Burnham Apex APX399 Installation, Operating And Service Instructions
  1. Manuals
  2. Brands
  3. Burnham Manuals
  4. Boiler
  5. Apex APX399
  6. Installation, operating and service instructions

Burnham Apex APX399 Installation, Operating And Service Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

inSTaLLaTiOn, OPEraTing anD
SErViCE inSTrUCTiOnS FOr
aPEX™
COnDEnSing HigH EFFiCiEnCY
DirECT VEnT
GAS - FIRED HOT WATER BOILER
9700609
Warning:
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
103022-04 - 8/13
Price - $5.00

Advertisement

Table of Contents
loading

Related Manuals for Burnham Apex APX399

Summary of Contents for Burnham Apex APX399

  • Page 1 inSTaLLaTiOn, OPEraTing anD SErViCE inSTrUCTiOnS FOr aPEX™ COnDEnSing HigH EFFiCiEnCY DirECT VEnT GAS - FIRED HOT WATER BOILER 9700609 Warning: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier.
  • Page 2 IMPORTANT INFORMATION - READ CAREFULLY 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.
  • Page 3 Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
  • Page 4 Warning This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. read and understand the entire manual before attempting installation, start-up operation, or service.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Unpacking Boiler..................10 III. Pre-Installation and Boiler Mounting............11 Venting...................... A. General Guidelines................15 B. CPVC/PVC Venting................18 C. Polypropylene Venting................. 26 D. Stainless Steel Venting................ 30 E. Concentric Polypropylene Venting............32 F.

  • Page 6: Product Description, Specifications And Dimensional Data

    I. Product Description, Specifications and Dimensional Data Apex™ Series boilers are condensing high efficiency ASME Boiler and Pressure Vessel Code, which provide a gas-fired direct vent hot water boilers designed for use maximum heat transfer and simultaneous protection against in forced hot water space or space heating with indirect flue gas product corrosion.

  • Page 10: Unpacking Boiler

    I. Product Description, Specifications and Dimensional Data (continued) Table 2a: rating Data - Models aPX399, aPX500 and aPX800 (0 to 5000 Feet Elevation above Sea Level) apex Series gas-Fired Boilers Heat Transfer net aHri Thermal input (MBH) Model * Output Combustion Boiler Water area...

  • Page 11: Pre-Installation And Boiler Mounting

    In particular, avoid areas near chemical products and accelerated component failure. Burnham Commercial DOES nOT warrant failures caused containing chlorines, chlorofluorocarbons, paint by mis-sized boiler applications.
  • Page 12 iii. Pre-installation and Boiler Mounting G. General (continued) Boiler Clearances to Combustible (and Non- Boiler Service Clearances – Applicable to all Boiler Combustible) Material: Models: APX399 and APX500 Boiler Models: Top = 24”, Front = 24”, Left Side = 24”, Right Side = 24”, Rear = 24”...
  • Page 13 iii. Pre-installation and Boiler Mounting G. General (continued) • Once bracket holes and side panel dimple Boiler Stacking alignment is verified, attach the bracket to 1. For installations with unusually high space heating top and bottom boiler left side panels with and/or domestic hot water heating loads, where the mounting screws.
  • Page 14 iii. Pre-installation and Boiler Mounting G. General (continued) b. Gas Piping - Follow instructions in Section piping selection/sizing based on combined VII “Gas Piping” of the manual for sizing heating capacity and/or gross output of and installation of an individual boiler. When the selected stackable boiler combination.

  • Page 15: Venting

    iV. Venting Warning Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Do not interchange vent systems or materials unless otherwise specified. The use of thermal insulation covering vent pipe and fittings is prohibited.
  • Page 16 iV. Venting A. General Guidelines (continued) Table 4: Vent/Combustion air System Options approved Direct Vent Component Orientation Termination Description Figures Part Vent System Material Table The system includes separate CPVC Standard vent pipe and PVC air intake pipe 4 thru 9A, (thru sidewall) terminating thru sidewall with individual 9B, 10...
  • Page 17 iV. Venting A. General Guidelines (continued) Figure 4: Location of Vent Terminal relative to Windows, Doors, grades, Overhangs, Meters and Forced air inlets (Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location - Two-Pipe System air intake Terminal not Shown) h.

