate medical attention if irritation persists.

If breathing diffi culty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing diffi culties persist.

Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention.

24

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.

NOITUACnehwnoitcennocsidotroirpseriwllalebaLesuacnacsrorregniriW.slortnocgnicivres

yfireV.noitareposuoregnaddnareporpmi.gnicivresretfanoitareporeporp

B. Inspect Housekeeping. Boiler area must be clear and free from combustible materials, gasoline and other fl ammable vapors and liquids. Remove obstructions to the fl ow of combustion and ventilation air.

C. Service Low water cut-off (if so equipped). Follow instructions provided with low water cut-off

D. Inspect Vent System for obstructions in vent pipe, soot accumulation, deterioration of pipe or joints, and proper support:1. Remove vent connector and vent pipe. See Figure

19.2. Remove all obstructions. Check and clean vent

terminal screens.3. Remove soot accumulations with wire brush and

vacuum.4. Replace deteriorated parts.5. Repair deteriorated joints. See Section V: Venting.

E. Inspect Boiler Flue Passages for blockage or soot accumulation. See Figure 19.

1. Disconnect vent connector from blower discharge fl ange.

2. Remove sheet metal screws securing Jacket Top Panel. Lift panel and rotate about relief valve piping until top of boiler is exposed. If piping or wall prevent full rotation of top panel for access to canopy, cut slot into relief valve opening and remove top panel.

3. Disconnect blower connection from wiring harness in vestibule.

4. Remove bolts securing canopy to boiler sections. Cut silastic sealant around base of canopy, pry canopy from boiler sections and remove canopy/blower assembly from boiler.

5. Using fl ashlight, examine all fl ue passageways.a. If passageways are free of soot and obstruction,

replace canopy, secure and seal using kit available from Burnham Distributors, Part No. 6111716.

b. If passageways need cleaning, remove burners as described in Paragraph F below. Using long handle wire or bristle fl ue brush and vacuum, brush fl ueways thoroughly from top of boiler as illustrated in Figure 19. Replace canopy and seal using kit available from Burnham Distributors, Part No. 6111716.

GNINRAW237-VTRhtiwdelaeserebtsumyponaC

tnettimretnIF005(tnalaeSrebbuRenociliS.)ytuD

6. Reinstall jacket top panel, vent pipe and vent connector in reverse manner. Reconnect electrical connector to blower.

F. Clean Main Burners and Firebox.1. To remove burners for cleaning, changing orifi ce

plugs, or repairs:a. Remove jacket Front Panel.b. Disconnect pilot tubing at gas valve.c. Disconnect igniter/sensor cable and ground wire

at Ignition Module.d. Disconnect Flame Rollout Switch wires.e. Remove Burner Access Panel.f. Mark Pilot Main Burner location on Manifold.g. Hold burner on throat. Lift slightly to clear

orifi ce. Pull burner from combustion chamber. See Figure 11. Pilot Main Burner can only be removed by lifting at 45 angle after adjacent burner to right is removed.

2. Brush top of burners with a soft bristle brush. See Figure 19. Vacuum burners.

3. Check orifi ces. Drilled passageways must be free of lint or dirt.

4. Vacuum tip of Pilot Burner.5. Clean fi rebox by vacuuming. Exercise care not to

disturb insulation inside base.6. Install burners by reversing procedure used to

remove burners. Burner with pilot assembly must be in same location as original installation. See Table 7. Burners must be properly located on support bracket at rear of burner. See Figure 11. Slide burner over orifi ce.

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 Section VII: System Start-up.

25

Table 7: Pilot Burner Location

Figure 18: Spark Gap Setting

Figure 19: Flueway Cleaning

H. Removal or replacement of pilot assembly or pilot assembly parts. If pilot assembly, sensor or pilot orifi ce need replacing, remove main burner with pilot using procedure described in Paragraph F.1.1. To replace orifi ce.

a. Disconnect pilot tubing. Pilot orifi ces screw into Pilot Burner. Replace with Honeywell 388146NE (Natural Gas) or Honeywell 388146KP (LP/Propane).

b. Reconnect pilot tubing and check for leaks.

2. To adjust or check spark gap between electrode and hood on Honeywell Q348A intermittent pilot. See Figure 18.a. Use round wire gauge to check spark

gap.b. Spark gap should be 1/8 inch for

optimum performance.

3. To replace complete pilot assembly.a. Remove two machine screws holding

pilot burner to pilot bracket.b. Disconnect pilot tubing.c. Disconnect all other leads to pilot.d. Select pilot assembly with identical

model number, reconnect leads and pilot tubing. Resecure to pilot bracket.

4. Reinstall main burner following procedure described in Paragraph F.

I. Lubrication. There are no parts requiring lubrication by service technician or owner. Circulator bearings are water lubricated. Blower motor bearings are factory sealed.

