Burnham PVG Installation, Operating And Service Instructions

Burnham PVG Installation, Operating And Service Instructions

Gas-fired boiler
Table of Contents

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As an ENERGY STAR
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guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
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Price - $5.00

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Summary of Contents for Burnham PVG

  • Page 1 ™ ® As an ENERGY STAR Partner, Burnham Hydronics has determined that the PVG Series meets the ENERGY guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). ® STAR 8140708R10-6/09 Price - $5.00...
  • Page 2 All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations. The New York City Department of Buildings has approved the PVG™ Series boiler: Approval No. MEA 5-06-E Vol. II. The City of New York requires a Licensed Master Plumber supervise the installation of this product.
  • Page 3 Special Installation Requirements for Massachusetts A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the side wall 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 I. Pre-Installation ....... 7 VI. Electrical ........29 II. Unpack Boiler ........ 8 VII. Modular Installation ....38 III. Venting ........... 9 VIII. System Start-up ......40 IV. Water Piping and Trim ....21 IX. Service .......... 47 V. Gas Piping ........26 X. Repair Parts ........54 Figure 1: Minimum Clearances to Combustibles...
  • Page 7: I. Pre-Installation

    I. Pre-Installation Provide combustion and ventilation air in accordance WARNING with applicable provisions of local building codes, or: USA - National Fuel Gas Code, NFPA 54/ANSI If you do not follow these instructions exactly, Z223.1, Air for Combustion and Ventilation; a fire or explosion may result causing property Canada - Natural Gas or Propane Installation Code, damage or personal injury.
  • Page 8: Ii. Unpack Boiler

    space(s) of sufficient volume such that combined by duct with the outdoors or spaces (crawl or attic) volume of all spaces meet criteria for unconfined freely communicating with the outdoors. Locate one opening within twelve (12) inches of top of space. space.
  • Page 9: Iii. Venting

    3. Horizontal 45° Elbow horizontally (snorkel through a side wall) Table : Vent System Components Included with Boiler Gasketed Vent System Components Part Number Vent Terminal 3” -Horizontal PVG-3 thru PVG-7) 8110701 Vent Terminal 4” -Horizontal (PVG-8 & PVG 9) 8110702...
  • Page 10 100184-01 3” Double Wall Thimble 8116115 4” Double Wall Thimble 100185-01 Table 4: Vent Length 3” Vent Pipe 4” Vent Pipe (Equiv. Ft.) (Equiv. Ft.) Model Min. Max. Min. Max. PVG-3 & PVG-4 PVG-5 & PVG-6 PVG-7 PVG-8 & PVG-9...
  • Page 11 Vent Guidelines Due to Removal of an Existing General Guidelines Boiler 1. Vent system installation must be in accordance For installations not involving the replacement of an with National Fuel Gas Code, NFPA 54/ANSI existing boiler, proceed to Step B. Z221.3 or applicable provisions of local building codes.
  • Page 12 a. Minimum twelve (12) inches above grade plus requires a minimum installed length of 12¾ inch normally expected snow accumulation level, or and can adjust across a 7 inch gap up to a maximum seven (7) feet above grade if located adjacent of 19¾...
  • Page 13 c. Tighten locking band by HAND with a 5/16” from boiler. See Figure 4A. See Figure 4B for an nut driver until snug plus ¼ turn. DO NOT alternate horizontal installation. SECURE JOINTS WITH SHEET METAL 4. Use appropriate designed thimbles when passing SCREWS OR POP RIVETS.
  • Page 17 E. Separate Vertical Venting System - See Figures 6, 7, 8 and 9. NOTICE Roof penetrations require the use of roof flashing and storm collar - not supplied with boiler. Vertical Venting 5. Whenever possible, install vent straight through – the roof.
  • Page 20 Optional Exterior Separate Horizontal Vent Terminal Mounting – See Figure 9. 1. See Figure 29 on Page 48 for Blower Vent b. After penetrating wall/thimble, install an ® AL 29-4C 90° elbow so that elbow leg is in the Connector Assembly. Do not exceed maximum vent lengths.
  • Page 21: Iv. Water Piping And Trim

    Addition of excessive make-up water as a result of system leaks. What Kind b. Absorption through open tanks and fittings. The PVG boiler is designed to accept the wiring of the c. Oxygen permeable materials in the distribution Safgard Model 1100-H4 LWCO (P/N 100592-01). This system.
  • Page 22 LWCO wiring from LWCO Model 1100-H4 is eliminated. DO NOT pipe in any area where (P/N 100592-01) into the plug of the PVG factory freezing could occur. DO NOT install any shut-off wiring.
  • Page 23 Figure 10A: Supply Water Manifold Piping Install pipe tee between circulator and boiler return After the boiler and system have been cleaned and flushed, and before refilling the entire system add along with second tee in supply piping as shown in Figure 11 or 12.
  • Page 26: V. Gas Piping