  • Page 18: Cpvc/Pvc Venting

    iV. Venting A. General Guidelines (continued) CPVC/PVC Venting q. The minimum horizontal distance between any adjacent individual module (boiler) roof vent Warning terminations is one (1) foot. 7. Use noncombustible ¾" pipe strap to support all CPVC vent components (supplied with boiler) horizontal runs and maintain vent location and must be used for near-boiler vent piping before slope while preventing sags in pipe.
  • Page 19 iV. Venting B. CPVC/PVC Venting (continued) Table 5B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal (Snorkel) Termination Quantity Part aPX399 and aPX500 aPX800 Vent Components number Horizontal (Snorkel) Horizontal (Snorkel) Termination Termination 4" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run 6"...
  • Page 20 iV. Venting B. CPVC/PVC Venting (continued) Table 6: Vent System and Combustion Air System Components Equivalent Length vs. Component nominal Diameter Vent or Combustion air System Equivalent Length (Ft.) for Vent or Combustion Air System Component Component Description vs. Component nominal Diameter (in.) Component nominal Diameter, in.
  • Page 21 iV. Venting B. CPVC/PVC Venting (continued) Figure 6: Field installation of CPVC/PVC Two-Pipe Vent System Connector Near-Boiler Vent/Combustion Air Piping long CPVC pipe and 4” Schedule 80 CPVC 90° Elbow) must be used for near-boiler piping Refer to Figure 7 and the following Steps: before transitioning to Schedule 40 PVC (ASTM APX399 and APX500 Boiler Models: 2665) pipe components for reminder of vent...
  • Page 22 iV. Venting B. CPVC/PVC Venting (continued) Table 8: Vent/Combustion air Pipe Length – Two-Pipe Direct Vent System Options CPVC/PVC Polypropylene (PP) or Polypropylene (PP)/PVC Stainless Steel/PVC or galvanized Steel) 4” Combustion Air Pipe 6” Combustion Air Pipe 4” Vent Pipe 6”...
  • Page 23 iV. Venting B. CPVC/PVC Venting (continued) e. Clean all vent and combustion air pipe joints with primer and secure with transition cement (4-oz. bottles of primer and cement are supplied with boiler inside vent carton). Follow application instructions provided on primer and cement bottles.
  • Page 24 • If above three conditions cannot be met simultaneously when penetrating a combustible wall, use a single wall Figure 10: rodent Screen installation thimble [Burnham Commercial part numbers 102181-01 (4”) and 103419-01 (6”)]. • Thimble use is optional for non- combustible wall.
  • Page 25 iV. Venting B. CPVC/PVC Venting (continued) CaUTiOn nOTiCE Vertical venting combustion roof Exterior run to be included in equivalent vent/ penetrations (where applicable) require the use combustion air lengths. of roof flashing and storm collar, which are not Vent Piping supplied with boiler, to prevent moisture from •...

  • Page 26: Polypropylene Venting

    iV. Venting B. CPVC/PVC Venting (continued) Figure 13: Direct Vent - Vertical Terminations with Sloped roof Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of twelve (12) inches (18 inches Canada) from roof surface. allow additional vertical (‘X’) distance for expected snow accumulation.
  • Page 27 iV. Venting C. Polypropylene Venting (continued) Table 9: approved Polypropylene Pipe, Fittings and Terminations - M&g/DuraVent M&g / DuraVent Part numbers/Sizes Boiler Male Boiler adapter, Pipe Joint Side Wall Chimney Kit for Model rigid Pipe Flex Pipe PVC to PP Locking Band Termination Tee Venting Only...
  • Page 28 Thru Unused Chimney Chase (see Figure 15). dielectric grease (grease pouch taped to the vent Apex APX399 and APX500 boilers are approved for system connector) all around to the vent or air vertical venting by installing Flexible Vent in an UNUSED connection inner red silicon gasket.
  • Page 29 iV. Venting C. Polypropylene Venting (continued) Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 15: Flexible Vent in Masonry Chimney with Separate air intake Warning Follow installation instructions included by the original polypropylene venting component manufacturers, M&g/DuraVent or Centrotherm, whichever applicable.

