U.S. Boiler Company Burnham Hydronics Revolution RV3 Installation, Operating And Service Instructions

U.S. Boiler Company Burnham Hydronics Revolution RV3 Installation, Operating And Service Instructions

Gas-fired boiler

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As an ENERGY STAR
Partner, Burnham Hydronics has determined that the Revolution Series meets the ENERGY
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guidelines for energy effi ciency established by the United States Environmental Protection Agency (EPA).
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Price - $5.00

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Summary of Contents for U.S. Boiler Company Burnham Hydronics Revolution RV3

  • Page 1 ® ® As an ENERGY STAR Partner, Burnham Hydronics has determined that the Revolution Series meets the ENERGY ® STAR guidelines for energy effi ciency established by the United States Environmental Protection Agency (EPA). 8140638R4-2/06 Price - $5.00...
  • 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 f i l l i t . r i l l i t i l t t i i l i...
  • Page 4: Table Of Contents

    Table of Contents VII. Electrical ........51 I. Pre-Installation ....... 6 VIII. Modular Installation ....66 II. Unpack Boiler ........ 7 IX. System Start-up ......70 III. Venting/Air Intake Piping ....8 X. Service .......... 75 IV. Condensate Drains ....... 43 V.
  • Page 6: Pre-Installation

    I. Pre-Installation Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.). Provide combustion and ventilation air in accordance with applicable provisions of local building codes, or: USA - National Fuel Gas Code, NFPA 54/ANSI Z223.1, Air for Combustion and Ventilation;...
  • Page 7: Unpack Boiler

    5. For boiler located in an unconfi ned space in a equipment in space. Duct cross-sectional area building of other than unusually tight construction, shall be same as opening free area. adequate combustion and ventilation air is normally c. Horizontal ducts. Minimum free area of one (1) provided by fresh air infi...
  • Page 8: Venting/Air Intake Piping

    III. Venting / Air Intake Piping ® . ) . l i t . r i . i ( . r i Figure A: Burnham Vent , t i...
  • Page 9 Table 1: Air Intake / Vent System Options y l l ) l l y l l y l l " 5 y l l o l l " 4 & ] l l Table 2: Vent System Components Included with Boiler "...
  • Page 10 Table 4: Vent/Air Intake Length " 3 " 4 " 3 . v i ) . t . v i ) . t . v i ) . t & & A. Vent Guidelines Due to Removal of an 7. Any improper operation of the common venting Existing Boiler system should be corrected so the installation conforms with the National Fuel Gas Code, NFPA...
  • Page 11 10. Enclose vent passing through occupied or unoccu- 5. Horizontal vent pipe must maintain a minimum ¼ pied spaces above the boiler with material having a inch per foot slope down towards boiler. fi re resistance rating of at least equal to the rating of 6.
  • Page 12 C. Install Vent Pipe, Burnham Gasket-Less Vent System. 1. Procedure for Joining Burnham Gasket-Less Vent Pipe and Fittings. See Figure 3A. Figure 3A: 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.
  • Page 13 c. Tighten locking band by HAND with a 5/16” nut driver until snug plus ¼ 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 conden- sate will not escape.
  • Page 14 a. Clean joints of pipe or fi ttings using an alcohol Air Intake piping - See Figures 4 and 5. pad to remove any dirt and grease. 8. Locate air intake termination on the same wall as the vent termination if possible, to prevent nuisance b.
  • Page 17 G. Separate Vertical Venting System - See Figures 6, 7, 8 and 9. " 3 a l l " 3 Vertical Venting – 1. Do not exceed maximum vent lengths. Refer to b. Extend vent pipe to maintain minimum vertical Table 4.
  • Page 18 7. Locate air intake termination on the same roof 13. Inlet air pipe penetration: location as the vent termination if possible, to Vertical - Size roof opening to allow easy insertion prevent nuisance boiler shutdowns. However, boiler of inlet piping and allow proper installation of may be installed with vertical venting and sidewall fl...
  • Page 21 Figure 9: Vertical Air Intake Piping...
  • Page 22 H. Combination Horizontal Venting System – See Figures 10 and 11. 1. Do not exceed maximum vent/air intake lengths. Refer to Table 4. Install Combination Vent/Air Terminal. See Figure 11. a. After determining the location with reference to Section B - General Venting Guidelines, cut a 6-1/8 inch square opening in the wall for the air box sub-assembly which is 6 inch square.
  • Page 23 c. From exterior of building, insert air box sub- Install Vent Piping . See Figure 10 and 11. assembly into square opening. Push air box a. Start at vent connector on boiler and work inward until wall fl ange is against wall, check for towards combination vent/air terminal.
  • Page 26 I. Combination Vertical Venting System – See Figures 12, 13 and 14. " 4 " 3 " 4 ¼...
  • Page 27 The following parts are required for installation which are 8. Join vent disc terminal to vent terminal elbow. not included with this kit. Parts are supplied by others. Refer to Sections C through E for proper procedures for joining vent pipe and fi ttings. •...
  • Page 28 e. Install vent piping, connect vent connector on d. Start at collar on burner enclosure (inside boiler top of boiler and vent pipe positioned in B-vent. jacket) and work towards the air intake adapter Refer to Sections C through E for proper on the interior B-vent tee’s horizontal leg.
  • Page 29 Figure 12: Combination Vertical – Vent/Air Installation Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation. All ex- posed B-Vent must be protected with a high quality, non-latex, enamel paint.
  • Page 32 J. Indoor Air Installation – See Figures 15, 16, 17, 18 and 19. ° 0 ) " ) " ° 5...
  • Page 33 1. Do not exceed maximum vent length. Refer to Fire stop manufacturers are Air-Jet, American Metal Table 4. Products, Metal-Fab, and Simpson Dura-Vent. 11. Whenever possible install vent straight through roof. Horizontal – Refer to Figure 16 if offset is necessary. Maintain 2.
  • Page 36 Figure 17 Figure 18: Indoor Air - Horizontal / Vertical Vent Terminal Installation Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.
  • Page 38 K. PVC Air Intake System – See Figures 20, 21 and 22. " 4 . v l " 3 . v l " 4 " 3 " 4 " 3 " 4 & & t t i - f l l l i...
  • Page 39 1. Do not exceed maximum vent/air intake length. a. Secure with three (3) self-drilling sheetmetal Refer to Table 4. screws provided. 7. Maintain minimum of ¼ inch per foot slope on 2. Install vent piping for desired venting system. Refer horizontal runs.
  • Page 40 Figure 21: PVC Air Intake - Separate Horizontal/Vertical Air Intake Terminal Installation Figure 22: PVC Air Intake - Combination Horizontal/Vertical Air Intake Pipe Installation...
  • Page 41 L. Optional Separate Horizontal Vent/Air Intake Terminal Mounting – See Figures 23, 24 and 25. 1. Do not exceed maximum vent/air intake lengths. e. If installation requires indoor air, install Refer to Table 4. ® AL 29-4C 45° elbow (provided in indoor air kit) to upper AL 29-4C ®...
  • Page 42 Figure 24: Optional Separate Horizontal – Air Intake Terminal Installation Figure 25: Optional Indoor Air – Vent Terminal Installation...
  • Page 43: Condensate Drains

