Burnham CHG CHG225 Installation & Operation Manual
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Burnham CHG CHG225 Installation & Operation Manual

Burnham CHG CHG225 Installation & Operation Manual

Chg series condensing high efficiency gas - fired hot water boiler
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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.
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  • Page 1 : 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. 100343-01-3/06 ™...

  • Page 2: Table Of Contents

    V. Air For Ventilation ... 6 VI. Venting ... 8 A. Vent System Design ... 8 B. Removing An Existing Boiler From Common Chimney ... 15 C. Vent/Intake System Assembly ... 15 VII. Condensate Drain Line ... 20 VIII. Gas Piping ... 22 IX.

  • Page 3: I. Product Description

    The CHG is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors. This boiler is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen. Table 2.2: Specifications MAXIMUM NO. OF MODEL* INPUT SECTIONS (BTU/hr) CHG150 150,000 CHG225 225,000 * MODELS SHOWN ARE FOR NATURAL GAS. ADD “LP” SUFFIX TO MODEL NUMBER SHOWN FOR PROPANE MODEL NUMBER (ie CHG225LP). PERFORMANCE RATINGS ARE THE SAME FOR BOTH FUELS.

  • Page 4: Iii. Before Installing

    ImPOrTaNT INfOrmaTION abOuT INsTallINg ThIs PrODuCT wIThIN ThE COmmONwEalTh Of massaChusETTs. 1) Observe the minimum clearances shown in Figure 4.1. These clearances apply to both combustible and non- combustible materials. Observe the minimum clearances to combustibles for vent pipe shown in Table 4.2. 2) Note the recommended service clearances in Figure 4.1. The recommended service clearances may be reduced to the minimum combustible clearances with the understanding that servicing the boiler will become increasingly difficult as the clearance is reduced. 3) Boiler may be installed on non-carpeted combustible surface. 4) The relief valve must be installed in the factory specified location. 5) The boiler should be located so as to minimize the length of the vent system. 6) The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will contaminate combustion air. Avoid areas near chemical products containing chlorine, chloride based salts, chloro/fluorocarbons, paint removers, cleaning solvents and detergents. III Before Installing NOTICE IV Locating the Boiler...
  • Page 5 Figure 4.1: Clearances To Combustible Or non-combustible Material Table 4.2: Clearances From Vent Piping To Combustible Construction TYPE OF VENT PIPE PIPE DIRECTION BURNHAM AL29-4C VERTICAL OR ALTERNATE: HORIZONTAL HEAT FAB SAF-T VENT PROTECH FASNSEAL HORIZONTAL OR VERTICAL Z-FLEX Z-VENT III...

  • Page 6: V. Air For Ventilation

    Total input in thousands of BTU/hr = (225000 BTU/hr + 30000 BTU/hr) / 1000 = 255 MBTU/hr Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft3 350/255 = 1.37. Since 1.37 is less than 50, the boiler room is a confined space. Step 2a: If the boiler is to be placed in a confined space, provide two openings into the boiler room, one near the floor and one near the ceiling. The top edge of the upper opening must be within 12” of the ceiling and the bottom...
  • Page 7 Figure 5.1: Boiler Installed In A Confined Space, Ventilation Air From Inside Step 2b: If the boiler is to be placed in an unconfined space the natural infiltration into the boiler room will provide adequate air for ventilation without additional openings into boiler room.