  • Page 30: Stainless Steel Venting

    Refer to Figure 9A. inlet piping sections are connected with PVC Vent Termination cement. • Use Burnham Commercial stainless d. Longitudinal welded seams should not be placed exhaust terminal [P/N 100184-01 (4”)]. at the bottom of horizontal sections of exhaust The outer edge of this terminal must be pipe.
  • Page 31 • Brace exterior piping if required. • Apply a heavy bead of silicone to the male end of the terminal before inserting Table 11a: Burnham Commercial Vent System it into the last piece of pipe. Orient the Components (Stainless Steel) terminal so that the seam in the terminal is at 12:00.

  • Page 32: Concentric Polypropylene Venting

    iV. Venting D. Stainless Steel Venting (continued) Concentric Polypropylene Venting ii. Combustion Air Termination 1. Vent Length Restrictions • After penetrating wall, install a 90° elbow so that the elbow leg is in the up a. Vent length restrictions are based on equivalent direction.
  • Page 33 iV. Venting E. Concentric Polypropylene Venting (continued) Figure 17: Field installation of Boiler Concentric Vent Collar c. Align collar plate clearance holes with rear/ ii. The remaining Concentric Vent Fixed bottom panel engagement holes; then secure the Extensions shown in Table 13 CANNOT collar to rear/bottom panel with six mounting BE CUT.
  • Page 34 iV. Venting E. Concentric Polypropylene Venting (continued) Figure 20: Cutting Straight Pipe pipe square. De-burr the cut edge of the plastic pipe with a file, razor blade or fine sandpaper. vi. Reinstall the inner pipe. e. To join Concentric Vent Pipe refer to Figure 21 “Joining Cuttable Pipe”...
  • Page 35 iV. Venting E. Concentric Polypropylene Venting (continued) iii. For horizontal (sidewall) installation, the Horizontal (Wall) Terminal will extend past outer wall surface by 5½” (100/150 mm). See Figure 23 “Horizontal Concentric Venting”. iv. Install the Horizontal (Wall) Terminal: • Cut a 6½” (for 100/150 mm) at the planned location of the horizontal terminal.
  • Page 36 iV. Venting E. Concentric Polypropylene Venting (continued) Figure 25: Cutting Vent Terminal Pipe mark (see Step v) is no longer visible. CaUTiOn • Re-install locking band clamp onto the Exterior wall surface must be reasonably flat to joint to secure the terminal to the collar or the last section of the vent pipe.
  • Page 37 iV. Venting E. Concentric Polypropylene Venting (continued) Figure 26: Completing Horizontal (Wall Terminal installation) Figure 27: Vertical Concentric Vent installation Figure 28: Dimension "H"...

  • Page 38: Removing The Existing Boiler

    iV. Venting E. Concentric Polypropylene Venting (continued) • Install the roof flashing using standard practice on the roofing system of the structure. • If not already done, assemble the venting system inside the building. The last section of pipe needs to be on the same center line as the terminal and within 19-1/4”...
  • Page 39 iV. Venting F. Removing the Existing Boiler (continued) When an existing boiler is removed from a common venting system are located and other spaces of the venting system, the common venting system is likely building. Turn on clothes dryers and any appliance to be too large for proper venting of the remaining not connected to the common venting system.

  • Page 40: Multiple Boiler Installation Venting

    iV. Venting G. Multiple Boiler Installation Venting (continued) Multiple Boiler Installation Venting c. The individual module (boiler) maximum combustion air intake pipe length - see Table 8. 1. CPVC/PVC or Polypropylene Venting d. If possible, locate each individual module a. Multiple Boiler CPVC/PVC or polypropylene (boiler) both combustion air intake termination direct venting is shown in Figure 32.

  • Page 43: Condensate Disposal

    iV. Venting G. Multiple Boiler Installation Venting (continued) If vertical vent terminals cannot end in one Sufficient inside space available at the base plane, they must be spaced no closer then three of the chimney to install multiple chimney (3) feet horizontally. chase brackets and support elbows.
  • Page 44 V. Condensate Disposal (continued) 2. A Condensate Neutralizer Kit (P/N 101867-01) effectiveness over time. Therefore, periodic is available as optional equipment. Follow local condensate neutralizer maintenance and limestone codes and instructions enclosed with the kit for chip replacement must be performed. A pH test or Condensate Neutralizer installation.