J. Procedure for measuring blower inlet pressure. See Figure 20.1. With boiler off, remove hose at pressure

switch.2. With tee connect water manometer as shown

with additional tubing.

relioBledoM

htiwrenruBniaM*tekcarBtoliP06

detacoLrenruBtoliPniaMneewteB

*srenruB

VP302 1 2&1

VP402 2 3&2

VP502 3 4&3

VP602 4 5&4

morfdeweivsathgirottfelderebmunsrenrubniaM*.reliobfotnorf

26

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 Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.

Table 8: Minimum Fan Pressure

Figure 20: Procedure for Measuring Fan Pressure

3. Start boiler and read pressure on manometer when boiler water temperature reaches operating temperature. Refer to Table 8 for minimum readings.

NOTE: If switch drops-out before boiler reaches temperature or if pressure reading is below minimum shown in Table 8, check for cracks in hose or contact your nearest Burnham representative.

4. Stop boiler, remove manometer and reconnect hose to pressure switch.

ledoMrelioB rewolBmuminiMerusserPtelnI

VP302 .c.wsehcni04.0-

VP402 .c.wsehcni04.0-

VP502 .c.wsehcni07.0-

VP602 .c.wsehcni07.0-

27

yeK.oN noitpircseD

rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602

ylbmessAnoitceS.1 123071716 124071716 125071716 126071716

ylbmessArewolB/yponaC.2

A2 yponaC ]1[ 43071116]1[

44071116]1[

45071116]1[

46071116

B2 "1x02-,tloBegairraC erawdraHnommoC]2[C2 EAS,,rehsaW erawdraHnommoC]01[D2 xeHyvaeH,02-,tuN erawdraHnommoC]2[E2 ]F2.oNyeKnidedulcnI[teksaGgnitnuoMrewolB 8406028]1[ 9406028]1[F2 rewolB 4171116]1[ 5171116]1[G2 ]F2.oNyeKnidedulcnI)2([teksaGetalPecifirO 2406028]2[ 5306028]2[

H2 etalPecifirO ]1[ 53071117]1[

54071117]1[

55071117]1[

56071117

J2 803AreywD,gnittiFerusserP 756228]1[K2 ]F2.oNyeKnidedulcnI)4([ssarB,02-4/1,tuNxeH 42406808]4[L2 02-,tunkcoLxeH erawdraHnommoC]4[

28

yeK.oN noitpircseD

rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602

puorGylbmessAesaB.33 etelpmoC,ylbmessAesaB 193006816]1[ 194006816]1[ 195006816]1[ 196006816]1[A3 ylbmessAyarTesaB 193006817]1[ 194006817]1[ 195006817]1[ 196006817]1[B3 repparWesaB 113006817]1[ 114006817]1[ 115006817]1[ 116006817]1[1B3 noitalusnIdnEesaB 106027]2[2B3 noitalusnIraeResaB 53006027]1[ 54006027]1[ 55006027]1[ 56006027]1[

C3 ylbmessAlenaPtnorFesaB 143006816]1[ 144006816]1[ 145006816]1[ 146006816]1[D3 yarTrenruB 503006817]1[ 504006817]1[ 505006817]1[ 506006817]1[E3 ylbmessAgeLesaB 1006816]4[1E3 geLesaB 12006817]4[2E3 edilGnolyN 6006818

F3 lenaPsseccArenruB 163006817]1[ 164006817]1[ 165006817]1[ 166006817]1[G3 tfeL,tekcarBtnemhcattAtekcaJ 11006407]1[H3 thgiR,tekcarBtnemhcattAtekcaJ 21006407]1[

J3 "2x",teksaGtlefareC 004-FRCellivsnaM-snhoJ 2006026]1[

K3 naPspillihP,FepyTgnippaT-fleS,wercS detalP,"x02-,daeH 00706808]02[

L3 "1x81-"61/5,gnippaTfleS,wercS 71706808]4[M3 "61/5,rehsaWtalF erawdraHnommoC]4[N3 81-"61/5,tuNkcoLxeH 46406808]4[P3 "x8#,daeHspillihP,lateMteehS,wercS erawdraHnommoC]2[

29

.oNyeK noitpircseDrebmuNtraP]ytitnauQ[

VP302 VP402 VP502 VP602

srenruBniaMdnadlofinaM.4A4 renruBniaM 9906328]2[ 9906328]4[ 9906328]6[ 9906328]8[B4 tekcarBtoliP06htiwrenruBniaM 8906328]1[C4 dlofinaM 33006228]1[ 34006228]1[ 35006228]1[ 36006228]1[

larutaN(D4)ylnOsaG kniP,54#,ecifirOrenruBniaM 117228]3[ 117228]5[ 117228]7[ 117228]9[