  • Page 8: Vi. Venting

    • Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. • Do not attempt to mix components from different approved vent systems.
  • Page 9 The Vent Option #1 column in Table 6.2a describes a horizontal direct vent system using 3” vent pipe. From this column, we see that a CHG150 may have a vent length of up to 55ft. The first 90 elbow and the termination elbow are not considered. From Table 6.6, the equivalent length of the 3” 45 elbow is 4ft and the equivalent length of the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore: 55ft – 4 ft – 5.5ft = 40ft Since the planned installation has only 14 ft of straight pipe, the planned vent length is acceptable. Figure 6.1: Horizontal Direct Venting (Vent Options 1,2) 3) Minimum Vent and Air Intake Lengths - Minimum vent length is 2ft. Minimum air inlet length is 2ft. 4) Permitted Terminals for Horizontal Venting (Vent Options 1,2) - The vent terminal is either a tee or an elbow supplied by the vent system manufacturer and equipped with a rodent screen. Vent system manufacturer’s part numbers for these fittings are shown in Table 6.5. In some cases, the elbows and tees shown in Table 6.5 require separate rodent screens. When this is the case, vent manufacturer part numbers for these additional parts are shown in Table 6.5 along with the termination fitting. The air intake fitting on a horizontal vent systems is always a 90 degree elbow with a rodent screen. This elbow is made out of the same material as the rest of the air inlet system (either galvanized or PVC) and is installed as shown in Figure 6.1.
  • Page 10 • Do not locate the vent terminal under decks or similar structures. • Top of vent terminal must be at least 5 feet below eves, soffits, or overhangs. Maximum depth of overhang is 3 ft. • Vent terminal must be at least 6 feet from an inside corner. • Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected. • If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if the terminal is subjected to winds in excess of 40 mph. Table 6.2a: Summary of Horizontal Venting Options VENT OPTION # CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE VENT PIPE STRUCTURE PENETRATION AIR INTAKE PIPE STRUCTURE...
  • Page 11 Table 6.2b: Summary of Vertical Venting Options VENT OPTION # CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE VENT PIPE STRUCTURE PENETRATION AIR INTAKE PIPE STRUCTURE PENETRATION VENT PIPE SIZE AIR INTAKE PIPE SIZE EXHAUST TERMINAL AIR INTAKE TERMINAL VENT MATERIAL AIR INTAKE MATERIAL “N.R” - Not recommended “N.A.” - Not applicable VERTICAL...
  • Page 12 Figure 6.3a: Location of Vent Terminal Relative to Windows, Doors, Grade Figure 6.3b: Location of Vent Terminal relative to Meters and Forced air inlets Figure 6.3c: Positioning Vent Terminal Under Overhangs...
  • Page 13 • Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See Section IV for more information on possible contaminates. 6) Permitted Terminals for Vertical Venting (Vent Options 6, 7) - A rodent screen is installed in the end of the vent pipe. Vent manufacturer part numbers for these screens are shown in Table 4. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 6.4. 7) Vertical Vent Terminal Locations (Vent Options 6,7) - Observe the following limitations on the location of all vertical vent terminals (see Figure 6.4): • The top of the vent pipe must be at least 2 feet above any object located within 10 feet. • The vertical distance between top of the vent and air inlet terminal openings must be at least 12”. • The bottom of the air inlet terminal must be at least 12” above the normal snow accumulation that can be expected on the roof. • The air intake terminal must be located on the roof and must be no further than 24” horizontally from the exhaust pipe. 8) Wall thimbles – Wall thimbles are required where the vent pipe passes through combustible walls with less than the required clearance shown in Table 4.2 or as required by local codes. Vent manufacturer’s wall thimble part numbers are shown in Table 6.5. 9) Pitch of Horizontal piping – All horizontal vent piping must be pitched ¼” per foot so that any condensate which forms in this piping will run towards the boiler. 10) Vertical and horizontal sections of piping must be properly supported. See vent system manufacturer’s instructions for more information. 11) Fire Stops – Use fire stops where required by code or by the vent system manufacturer. Consult vent system manufacturer’s literature for information on suitable fire stops. Figure 6.4: Vertical Vent System (Vent Options 6,7)
  • Page 14 Table 6.5: Burnham Vent/air intake System Components ParT VENT sysTEm COmPONENT NumbEr 3” DIA. PIPE X 1 FT. 8116296U 4” DIA. PIPE X 1 FT. 100176-01 3” DIA. PIPE X 3 FT. 8116298U 4” DIA. PIPE X 3 FT. 100177-01 3”...