  • Page 45: Water Piping And Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham Commercial’s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
  • Page 46 Vi. Water Piping and Trim A. Factory Supplied Piping and Trim (continued) f. Locate and remove 1½” NPT x 2” long black b. Install close nipple into tee branch, then, screw nipple, 1½” x 1½” x ¾” NPT black tee, ¾” x ¼” the assembly into boiler left side front ¾”...
  • Page 47 Vi. Water Piping and Trim B. Piping System To Be Employed (continued) outlet, then, attach 2” x 2” x ¾” tee onto the Space heating only - refer to Table 15 and nipple opposite end, making sure ¾” branch Figure 36 “Near Boiler Piping - Heating outlet is in horizontal plane and facing the boiler Only”...
  • Page 48 Vi. Water Piping and Trim C. Standard Installation Requirements (continued) 4. Fill Valve (Required) – Either manual . Standard Installation Requirements. (recommended) or automatic fill valve may be used. Observe the following guidelines when making the However, if automatic refill is employed, a water actual installation of the boiler piping: meter must be added to evaluate the makeup water 1.
  • Page 49 Vi. Water Piping and Trim C. Standard Installation Requirements (continued) Table 16: Fitting and Valve Equivalent Length Table 16: Fitting and Valve Equivalent Length (cont’d) Copper Fitting and Sweat Valve Equivalent Length (Ft) Threaded Fitting and Valve Equivalent Length (Ft) Copper Pipe or Valve Size Black Threaded Pipe or Fitting or Valve...
  • Page 52 Vi. Water Piping and Trim D. Special Situation Piping Installation Requirements (continued) 2. Piping with a Chiller - If the boiler is used in Special Situation Piping Installation Requirements conjunction with a chiller, pipe the boiler and chiller Observe the following guidelines when making the in parallel.
  • Page 53 Vi. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued) Figure 38B: isolation of the Boiler From Oxygenated Water with a Plate Heat Exchanger (iWH Piped Off System Header) 2. For installations where indirect domestic hot water Multiple Boiler Installation Water Piping - See Table 17 heater is combined with space heating, the Alliance and Figures 39B and 40B.

  • Page 59: Gas Piping

    Vii. gas Piping Minimum gas valve inlet pressure is stamped on Warning the rating label located in the boiler’s vestibule compartment. Failure to properly pipe gas supply to boiler may 2. Maximum gas demand. Refer to the boiler’s input as result in improper operation and damage to the printed on its rating label.
  • Page 60 Vii. gas Piping (continued) Connect boiler gas valve to gas supply system. Warning Warning Failure to use proper thread compounds on all gas supply to boiler and system must be absolutely shut off prior to installing or servicing gas connectors may result in leaks of flammable boiler gas piping.
  • Page 61 Vii. gas Piping (continued) Table 21: Specific Gravity Correction Factors Specific Correction Specific Correction gravity Factor gravity Factor 0.60 1.00 0.90 0.82 0.65 0.96 1.00 0.78 0.70 0.93 1.10 0.74 0.75 0.90 1.20 0.71 0.80 0.87 1.30 0.68 0.85 0.81 1.40 0.66 1.
  • Page 62 Vii. gas Piping (continued) 2. For the low and high gas pressure switches proper 3. An additional gas pressure regulator(s) may need to operation, the boiler inlet gas pressure must be be installed to properly regulate inlet gas pressure at within 4.5”...