D4enaporP/PL(

)ylnOneerG,55#,ecifirOrenruBniaM 807228]3[ ----- ----- -----

elpruP,mm52.1,ecifirOrenruBniaM ----- 507228]5[ 507228]7[ 507228]9[E4 "61/3x23-01#,enihcaM,wercS 00806808]2[

F4 spillihP,FepyTgnippaT-fleS,wercS detalP,"2/1x02-4/1,daeHnaP 00706808]4[

30

yeK.oN noitpircseD

rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602

evlaVsaGdnarenruBtoliP.5

A53331A843QllewyenoH,saGlarutaN,ylbmessAtoliP 4016328]1[

1431A843QllewyenoH,saGPL,ylbmessAtoliP 7016328]1[

B5EN641883llewyenoHsaGlarutaN,ecifirOtoliP

A5.oNyeKhtiwdedulcnIPK641883llewyenoHenaporP/PL,ecifirOtoliP

C5 TPNxDO"8/1,gnittiF/tuNnoisserpmoC E5dnaA5.oNyeKhtiwdedulcnI

D5 "03xDO"8/1,gnibuTtoliP 0116328]1[

E50006C4028RVllewyenoH,saGlarutaN,x,evlaVsaG 67106618]1[8106C4028RVllewyenoH,enaporP/PL,x,evlaVsaG 08106618]1[

F5 63-008493llewyenoH,"63,elbaCrosneS/retingI 4806328]1[G5 ylbmessAeriWdnuorG 4506316]1[

31

yeK.oN noitpircseD

rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602

tekcaJ.6A6 )1(lenaPdnuoR-A-parWtekcaJ 713071406]1[ 714071406]1[ 715071406]1[ 716071406]1[B6 )1(lenaPelubitseVreppUtekcaJ 1223071406]1[ 1224071406]1[ 1225071406]1[ 1226071406]1[C6 lenaPelubitseVrewoLtekcaJ 2223071406]1[ 2224071406]1[ 2225071406]1[ 2226071406]1[D6 )2()1(lenaPpoTtekcaJ 433071406]1[ 434071406]1[ 435071406]1[ 436071406]1[E6 rooDelbavomeRtnorFtekcaJ 443071406]1[ 444071406]1[ 445071406]1[ 446071406]1[F6 lenaPtnorFrewoLtekcaJ 313071406]1[ 314071406]1[ 315071406]1[ 316071406]1[G6 "x8#,lateMteehS,wercS erawdraHnommoC]02[H6 51-3901-BSocyeH,gnihsuBpanS 7526318]2[J6 62-0002-BSocyeH,gnihsuBpanS 6626318]1[K6 5-734-BSocyeH,gnihsuBpanS 8406318]1[L6 etalPogoLmahnruB 70106418]1[

.gniredronehw'adanaCroF'etacidni,adanaCnidellatsnisreliobroF)1(.gniredronehw'ainrofilaCroF'etacidni,ainrofilaCnidellatsnisreliobroF)2(

32

33

yeK.oN noitpircseD

rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602

slortnoCdnamirTsuoenallecsiM.7

A7 ,TPN,isp03,evlaVfeileRytefaS 50-804-01ocarbnoC 91306618]1[

B7 4321D0804LllewyenoH,timiL 10-981001]1[1B7 TPN,lleWnoisremmI B7htiwdedulcnI

2B7 lauD(A078321llewyenoH,TPN,lleWnoisremmI )ylnOtimiL 62406108]1[

3B7 )ylnOtimiLlauD(2121B0804LllewyenoHtimiL 47406108]1[C7 1005D5828RllewyenoH,yaleR/remrofsnarT U55106108]1[

1C7 6001U2228RllewyenoH,TSPD,yaleR U69006108]1[2C7 "1x"4x"4,xoBnoitcnuJ 9526318]1[

D7 hctiwStuolloRemalF 44006108]1[1D7 tekcarBhctiwStuolloRemalF 8106817]1[

E7 hctiwSerusserP 67806106]1[ 77806106]1[

1E7

)VP402/302(gnoL"21x.D.I"61/3,gnibuTenociliS

)htgneLyficepS(7006109)VP502(gnoL"31x.D.I"61/3,gnibuTenociliS )VP602(gnoL"51x.D.I"61/3,gnibuTenociliS"51x"8/1,gnibuTenociliS

F7 7001E0768SllewyenoH,eludoMnoitingI 80106108]1[G7 eguaGerusserP-erutarepmeT U4616508]1[

H7

22-RFNttessoG&lleB,steksaGhtiwrotalucriC 4716508]1[F24-51PUsofdnurG,steksaGhtiwrotalucriC 3716508]1[

F700ocaT,steksaGhtiwrotalucriC 0716508]1[0100ocaT,steksaGhtiwrotalucriC 6716508]1[