  • Page 15: C. Vent/Intake System Assembly

    I n some cases, there are differences between the vent system installation instructions in this manual and those in the vent system manufacturer’s manual. Where such differences exist, this manual takes precedence over the vent system manufacturer’s manual. VENT SySTEMS MADE By BuRNHAM, HEAT FAB, PRoTECH, AND Z-FLEx RELy oN GASkETS FoR PRoPER SEALING. WHEN THESE VENT SySTEMS ARE uSED, TAkE THE FoLLoWING PRECAuTIoNS: • MAkE SuRE THAT GASkET IS IN PoSITIoN AND uNDAMAGED IN THE FEMALE END oF THE PIPE.
  • Page 16 I nsert the male end of the pipe into the boiler vent collar until it bottoms out. f) A pply an additional bead of silicone over the outside of the joint and smooth out. g) R eplace and tighten the clamp on the vent collar. h) C lean the female end of the first piece of pipe. Also clean the male end of the next piece of pipe. i) A pply silicone as in step (d) (Fig 6.7b). j) A lign the longitudinal seams of the pipe and insert the male end of the second pipe into the female end of the first pipe. k) I nsert a Star-34 joiner band into the inlet of the beaded channel. Feed the joiner band in so that it makes its way around the channel and overlaps by approximately ½” (Fig 6.7b). Figure 6.: Burnham Gasketed Vent Joint Detail Stainless ®...
  • Page 17 Figure 6.7a: Star-34 Connection to Vent Collar l) C ut the excess joiner band so that it lays flat in the beaded channel (Fig 6.7b). m) F ill the inlet of the beaded channel with silicone. Smooth the silicone over the channel inlet as well as the silicone between the female end and the stop bead of the male end (Fig 6.7b). n) R epeat Steps (h) – (m) for the remaining Star-34 components. p) A llow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler. 5) Assembly of Z-Flex Z-Vent III: a) G eneral Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. See the following instructions. • Support horizontal piping sections at intervals of 48” or less. • Vertical venting systems must be supported by at least one Z-Flex fire stop. An additional vertical support is required after any offset and as required by the Z-Vent III installation instructions. b) S tart assembly of the vent system at the boiler. Remove the hose clamp shipped on the CHG vent collar.
  • Page 18 A lign the second piece of pipe with the first and push them together as far as they will go, but not less t han 1-3/4”. j) T ighten gear clamp to a minimum torque of 40 in-lbs and a maximum of 50 in-lbs. k) R epeat Steps (h) – (j) for the remaining Z-Vent III components. l) In horizontal vent systems, a locking band or gear clamp must be used at either side of the wall penetration to prevent shifting of the vent system in and out of the wall. This applies to both combustible and non- combustible walls. n) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler. 6) Assembly of Heat Fab Saf-T Vent EZ Seal: a) S af-T Vent General Notes: T hese instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. • In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T Vent slip connector and connections to the boiler vent collar. In these cases, use a sharp pair of aviation snips, an abrasive cut-off, or a plasma cutter. See the Saf-T Vent instructions for information on cutting the slip connector. • Orient Saf-T Vent components so that the arrows on the piping labels are in the direction of flue gas flow. • Support horizontal piping sections at intervals of 6 feet or less. • Vertical venting systems must be supported by at least one Heat Fab support. An additional vertical support is required after any offset.
  • Page 19 Figure 6.: SaF-T Vent Ezseal Connection to Vent Collar 7) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of flue gas flow. • Support horizontal piping sections at intervals of 6 feet or less. • Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required after any offset. b) Remove the hose clamp shipped on the CHG vent collar. Bend the three hose clamp tabs on this collar outward slightly. Clean the exterior of the male end of the first piece of pipe and the inside of the vent c ollar on the boiler. Remove dirt, grease, and moisture from the surfaces to be sealed. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately 1/4 inch from the male end of the pipe. Insert the male end of the pipe into the boiler vent collar until it bottoms out. Apply an additional bead of silicone over the outside of the joint and the seams on the vent collar and smooth out (Fig 6.10). Replace and tighten the clamp on the vent collar. c) All other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal. d) Align the longitudinal seam of both pipes. Insert the male end of the second pipe into the female end of the first pipe until the bead on the male end contacts the flare on the female end. e) Tighten the locking band with a nut driver. f) Repeat (d) and (e) for the remaining FasNSeal components. g) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.

  • Page 20: Vii. Condensate Drain Line

    1) All condensate which forms in the boiler or vent system collects in the sump under the heat exchanger and leaves the boiler through the condensate trap. This trap allows condensate to drain from the sump while retaining flue gases in the boiler. A length of drain hose is supplied with the boiler and is connected to the trap as shown in Figure 6.11. This hose may be routed through the back of the boiler or to either side through the knockouts provided. Route this hose to a drain or other suitable point for disposal. Note the following when d isposing of the condensate: a) If the condensate drain line must be extended, construct the extension from PVC or CPVC pipe. Insert the hose provided with the boiler into the end of the extension as shown in Figure 6.11. b) Condensate is slightly acidic. Do not use metallic pipe or fittings in the condensate drain line. Do not route the drain line through areas that could be damaged by leaking condensate. c) Some jurisdictions may require that the condensate be neutralized before being disposed of. Dispose of condensate in accordance with local codes. d) Do not route, or terminate, the condensate drain line in areas subjected to freezing temperatures. e) If the point of condensate disposal is above the trap, it will be necessary to use a condensate pump to move the condensate to the drain. In such cases, select a condensate pump that is approved for use with condensing furnaces. If overflow from this pump would result in property damage, select a pump with an overflow switch and use this switch to shut down the boiler. Alternatively, if heat is a necessity, use the overflow switch to trigger an alarm. f) Do not attempt to move the trap from the location shown in Figure 6.11. Do not attempt to substitute another trap for the one provided with the boiler. g) The vent shown in Figure 6.11 must be left open for the trap to work properly. Figure 6.10: FasnSeal Connection to Vent Collar VII Condensate Drain Line...
  • Page 21 Figure 6.11: Condensate Piping Arrangement WARNING BOILER CONDENSATE IS CORROSIVE. ROUTE CONDENSATE DRAIN LINE IN A MANNER SUCH THAT ANY CONDENSATE LEAKAGE WILL NOT CAUSE PROPERTY DAMAGE. SOME JURISDICTIONS MAY REQUIRE THAT CONDENSATE BE NEUTRALIZED PRIOR TO DISPOSAL.