  • Page 63: Electrical

    Viii. Electrical DangEr Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. Warning Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source.
  • Page 64 Viii. Electrical (continued) Low Voltage (24 VAC) Connections - see Figure 44. Warning 3. The terminal block TB-2 in conjunction with terminal screw identification label is attached to When making low voltage connections, make the junction box front and located inside Sage2.1 sure that no external power source is present Control compartment on the left side.
  • Page 65 Viii. Electrical (continued) Figure 43: Ladder Diagram...
  • Page 68 Viii. Electrical (continued) Figure 45A: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus alternately Piped indirect Water Heater...
  • Page 73 Viii. Electrical (continued) . Multiple Boiler Operating Information 1. Required Equipment and Setup a. Header Sensor (P/N 101935-01 or 103104-01) A header sensor must be installed and wired to the Master Sequencer “enabled” Sage2.1 Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master.
  • Page 74 Viii. Electrical (continued) . Multiple Boiler Operating Information (continued) 1. Required Equipment and Setup (continued) Figure 50: rJ45 Splitter installation Detail d. Multiple Boiler Setup Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the Header nOTE Sensor...

  • Page 75: System Start-Up

    iX. System Start-up Verify that the venting, water piping, gas piping and from gas supplier. electrical system are installed properly. Refer to 2. Apex gas valves have inlet and outlet pressure installation instructions contained in this manual. taps with built-in shut off screw. Turn each screw from fully closed position three to four Confirm all electrical, water and gas supplies are turns counterclockwise to open taps.
  • Page 76 iX. System Start-up (continued) Apex™ Series Lighting and Operating Instructions Figure 51: Lighting instructions...
  • Page 77 iX. System Start-up (continued) Status Control action Warning Initiate Power-up The outlet pressure for the gas valve has been This state is entered when a delay is factory set and requires no field adjustment. This Standby Delay needed before allowing the burner control setting is satisfactory for both natural gas and to be available and for sensor errors.
  • Page 78 iX. System Start-up (continued) Figure 52: Burner Flame value listed on the boiler rating label. If a boiler probe directly into flue sensor port. Reinstall the sensor is equipped with two gas valves, throttle screw and the cap upon combustion testing completion. adjustments must be done to both gas valves equally Check CO (or O...
  • Page 79 iX. System Start-up (continued) Test External Limits Test any external limits or other controls in accordance with the manufacturer’s instructions. Check Thermostat Operation Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect water heater thermostat.
  • Page 80 iX. System Start-up (continued) (including the converted boiler) both on and off. Warning 9. A label sheet is provided with the boiler for conversions from natural to LP gas. Once conversion is completed, These instructions include a procedure for apply labels as follows: adjusting the air-fuel mixture on this boiler.

  • Page 81: Operation

    X. Operation Overview 6. Warm Weather Shutdown (WWSD) Some boilers are used primarily for heating buildings, 1. Sage 2.1 Controller and the boilers can be automatically shutdown when The Sage 2.1 Controller (Control) contains features and the outdoor air temperature is warm. When outside air capabilities which help improve heating system operation, temperature is above the WWSD setpoint, this function and efficiency.

  • Page 82: Supply Water Temperature Regulation

    X. Operation B. Supply Water Temperature Regulation (continued) Supply Water Temperature Regulation 4. Outdoor Air Reset If an outdoor temperature sensor is connected to the boiler 1. Priority Demand and Outdoor Reset is enabled, the Central Heat setpoint The Control accepts a call for heat (demand) from will automatically adjust downwards as the outdoor multiple places and responds according to it’s “Priority”.

  • Page 83: Boiler Protection Features

    X. Operation C. Boiler Protection Features (continued) 5. External Limit Boiler Protection Features An external limit control can be installed between 1. Supply Water Temperature High Limit terminals 11 and 12 on the low voltage terminal strip. The boiler is equipped with independent automatic reset Be sure to remove the jumper when adding an external and a manual reset High Limit devices.

  • Page 84: Multiple Boiler Control Sequencer

    X. Operation D. Multiple Boiler Control Sequencer (continued) 6. Multiple Demands Multiple Boiler Control Sequencer The Sequence Master responds to Central Heat, DHW 1. “Plug & Play” Multiple Boiler Control Sequencer and frost protection demands similar to the stand alone When multiple boilers are installed, the Control’s boiler.

  • Page 85: Boiler Sequence Of Operation

    X. Operation E. Boiler Sequence Of Operation (continued) Boiler Sequence of Operation 1. Normal Operation Table 29: Boiler Sequence of Operation Status Screen Display Description Boiler 1 Priority: 140 F Supply (burner Off, circulator(s) Off) Standby > 140 F < Setpoint Boiler is not firing and there is no call for heat, priority equals standby.