    IV. Condensate Drains 1. Each boiler contains two (2) condensate drain tubes. 2. Pipe condensate trap to a fl oor drain or condensate Insert both tubes into the condensate trap provided pump/sump. with boiler. See Figure 26. 3. Use ¾” PVC or CPVC for condensate piping. a.
  • Page 44: Water Piping And Trim

    V. Water Piping and Trim l l i i l ( Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contami- nation such as: a.
  • Page 45 Space heating and domestic water heating with Oil, grease, and other foreign materials which Alliance™ water heater. Install Alliance water heater as accumulate in new hot water boilers and a new or a separate heating zone. Refer to Alliance Installation, reworked system should be boiled out, and then Operating and Service Instructions for additional thoroughly fl...
  • Page 48: Gas Piping

    VI. Gas Piping 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 7, unless authority having jurisdiction specifi es a gravity factor be applied. For specifi...
  • Page 49 Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Gas Pressures of 0.5 psig or Less ½ ¾ ¼ ½ ¾ ¼ * 1 CFH of Natural Gas is approximately equal to 1 MBH; 1 CFH of LP is approximately equal to 2.5 MBH; con- tact your gas supplier for the actual heating value of your gas.
  • Page 50 4. All above ground gas piping upstream from manual piping by closing boiler’s individual manual shutoff shut-off valve must be electrically continuous and valve. bonded to a grounding electrode. Do not use gas 2. Locate leaks using approved combustible gas piping as grounding electrode.
  • Page 51: Electrical

    VII. Electrical . f f boiler can be shut-off without exposing personnel to General. Install wiring and electrically ground boiler in danger in the event of an emergency. Connect the main accordance with authority having jurisdiction or, in the power supply and ground to the three (3) boiler wires absence of such requirements, follow the National (black, white and green) located in the junction box at Electrical Code, NFPA 70, and/or CSA C22.1 Electrical...
  • Page 53 . ) t Figure 32: Internal Boiler Wiring Ladder Diagram...
  • Page 54 System Controls and Wiring 1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code. 2. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes. 3.
  • Page 55 8. Conventional Zone Valve Zoned System – Refer to Figure 36. If a system water temperature limit is used, refer to Figure 37. Wiring to the most popular models of zone valves is given in Figure 38. Locate the group of two (2) wires (yellow and white) in the junction box at the inside top of the boiler jacket. Connect wires from these boiler wire leads to the system circulator wire leads.
  • Page 57 . ) t...
  • Page 61 Figure 38: Different Manufacturer’s Zone Valve Connections to Honeywell R8889...
  • Page 66: Modular Installation