  • Page 22: Viii. Gas Piping

    Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code. Figure 7.1 shows typical gas piping connection to the CHG boiler. A sediment trap must be installed upstream of all gas controls. Install the factory provided manual shut-off valve outside the jacket with a ground joint union as shown. The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of 1/2 psi. When pressure testing the gas system at pressures of 1/2 psi or less, isolate the boiler from the gas supply system by closing its individual manual shut-off valve. VIII Gas Piping Figure .1: Gas Connection To Boiler...

  • Page 23: A. General System Piping Precautions

    MAKEUP WATER. REGULAR ADDITIONS OF MAKEUP WATER MAY CAUSE SEVERE HEAT EXCHANGER DAMAGE. • BEFORE CONNECTING BOILER, MAKE SURE THAT THE SYSTEM IS FREE OF SEDIMENT, FLUX AND ANY RESIDUAL BOILER WATER ADDITIVES. FLUSH THE SYSTEM IF NECESSARY TO ENSURE THAT THESE CONTAMINATES ARE REMOVED.
  • Page 24 Method 1: Primary/Secondary Piping - Boiler in Secondary Loop This method can be used in heat-only applications as shown in Figure 8.2 or with an indirect water heater as shown in Figure 8.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler. In this system, the flow rate through the boiler is completely independent of the flow rate through the heating system. Use the following guidelines to ensure that boiler will have the required flow shown in Table 8.1 regardless of the flow in the heating system. 1) Primary Loop Piping - Size the primary circulator and piping to obtain the design flow rate through the heating system as you would on any other heating system. All piping between the expansion tank and secondary connection tees must be at least as large as that shown in Table 8.5, column a. In order to keep the flow rates in the primary and secondary loops independent of each other, provide at least 8 diameters of straight pipe upstream of the first secondary tee and 4 diameters downstream of the second secondary tee. Keep the distance between the expansion tank and the first secondary tee as short as practical. 2) Secondary Loop (“Boiler Loop”) Piping – All piping must be the size shown for the boiler in Table 8.5, column a. To size the circulator: a) C ount all fittings in the planned secondary loop (the secondary loop consists of the shaded piping in Figure 8.4a). In doing so, do not count the secondary connection tees, unions, or the fittings supplied with the boiler (these have already been accounted for). b) U sing Table 8.7, find the equivalent lengths of all fittings in the secondary loop. Total these equivalent lengths and add them to the total length of planned straight pipe in the secondary loop. The result is the total equivalent length of the secondary loop. c) U sing Table 8.5, find the boiler size being installed and select a boiler secondary circulator that shows a “maximum equivalent length” (column d) in excess of the total equivalent length calculated in Step b.
  • Page 25 Figure .2: Piping Method #1 - Heat Only Figure .3: Piping Method #1 - Heat + indirect Water Heater...
  • Page 26 Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded) Figure 8.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded)
  • Page 27 Table .5: Pipe and Circulator Sizing for Boiler Loop BOILER MODEL CHG150 CHG150 CHG225 CHG225 NOTE: For piping method #1, “boiler loop” is heating system secondary loop For piping method #2, “boiler loop” is heating system primary loop Table .6: Pipe and Circulator Sizing for indirect Water Heater Loop BOILER PIPE SIZE FLOW MODEL (in NPT) (GPM) CHG150 1 1/4...
  • Page 28 Method 2: Primary/Secondary Piping - Boiler in Primary Loop This method can be used in heat-only applications as shown in Figure 8.8 or with an indirect water heater as shown in Figure 8.9. Like Method 1, this method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler. In this system, the flow rate through the boiler is completely independent of the flow rate through the heating zones. The boiler is installed in the heating system primary loop as shown. This system provides more accurate control of the water temperature entering the heating zones as the number of zones calling for heat changes. When this piping method is used, the boiler control is set to provide the highest supply temperature required by any heating zone and some other means, such as 3-way valves, are used to control the water temperatures required by any zones requiring lower temperature water. This system is only recommended when the primary loop (shown bolded in Figure 8.10b) is to be constructed as part of the boiler installation and can be constructed as shown. Also, if the boiler is to accurately control the temperature entering each secondary loop, the flow rate in the primary loop must be at least as great as the sum of the flows through all secondary loops. Use the following guidelines to ensure that boiler will have the required flow shown in Table 8.1 regardless of the flow in the heating system. 1) Heating System Secondary Loop Piping - The heating system secondary loop piping is shown in Figure 8.10a. Size each secondary zone circulator and piping to obtain the design flow rate for that zone as you would on any other heating system. When the heating zone requires a water temperature below that to be controlled by the boiler, provide a mixing valve or blending station for that zone. In order to keep the flow rates in the primary and secondary loops independent of each other, provide at least 8 diameters of straight pipe upstream of the first secondary tee and 4 diameters downstream of the second secondary tee. 2) Heating System Primary Loop (“Boiler Loop”) – The primary loop (“boiler loop”) piping is shown bolded in Figure 8.10b. All piping in this loop must be the size shown for the boiler in Table 8.5, column a. To size the circulator: a) S tarting at the boiler, trace a path through the heating system primary loop from the boiler supply connection to the boiler return connection, counting fittings and straight pipe as you go. Where the primary loop breaks into parallel paths, follow just one of these paths (it doesn’t matter which one). Do not count the secondary connection tees, unions, or the fittings supplied with the boiler (these have already been accounted for). b) U sing Table 8.7, find the equivalent lengths of all fittings counted in (a). Total these equivalent lengths and add them to the total length of straight pipe measured in step (a). The result is the total equivalent length of the primary loop.
  • Page 29 Figure .: Piping Method #2 - Heat Only Figure .: Piping Method #2 - Heat + indirect Water Heater...
  • Page 30 Figure 8.10a: Piping Method #2 - Secondary Loop Piping (Bolded) Figure 8.10b: Piping Method #2 - Primary Loop Piping (Bolded)
  • Page 31 Figure 8.10c: Piping Method #2 - Indirect Water Heater Loop Piping (Bolded) Figure .11: Piping Method #3 - Direct Connection of Boiler to Heating System...