  • Page 86: Using The Display

    X. Operation E. Boiler Sequence Of Operation (continued) 2. Using The Display The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen navigation “buttons” and symbols. Navigation features are shown below. The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the display reverts to the “Home Screen”...

  • Page 87: Viewing Boiler Status

    X. Operation F. Viewing Boiler Status (continued) Viewing Boiler Status 1. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status”...

  • Page 88: Detail Screens

    X. Operation F. Viewing Boiler Status (continued) 1. Status Screens (continued) Pump Status/Cycles Heat Demand Central Heat On System On < > < > Domestic Hot Water Off Boiler On Sequence Master Off DHW Off Frost Protection Off Frost Protection On Exercise On Pumping is a major part of any hydronic system.

  • Page 89: Multiple Boiler Sequencer Screens

    X. Operation F. Viewing Boiler Status (continued) 3. Multiple Boiler Sequencer Screens When the Sequence Master is enabled the following screens are available: The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled. Rate: Header: The rate % value is equal to the...

  • Page 90: Changing Adjustable Parameters

    X. Operation G. Changing Adjustable Parameters (continued) Changing Adjustable Parameters Adjust 1. Entering Adjust Mode Active Fault The Control is factory programmed Warning! Only Qualified to include basic modulating boiler Technicians Should Adjust functionality. These settings are password Controls, Contact Your protected to discourage unauthorized or For Service Contact: Qualified Heating Professional...
  • Page 91 X. Operation G. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System Modulation Setup...
  • Page 92 X. Operation G. Changing Adjustable Parameters (continued) 2. Adjusting Parameters (continued) Warning Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
  • Page 93 X. Operation G. Changing Adjustable Parameters (continued) Pump Setup “Press” button to access the following parameters: Factory Setting range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat.
  • Page 94 X. Operation G. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater Piped to Primary, Optional Domestic Hot Water Priority. Parameter Selections: System Pump= “Central Heat , Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional Explanation: This piping arrangement permits the...
  • Page 95 X. Operation G. Changing Adjustable Parameters (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
  • Page 96 X. Operation G. Changing Adjustable Parameters (continued) Contractor Setup “Press” button to access the following parameters: Contractor name For Service Contact: Bill Smith Press box to input contractor information. > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
  • Page 97 X. Operation G. Changing Adjustable Parameters (continued) Central Heat “Press” button to access the following parameters: Factory range / Parameter and Description Setting Choices 80°F to Central Heat Setpoint 180°F 190°F Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
  • Page 98 X. Operation G. Changing Adjustable Parameters (continued) Outdoor “Press” button to access the following parameters: Reset Factory range / Parameter and Description Setting Choices Outdoor reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 57.
  • Page 99 X. Operation G. Changing Adjustable Parameters (continued) Central Heat Setpoint Boost Maximum Off Point Low Outside Air Temp = Central Heat Setpoint =180 F & 0 F minus Diff Above 10 F Default Boost Outdoor Air Reset Setpoint (Shown with thin lines, typical) TOD Setback Setpoint (Reset setpoint increased by 10 F every Default = 170 F...
  • Page 100 X. Operation G. Changing Adjustable Parameters (continued) Remote “Press” button to access the following parameters: 4-20mA Factory range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off Local, demand directly without using the internal setpoint.

  • Page 101: Service And Maintenance

    Xi. Service and Maintenance DangEr This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
  • Page 102 Remove insulation disc and clean the 946-1611 and/or selected HVAC distributors. surfaces by flushing with clean water. If the disc has Contact Burnham Commercial for specific signs of damage, it must be replaced. Drain and flush the details.
  • Page 103 Note that the switch has factory applied 1611 and/or selected HVAC distributors. silicon adhesive seal, which may have to be carefully Contact Burnham Commercial for specific cut all around to facilitate the switch removal. details. d. Insure the trap overflow switch port is not obstructed b.
  • Page 104 Xi. Service and Maintenance (continued) e. Using pliers, release spring clip securing the k. Restore power supply to boiler. Fill up the trap overflow switch to condensate trap body and remove (see Section V “Condensate Disposal”) and the switch. Note that the switch has factory applied verify the switch operation.