    VIII. Modular Installation 2. The maximum air intake length for each boiler is General Guidelines fi fty-two (52) equivalent feet. 1. Read and follow all venting, combustion air, water 3. Locate air intake termination on the same wall as the piping, gas piping and electrical instructions vent termination if possible, to prevent nuisance contained in this manual unless otherwise instructed...
  • Page 67 boiler drain lines must be connected such that Electrical one drain pipe cannot back feed into another 1. Each boiler must be provided with a fused discon- boiler drain. nect and service switch. 3. Consult local authorities regarding disposal 2. Install wiring in accordance with requirements of of fl...
  • Page 69 Figure 44: Alternate Modular Boiler Piping...
  • Page 70: System Start-Up

    IX. System Start-up Safe operation and other performance criteria were 3. Attach a hose to the vertical hose bib located prior to met with gas manifold and control assembly provided the full port ball valve in the system supply piping. on boiler when boiler underwent tests specifi...
  • Page 71 Figure 45: Operating Instructions...
  • Page 72 Figure 47A: 40mm Main Burner Flame Figure 47B: 1 Inch Main Burner fl ame Figure 46: Sequence of Operation Figure 48: Pilot Burner Flame Sequence of Operation. See Figure 46. If boiler fails to operate properly, see Troubleshooting Tree in Section X: Service.
  • Page 73 Check main burner fl ame. See Figures 47A and 47B. 4. Determine Input Rate. Multiply gas fl ow rate by gas Flame should have clearly defi ned inner cone with no heating value. yellow tipping. Orange-yellow streaks should not be 5.
  • Page 74 Figure 49: Variable Speed Control Sequence of Operation Figure 50: Internal Primary / Secondary Piping...
  • Page 75: Service

    X. Service sure electrical contacts are clean and that they General. Inspection and service should be conducted function properly. Give special attention to annually. Turn off electrical power and gas supply while solder joints on bellows and fl oat when this type conducting service or maintenance.
  • Page 76 3. Pipe must be full round shape, and show no damage 10. Connect Silicone Tubing between Pressure Fittings from impact or excessive temperature. on Canopy Assembly and Pressure Switch. Route through bushings in Vestibule Panel . See Figure 4. Pipe must be supported at minimum fi ve (5) foot intervals and must not sag.
  • Page 78 Table 11: Pilot Burner Location " 1 ° 0 ° 1 & & & & & & & & & & 2. With tees and ¼ inch aluminum stubs, connect water Main Burners and Firebox. manometer as shown with additional tubing. 1.
  • Page 79 NOTE: If switch drops-out before boiler reaches First measure the temperature using the thermometer temperature or if pressure differential readings are and then measure the resistance of the sensor at the below minimums shown in Table 12, check for control. The wires from the sensor must not be cracks in hose or contact your nearest Burnham connected to the control while the test is performed.
  • Page 80 Revolution Troubleshooting Tree...
  • Page 81 Revolution Troubleshooting Tree...
  • Page 82: Repair Parts

    XI. Repair Parts All Revolution ® 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 Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 83 t i t , y l ¼ " " 9 ½ " ½ " " 9 " 2 ¼ " ¼ " " 4 , l l ½ , " " 8 ¼ " ¼ " ¾ " ¾ , " ¼...
  • Page 85 t i t ] " ] " ] " ] " ] " , t l ½ v l i f i r f i r & t t i , t l ¼ ¼ ¼ c i l " 6 , "...
  • Page 87 t i t - l l - l l " 1 - l l ] " ] " ] " ] " ] " " 8 ½ " ] " ] " ] " ] " ] " ½ " "...
  • Page 89 t i t - - - - - - - - - - - - ½ " " 3 - - - - - - ¾ " " 3 ½ " - - - - - - ¾" ½ " "...
  • Page 91 t i t ½ "...
  • Page 93 t i t , l l ½ " ) . t ) . t ) . t " 1 ) . t...
  • Page 94 t i t , y l " 3 " 4 ½ " ¾ " " 8 ¾ "...
  • Page 95 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 96 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 97 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 98 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.
  • Page 99: Appendix Low Water Cut Off

    XII. Low Water Cut Off (LWCO) on Hot Water Boilers f i t . f f When manufacturers recommend an annual inspection of the probe. A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is How to Wire installed below the top of the hot water boiler (i.e.
  • Page 100 Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS Subject to the terms and conditions set forth below, U.S. Boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. Co., Inc. Lancaster, Pennsylvania hereby extends the following limited These warranties will be inapplicable if the residential grade water boiler warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1,1991:...

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