  • Page 32: C. Standard Piping Installation Requirements

    6.00 5.00 4.00 3.00 2.00 1.00 0.00 Figure .12: Boiler Head Loss Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 1. The relief valve is set to open at 30 psi. If the valve is replaced, the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler. Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve discharge is not piped to a drain, it must terminate at least 6 inches above the floor. Do not run relief valve discharge piping through an area that is prone to freezing. The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris. 2) The fitting in which the gauge, relief valve and LWCO are to be mounted must not be moved from the factory specified location (Figure 2.1). • PIPE rElIEf ValVE DIsChargE TO a safE lOCaTION. • DO NOT INsTall a ValVE IN ThE rElIEf ValVE DIsChargE lINE.

  • Page 33: D. Piping For Special Situations

    4) Circulator (Required) - Usually at least two circulators will be required to properly install a CHG Series boiler. See previous section (System Design) for information on sizing the circulators. 5) Expansion Tank (Required) - If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing. 6) Fill Valve (Required) - Either a manual or automatic fill valve may be used. The ideal location for the fill is at the expansion tank. 7) Automatic Air Vent (Required) - At least one automatic air vent is required. Manual vents will usually be required in other parts of the system to remove air during initial fill. 8) Manual Reset High Limit (Required by some codes) - This control is required by ASME CSD-1 and some other codes. Install the high limit in the boiler supply piping just above the boiler with no intervening valves. Set the manual reset high limit to 200°F. Wire the limit per Figures 9.1 & 9.2 in the Wiring section. 9) Flow Control Valve (Required) - The flow control valve prevents flow through the system unless the circulator is operating. Flow control valves are used to prevent gravity circulation or “ghost flows” in circulator zone systems through zones that are not calling for heat. 10) Isolation Valves (Recommended) - Isolation valves are useful when the boiler must be drained, as they will eliminate having to drain and refill the entire system. 11) Drain Valve (Required) - The drain valve is installed on the return tee located in the lower vestibule compartment as shown in Figure 8.2. 12) Low Water Cut-off (Required) - The low water cut-off supplied with this boiler must not be removed. 1) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to an aluminum boiler such as the CHG. Some examples include: • Radiant systems that employ tubing without an oxygen barrier. • Systems with routine additions of fresh water. • Systems which are open to the atmosphere.
  • Page 34 Figure .13: isolation of the Boiler From Oxygenated Water with a Plate Heat Exchanger Figure .14: Chiller Piping...