  • Page 105: Troubleshooting

    Xii. Troubleshooting Warning Turn off power to boiler before working on wiring. Troubleshooting problems where no error code is displayed. Condition Possible Cause Boiler not responding to call for heat, “Status” and Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection, “Priority”...
  • Page 106 Xii. Troubleshooting (continued) Help Screen Faults indication Condition Possible Cause This alarm is active if the slave boiler has lost communication with the Sequence Master. Check the following: Sequencer Sequencer - RJ 45 peer-to-peer network disconnected Setup Setup - Sequencer Master was Enabled and then Disabled Fault - Master’s Boiler has been powered down.
  • Page 107 Xii. Troubleshooting (continued) Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the soft lockout.
  • Page 108 Xii. Troubleshooting (continued) Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout.

  • Page 109: Repair Parts

    Xiii. repair Parts All Apex™ Series Repair Parts may be obtained through your local Burnham Commercial Cast Iron Wholesale distributor. Should you require assistance in locating a Burnham Commercial Cast Iron distributor in your area, or have questions regarding the availability of Burnham Commercial Cast Iron products or repair parts, please contact Burnham Commercial Cast Iron Customer Service at (888) 791-3790 or Fax (877) 501-5211.
  • Page 110 Xiii. repair Parts (continued) 1P-3 1P-2...
  • Page 111 Xiii. repair Parts (continued) (Quantity) Part number Description aPX399 aPX500 aPX800 Bare Heat Exchanger 101931-06 101931-07 103261-01 Burner Head Assembly 101933-06 101933-07 103108-01 Replacement Igniter Kit 103005-01 103005-02 103308-01 Replacement Flame Sensor Kit 103339-01 103310-01 Replacement Partially Assembled Burner Door 102696-01 104597-01 Air Vent Valve...
  • Page 112 Xiii. repair Parts (continued) APX399 and APX500 Only (SIZE 500 ONLY) 2B-1 (SIZE 500) (SIZE 399) (Quantity) Part number Description aPX399 aPX500 aPX800 Blower 101530-01 101531-01 103222-01 Blower Inlet Shroud Assembly (includes Gas Orifice; Gas Orifice O-Ring; (3x) M4x20 mm or (3x) M4x25 mm 101704-04 101704-05 103223-01 Self-threading Screws;...
  • Page 113 Xiii. repair Parts (continued) (Quantity) Part number Description aPX399 aPX500 aPX800 Low Gas Pressure Switch 102702-01 High Gas Pressure Switch 102703-01 Gas Pressure Switch Wire Harness 102704-01...
  • Page 114 Xiii. repair Parts (continued) (Quantity) Part number Description aPX399 aPX500 aPX800 Air Pressure Switch 104426-01 Air Pressure Switch Tubing, Black 7016041 102770-01 103257-01 Condensate Trap, Blow Molded 101239-01 Blocked Condensate Drain Switch 101587-01 Spring Clip, Condensate Trap (2) 101632-01 Rubber Grommet, Condensate Trap 101595-01 Condensate Comp.
  • Page 115 Xiii. repair Parts (continued) (Quantity) Part number Description aPX399 aPX500 aPX800 5A Sage2.1 (Programmed) 104472-01 104472-04 Programmed Display (with Mounting Hard- 104427-01 ware) 5C Transformer 102516-01 103193-01...
  • Page 116 Xiii. repair Parts (continued)
  • Page 117 Xiii. repair Parts (continued) (Quantity) Part number Description aPX399 aPX500 aPX800 Jacket, Rear/Bottom Panel 103406-02 103407-01 Jacket, Left Side Panel 102776-06 102776-07 103232-01 Jacket, Right Side Panel 101766-02 102610-01 103233-01 Partition Shelf Assembly 102831-06 102831-07 103237-01 Jacket, Top Panel 101218-06 101218-07 103234-01 Heat Exchanger Support Assembly, Right Side...
  • Page 119 Xiii. repair Parts (continued) (Quantity) Part number Description aPX399 aPX500 aPX800 Jacket, Rear/Bottom Panel 103406-02 103407-01 Jacket, Left Side Panel 102776-06 102776-07 103232-01 Jacket, Right Side Panel 102776-02 102610-01 103233-01 Partition Shelf Assembly 102831-06 102831-07 103237-01 Jacket, Top Panel 101218-06 101218-07 103234-01 Heat Exchanger Support Assembly, Right Side...
  • Page 120 Xiii. repair Parts (continued) (Quantity) Part number Vent System Components Part number aPX399 aPX500 aPX800 4” Schedule 40 PVC Tee Vent/Combustion Air Terminal 102190-02 4” Stainless Steel Rodent Screens 102191-02 6” Stainless Steel Rodent Screens 102191-03 4” x 30” Schedule 40 CPVC Pipe 102193-02 6”...
  • Page 121 XIII. Repair Parts (continued) (Quantity) Part Number Description APX399 APX500 APX800 MISCELLANEOUS PARTS CARTON 102942-03 102942-03 102942-04 Temperature/Pressure Gauge 100282-01 External Gas Shut Off Valve 101615-01 816SOL0015 Relief Valve 81660302 81660375 Boiler Drain Valve 806603061 Boiler Stacking Brackets (2) 101679-01 Boiler Stacking Bracket Screws (8) 80860743 Outdoor Temperature Sensor (Not Shown)
  • Page 122 Xiii. repair Parts (continued) Part number Description aPX399 aPX500 aPX800 Complete Wiring Harness (includes 10A, 10B, 10C & 10D) 102701-02 10A Main (Low Voltage) Harness 103009-02 10B High Voltage Harness 103010-02 10C Blower Power Harness 103012-01 10D Communication Harness 103011-01 10E Igniter Harness 103486-01 10F Wiring Harness, Thermal Link and Burner Door Thermostat...
  • Page 123 important Product Safety information refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.