1H7

)03-CLS(22-RFNttessoG&lleB,teksaG 920206608]2[971015sofdnurG,teksaG 610206608]2[

seireS'00'ocaT,teksaG 600206608]2[J7 TPN1,egnalF 310206608]2[1J7 "1x41-61/7,daeHxeHpaC,wercS erawdraHnommoC]4[2J7 41-61/7,xeH,tuN erawdraHnommoC]4[

K7 30-203-53ocarbnoC,TPN,evlaVniarD 160306608]1[

34

yeK.oN noitpircseD

rebmuNtraP]ytitnauQ[VP302 VP402 VP502 VP602

notraCyrosseccAtneVdeteksaG.8 323071116 325071116A8 rotcennoCtneV 6036118]1[ 7036118]1[B8 lanimreTtneV 0171118]1[

35

A 24 VAC LWCO is used primarily for gas fi red boilers where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.

How to Test Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to operate. Increase the water level by fi lling the system. The boiler should attempt to operate once the water level is above the LWCO.

X. Low Water Cut Off (LWCO) on Hot Water Boilers

Wiring of Typical LWCO

When A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same fl oor level as the boiler). In addition, some jurisdictions require the use of a LWCO with a hot water boiler.

Where The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

What Kind Typically, in residential applications, a probe type

LWCO is used instead of a fl oat type, due to their relative costs and the simplicity of piping for a probe LWCO.

How to Pipe A tee is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

LWCO Location

draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.

How to Wire LWCOs are available in either 120 VAC or 24 VAC

confi gurations. The 120 VAC confi guration can be universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).

The presence of water in a properly installed LWCO will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO with the same line voltage boiler service as shown below.

Select the appropriate size tee using the LWCO manufacturers instructions. Often, the branch connection must have a minimum diameter to prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located above the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without

GNINRAW.)OCWL(ffOtuCretaWwoLtekramretfanallatsniotseriwyrotcaftucotTPMETTATONOD

.ffOtuCretaWwoLrofdeifitnediyllacificepssnoitcennocesuylnO

.snoitcurtsnis'rerutcafunam)OCWL(ffOtuCretaWwoLehtwollof,sesacllanI

36

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 modifi cation, or is damaged as a result of being otherwise improperly operated or serviced including, but not limited to, damage from any of the following: operation with insuffi cient water, allowing the boiler to freeze, subjecting the boiler to fl ood conditions, and operation with unapproved water or fuel additives which cause deposits or corrosion.5. Removal and Installation: These warranties do not cover expenses of removal or reinstallation. The owner is responsible for the cost of removing and reinstalling any defective part and its replacements and all labor and material connected therewith.6. Exclusive Remedy: U.S. Boiler Co., 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 Co., 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 Co., Inc. liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade water 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 Co., Inc. with respect to any defect in a residential grade water boiler and U.S. Boiler Co., 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 WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NO 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 attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will not void the owners 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 Co., Inc., Burnham Hydronics, at 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 Co., Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S. Boiler Co., 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.

Limited WarrantyFOR RESIDENTIAL CAST IRON WATER BOILERS

03/03

Subject to the terms and conditions set forth below, U.S. Boiler Co., Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1,1991:

ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS

U.S. Boiler Co., Inc. warrants to the original owner that its residential grade water boilers 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 water boiler is found to be defective in material or workmanship during this one year period, U.S. Boiler Co., Inc. will, at its option, repair or replace the defective part.

LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER U.S. Boiler Co., Inc. warrants to the original owner that the heat exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation. If a claim is made under this warranty during the fi rst ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option, repair or replace the heat exchanger. If a claim is made under this warranty after the expiration of ten years from the date of original installation, U.S. Boiler Co., 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 model 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 Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.

ADDITIONAL TERMS AND CONDITIONS1. 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 water boilers designated as residential grade by U.S. Boiler Co., Inc. and installed in a single or two-family residence and do not apply to steam boilers of any kind or to commercial grade boilers.2. Components Manufactured by Others: Upon expiration of the one year limited warranty on residential grade water boilers, all boiler components manufactured by others but furnished by U.S. Boiler Co., Inc. (such as oil burner, circulator and controls) will be subject only to the manufacturers warranty, if any.3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc. are conditioned upon the installation of the residential grade water boiler in strict compliance with U.S. Boiler Co., Inc. installation instructions. U. S. Boiler Co., Inc. specifi cally disclaims liability of any kind caused by or relating to improper installation.4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Co., Inc. conditioned upon the use of the residential grade water boiler

sraeYecivreSnI 01-1 11 21 31 41 51 61 71

egrahCecivreSfo%sa

ecirPliateR

oNegrahC 5 01 51 02 52 03 53

sraeYecivreSnI 81 91 02 12 22 32 42

dna52evoba

egrahCecivreSfo%sa

ecirPliateR04 54 05 55 06 56 07 57