  • Page 35: X. Wiring

    ExTErNal POwEr sOurCE Is PrEsENT IN ThE ThErmOsTaT Or lImIT CIRCuITS. IF SuCH A PoWER SouRCE IS PRESENT, IT CouLD DESTRoy THE BoILER’S MICRoPRoCESSoR CoNTRoL (MCBA). oNE ExAMPLE Of aN ExTErNal POwEr sOurCE ThaT COulD bE INaDVErTENTly CONNECTED TO ThE lOw VOlTagE CONNECTIONs Is a TraNsfOrmEr IN OlD ThErmOsTaT wIrINg.
  • Page 37 Figure .2: Ladder Diagram...
  • Page 38 Figure .3: Wiring of isolation relay for Control of Two Heating Circulators...

  • Page 39: Xi. Start-Up And Checkout

    3) Check all new piping for leaks and purge piping sections that are filled with air. See the National Fuel Gas Code for additional information on testing and purging gas lines. • NEVER uSE A FLAME To CHECk FoR GAS LEAkS. • MAkE SuRE THAT THE AREA ARouND THE BoILER IS CLEAR AND FREE FRoM CoMBuSTIBLE MATERIALS, GASoLINE AND oTHER FLAMMABLE VaPOrs aND lIquIDs 4) Vent system must be complete and free of obstructions before attempting to fire boiler. Make sure that the silicone cure time called for in the vent assembly instructions has passed before firing boiler.
  • Page 40 CHG Series Lighting and operating Instructions...
  • Page 41 7) Start the boiler using the lighting instructions on page 40. After the boiler is powered up, it should go through the following sequence. Sequence Display U.125 or Blank 0.SWT (After call for heat from heating thermostat) A.SWT 5.SWT 1.SWT 2.SWT 3.SWT 8) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. If more than 5 tries for ignition are needed, it will be necessary to press the reset button to restart the boiler. Once a flame has been established for the first time, subsequent calls for burner operation should result in a flame on the first try. 9) Inspect the flame visible through the window. On high fire the flame should be stable and mostly blue (Fig.10.1). No yellow tipping should be present; however, intermittent flecks of yellow and orange in the flame are normal. 10) Check the inlet pressure and adjust if necessary. Verify that the inlet pressure is between the upper and lower limits shown on the rating plate with all gas appliances on and off. ThE COrrECT OuTlET PrEssurE fOr ThE gas ValVE has bEEN faCTOry sET aND rEquIrEs NO fIElD aDJusTmENT. ThIs sETTINg Is saTIsfaCTOry fOr bOTh NaTural gas aND PrOPaNE.
  • Page 42 EaCh Chg sErIEs bOIlEr Is TEsTED aT ThE faCTOry aND aDJusTmENTs To THE AIR-FuEL MIxTuRE ARE NoRMALLy NoT NECESSARy. CoNSuLT A BuRNHAM REPRESENTATIVE BEFoRE ATTEMPTING To MAkE ANy SuCH aDJusTmENTs. ImPrOPEr gas ValVE Or mIxTurE aDJusTmENTs COulD RESuLT IN PRoPERTy DAMAGE, PERSoNAL INjuRy, oR LoSS oF LIFE.
  • Page 43 12) Test any external limits or other controls in accordance with the manufacturer’s instructions. 13) Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect water heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats. 14) As shipped, the heating and indirect water heater set point supply temperatures are both set to 180°F. If necessary, adjust these to the appropriate settings for the type of system to which this boiler is connected. See the Operation Section of this manual for information on how to do this. 15) Adjust the heating and indirect water heater thermostats to their final set points.