  • Page 124: Appendix A - Figures

    appendix a - Figures Figure Page Description number number Section I - Product Description, Specifications & Dimensional Data Figure 1A Model APX399 Figure 1B Model APX500 Figure 1C Model APX800 Section iii - Pre-installation and Boiler Mounting Figure 2 Clearances To Combustible and Non-combustible Material Figure 3 Stacking Boiler Attachment Bracket Placement Section iV - Venting...
  • Page 125 appendix a - Figures (continued) Figure Page Description number number Section iV - Venting (continued) Figure 33 Multiple Boiler Concentric Vent Termination Section V - Condensate Disposal Figure 34 Condensate Trap and Drain Line Section Vi - Water Piping and Trim Figure 35 Factory Supplied Piping &...
  • Page 126 appendix a - Figures (continued) Figure Page Description number number Section X - Operation Figure 54 Status Screens Figure 55 Detail Screens Figure 56 Adjust Mode Screens Figure 57 Outdoor Reset Curve Section Xi - Service and Maintenance Figure 58 Igniter Electrode Gap Figure 59 Condensate Overflow Switch Orientation...

  • Page 127: Appendix B - Tables

    Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent Table 10 Approved Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco Table 11A Burnham Commercial Vent System Components (Stainless Steel) Table 11B Alternate Vent Systems and Vent Components (Stainless Steel) Table 12...
  • Page 128 appendix B - Tables (continued) Table Page Description number number Section Viii - Electrical Table 23 Boiler Current Draw Section iX - System Start-Up Table 24 Recommended Combustion Settings, Natural Gas Table 25 Number of Clockwise Throttle Screw Turns for LP Conversion Table 26 Recommended Combustion Settings, LP Gas Section X - Operation...
  • Page 129 SErViCE rECOrD DATE SERVICE PERFORMED...
  • Page 130 SErViCE rECOrD DATE SERVICE PERFORMED...
  • Page 131 SErViCE rECOrD DATE SERVICE PERFORMED...

  • Page 132: Warranty

    If any part of a commercial grade boiler or i. Any damage resulting from combustion air contaminated with particulate any part or accessory provided by Burnham Commercial is found to be defective in which cause clogging of the burner or combustion chamber including but material or workmanship during this one year period, Burnham Commercial will, at its not limited to sheetrock or plasterboard particles, dirt, and dust particulate.

This manual is also suitable for:

Apex apx500Apex apx800

Table of Contents