  • Page 44: Xii. Operation

    1) The CHG boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the MCBA’s memory; one for space heating and one for domestic water production. If an outdoor tempera- ture sensor is connected to the boiler, the space heating supply set point will automatically adjust downwards as the outdoor temperature increases. For more information on this feature see the discussion on boiler water reset below. The MCBA modulates the boiler input by varying the fan speed. As the fan speed increases, so does the amount of gas drawn into the blower. As a result, a fairly constant air-fuel ratio is maintained across all inputs. The MCBA determines the input needed by looking at both current and recent differences between the supply temperature and the set point temperature. As the supply temperature approaches the set point temperature, the fan will slow down and the input drop. Depending on the model boiler, the minimum input is between 1/4 and 1/5 of maximum input. The MCBA also monitors boiler return and flue temperatures. In addition, all other safety controls, including the low water cut-off and safety limit, are connected into the MCBA. The MCBA uses input from all of these controls to either shut down the boiler when an unsafe condition exists or, in some cases, to correct the problem. 2) The display panel has three primary modes of operation. These are: • Standby Mode – Displays boiler’s current status. This is the default operating mode. • Parameter Mode – Used to change control settings • Information Mode – Displays boiler operating temperatures Under normal conditions, the boiler is in standby mode and the display looks like that shown in Figure 11.1. The three digits to the right of the decimal point are the boiler’s supply temperature. The digit to the left of the decimal point is the boiler’s status code. A list of status codes, and their meanings, is shown in Table 11.3. Figure 11.2 is a map of the menu structure for the control panel. Push the mode key to move from one mode to the next. As you change modes, the mode you are entering is shown on the display: a) “PArA” for Parameter Mode b) “Info” for Information Mode c) “Stby” for Standby Mode. Upon entering standby mode, “Stby” will briefly appear on the display and then the display will show the boiler’s status along with the supply temperature (Figure 11.1). The control will return to standby mode from any other mode if no key is pressed for 20 minutes. Figure 11.1: normal Display in Standby Mode...
  • Page 45 PushINg aND hOlDINg ThE “+” whIlE IN sTaNDby mODE wIll PrEVENT ThE BoILER FRoM RESPoNDING To A CALL FoR HEAT. PuSHING AND HoLDING THE “-” whIlE IN sTaNDby mODE wIll PrEVENT ThE bOIlEr frOm rEsPONDINg TO a CALL FoR DoMESTIC WATER. IF THIS HAPPENS, “CoFF” oR “DoFF” WILL APPEAR oN THE DISPLAy.
  • Page 47 Call for DHW ended. 10s DHW post pump period Burner off - on soft lockout. See Troubleshooting Section to determine meaning of error code. Boiler responding to call from heating zone Burner on - Held in high fire Burner on - Held in low fire...
  • Page 48 7) The sequence of operation for a CHG series boiler on a call for heat from a thermostat is as described below: a) When power is first turned on, 120V is provided to the MCBA, the combustion fan and the LWCO trans- former. A separate 50VA transformer, connected directly to the MCBA, powers all other low voltage circuits. b) For the first few seconds after power-up the control module goes through a self check. c) When there is a call for heat, the control module checks to make sure the air pressure switch is open. If it is, the combustion fan will be energized and will ramp up to ignition speed. When the air pressure switch closes, a 10 second prepurge is activated. d) After the prepurge, the control module energizes the gas control valve and the spark for 4.5 seconds. If a flame is established and proved, the control allows the flame to stabilize for 5 seconds at the combustion fan ignition speed setting. If the flame fails to prove, the control module will attempt to light the burner 4 more times. If a flame is still not established, the control will lockout. e) Once the flame stabilization period has ended, the MCBA allows the burner to modulate. The actual firing rate is dependent upon the measured current and recent differences between the set point temperature and the supply temperature. If an outdoor sensor is connected to the control module and the boiler is responding to a call for heat, the set point temperature will be determined by the outdoor reset curve shown in Figure 11.4.

  • Page 49: Xiii. Service And Maintenance

    Service and Maintenance warraNTy DOEs NOT COVEr bOIlEr DamagE Or malfuNCTION If ThE fOllOwINg sTEPs arE NOT PErfOrmED aT ThE INTErVals sPECIfIED. 1) Continuously: a) Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. b) Keep the area around the combustion air inlet terminal free from contaminates . c) Keep the boiler room ventilation openings open and unobstructed. 2) Monthly Inspections: a) Inspect the vent piping and outside air intake piping to verify they are open, unobstructed and free from leakage or deterioration. Call the service technician to make repairs if needed. b) Inspect the condensate drain system to verify it is leak tight, open and unobstructed. Call the service technician if the condensate drain system requires maintenance.
  • Page 50 Check the burner and clean off any foreign material that may have accumulated. This can be done by dusting with a soft bristle type brush or a vacuum cleaner. DO NOT USE A WIRE BRUSH TO CLEAN THE BURNER. Check for corrosion of the burner and its parts. If there is evidence of corrosion or deterioration, replace immediately. j) With the burner removed, inspect the combustion chamber and clean as necessary. k) Clean heat exchanger. Use vacuum to remove accumulation of any loose particulate from the pins and heat transfer surfaces. Clean the casting pins by flushing with clean water using a standard garden spray nozzle. Do not use any cleaning agents or solvents. A soft nylon brush may be used in accessible area. Remove inspection cover and inspect Condensate collector sump. Drain and flush the condense collector and condensate drain as required. l) Do not use any cleaning agents or solvents. m) Inspect the condensate trap to verify it is open and free from debris. Clean if necessary. n) Reinstall the burner, burner hood, combustion fan, gas valve assembly and the attenuator hose. o) Reconnect any wiring which has been disconnected. p) Qualified service personnel should thoroughly inspect the heating system and correct any deficiencies prior to restarting the boiler. q) Follow Section xI Start-up and Checkout instructions before leaving installation. r) Perform the combustion test outlined in Section xI. s) Ensure system water is within required PH range (6.0 and 8.5). t) Inspect vent system. • To ensure all joints and pipe connections are tight. • To ensure it is free from debris, cracks, corrosion and/or deterioration. If any piping needs replacing, do so immediately.

  • Page 51: Xiv. Troubleshooting

    TuRN oFF PoWER To BoILER BEFoRE REPLACING FuSES oR WoRkING oN wIrINg. A. Troubleshooting problems where no error code is displayed: Table 13.1: No Error Code Displayed CONDITION Display Blank, Fan off, LWCO lights off Display Panel Blank, Fan running Display reads “U.125” continuously, Fan running Boiler not responding to call for heat, Status code on display =”0”...
  • Page 52 • Sensor wiring reversed • Flow through boiler reversed. Verify correct piping and pump orientation. • No boiler water flow. Verify that system is purged of air and that appropriate valves are open. • Sensor wiring reversed. • Supply or return sensor defective.
  • Page 53 • Defective gas valve (check for 24 VDC at harness during trial for ignition before replacing valve) • Some other error on this list occurred and power to the boiler was then interrupted. Reset control and see if hard lockout reoccurs.

  • Page 54: Service Record

    SErViCE rECOrD DATE SERVICE PERFORMED...

  • Page 55: Xv. Parts

    All CHG Series 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...
  • Page 56 SAE # 32 Hose Clamp #10-24 x 3/8” Hex Wshr Hd Type F Aluminum Cable Tie Mount Vinyl Grommet - .825” ID (For 1.625” Hole) 1/4-20 x 1/2 Self Tapping Screw CHG REPLACEMENT PARTS LIST CHG150 BURNHAM PART # 100401-01 100402-01 100403-01 100404-01 100405-01...
  • Page 57 Terminal Block .375” c/c, 9-Pole Pressure Switch 40VA Transformer (LWCO Power Supply) Boiler Control Module (Natural Gas - Sea Level) Boiler Control Module (LP Gas - Sea Level) 50VA Transformer (Boiler Control Module) M5 x 0.8 x 25mm, Set Screw 77b1 M5 x 0.8 x 30mm, Set Screw...
  • Page 62 Inner Vestibule Hi Limit Harness Inner Vestibule Sensor Harness Inner Vestibule Line Voltage Blower Harness Ignition (Spark) Cable Harness Ribbon Cable Display Harness Vented Dust Cap CHG REPLACEMENT PARTS LIST CHG150 BURNHAM PART # 100488-01 100489-01 100490-01 100491-01 100492-01 100493-01...
  • Page 64 Not Shown Violet Jumper Wire Not Shown X5 Plug Not Shown Outdoor Sensor Not Shown 4” Inlet Screen CHG REPLACEMENT PARTS LIST DESCRIPTION CHG150 CHG225 BURNHAM BURNHAM QUANTITY PART # PART # 100533-01 100533-01 100534-01 100534-01 100535-01 100535-01 100536-01 100536-01...
  • Page 68 Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: 1. For direct-vent appliances, mechanical-vent heating appliances or domestic hot water equipment, where the bottom of the vent terminal and the air intake is installed below four feet above grade the following requirements must be satisfied: a. If there is not already one present, on each floor level where there are bedroom(s), a carbon monoxide detector and alarm shall be placed in the living area outside the bedroom(s). The carbon monoxide detector shall comply with NFPA 720 (2005 Edition). b. A carbon monoxide detector shall be located in the room that houses the appliance or equipment and shall: i. Be powered by the same electrical circuit as the appliance or equipment such that only one service switch services both the appliance and the carbon monoxide detector; ii. Have battery back-up power; iii. Meet ANSI/UL 2034 Standards and comply with NFPA 720 (2005 Edition); and iv. Have been approved and listed by a Nationally Recognized Testing Laboratory as recognized under 527 CMR. c. A product-approved vent terminal must be used, and if applicable, a product-approved air intake must be used. Installation shall be in strict compliance with the manufacturer’s instructions. A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation.
  • Page 69 SErViCE rECOrD DATE SERVICE PERFORMED...
  • Page 70 SErViCE rECOrD DATE SERVICE PERFORMED...
  • Page 71 SErViCE rECOrD DATE SERVICE PERFORMED...

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