    0% for applications at 10,000 feet above sea levels. Derate is based on % reduction per 1000 feet. The PVG boiler is available in two (2) altitude Models: The “S” Model 0 to 4,999 feet above sea level, and the “H” Model 5,000 to 10,000 feet above sea level.
  • Page 27 Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Natural Gas Pressures of 0.5 psig or Less 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop Length ½ ½ [Feet] ¾ 1¼ ¾ 1¼ 1,050 1,400 * 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 28 4. All above ground gas piping upstream from manual at ½ psig or less, isolate boiler from gas supply shut-off valve must be electrically continuous and piping by closing boiler’s individual manual shutoff bonded to a grounding electrode. Do not use gas valve.
  • Page 29: Vi. Electrical

    VI. 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 31 NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below. Figure 15: Internal Boiler Wiring Ladder Diagram...
  • Page 32 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 34 NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below.
  • Page 37 Figure 0: Different Manufacturer’s Zone Valve Connections to Honeywell R8889...
  • Page 38: Vii. Modular Installation

    VII. Modular Installation General Guidelines Gas Piping 1. Read and follow all venting, combustion air, 1. Refer to National Fuel Gas Code, Local Codes and water piping, gas piping and electrical instructions Tables 7 and 8 for gas pipe sizing. contained in this manual unless otherwise instructed Table 9: Modular Boiler Water Manifold Sizing in this section.
  • Page 40: Viii. System Start-Up

    VIII. System Start-up 4. Starting with one circuit at a time, open zone valve Safe operation and other performance criteria were or shut-off valve in system supply and return piping. met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in 5.
  • Page 41 Figure : Operating Instructions...
  • Page 42 numbers in the wiring ladder diagrams. The yellow Operating Instructions LED indicates the status of the flame, see Table 11. 1. Follow Operating Instructions to place boiler in The green LED indicates the status of the system, operation. See Figure 22. see Table 12.
  • Page 43 Table 1: Green LED Status Codes Green LED Flash Code Next System Action Recommended Service Action Indicates (X + Y) No “Call for Heat” None Startup - Flame sense Flash Fast None calibration Heartbeat Normal operation None If system fails to light on next trial for ignition check gas supply, pilot 5 minute Retry Delay- burner, spark and flame sense wir-...
  • Page 44 Honeywell Electronic Ignition Troubleshooting Guide Figure 4: Troubleshooting Guide...
  • Page 45 Figure 26: 1 Inch Main Burner flame Figure 7: Pilot Burner Flame . Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. Check ignition control module shut-off. Disconnect pilot lead wires from gas valve. If burners do not shutdown, determine cause of malfunction.
  • Page 46 ii. Remove gas orifices. Drill one (1) drill size temperature. Main burners and pilot burner should larger (drill size is stamped on orifice, or see extinguish, and blower should stop. Section X: Repair Parts). 3. Adjust limit to setting above observed temperature. iii.
  • Page 47: Ix. Service

    IX. Service 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 48 e. Mark location of Main Burner with Pilot Bracket on gas manifold. f. Hold Main Burner on throat. Lift front of burners to clear orifice. Burner which holds pilot can be removed by lifting the burner adjacent to its right first. 2.
  • Page 50 Table 14: Pilot Burner Location Main Burner with Pilot Bracket Boiler Model Pilot Burner Located Between Main Burners * 2 & 3 PVG-3 3 & 4 PVG-4 4 & 5 PVG-5 5 & 6 PVG-6 PVG-7 6 & 7 7 & 8...
  • Page 51 THIS PAGE LEFT BLANK INTENTIONALLY...
  • Page 54 XI. Repair Parts All PVG Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer Service at...
  • Page 55 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 1. CASTING ASSEMBLY Section Assembly 61707031 61707041 61707051 61707061 61707071 61707081 61707091 71707001 Left End Section Center Section 71707003 71707003 71707003 71707003 71707003 71707003 71707003 71707002 Right End Section...
  • Page 57 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 2. BASE ASSEMBLY 71807031 71807041 71807051 71807061 71807071 71807081 71807091 Base Wrapper 71807032 71807042 71807052 71807062 71807072 71807082 71807092 Base Tray Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071...
  • Page 58 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 3. BASE ASSEMBLY Burner Cover (Natural Gas Only) 102033-03 102033-04 102033-05 102033-06 102033-07 102033-08 102033-09 Manifold Support Bracket 718070001 Sheet Metal Screw, #8 x 1/2” [2] 80860000 Self Tapping Screw, 10-32 x 3/8”...
  • Page 59 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 4. FAN/CANOPY ASSEMBLY Canopy Assembly - Sea Level 61107031 61107041 61107051 61107061 61107071 61107081 61107091 Canopy Assembly - High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092 Cerafelt 9206005...
  • Page 61 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 5. BURNER ASSEMBLY Gas Valve (Natural Gas), 81660282 Honeywell VR8204P1171 Gas Valve (Natural Gas), 81660283 Honeywell VR8304P4496 Gas Valve (LP Gas), 81660146 Honeywell VR8204C3015 Gas Valve (LP Gas), 81660181 Honeywell VR8304P4280 Nipple, ½”...
  • Page 62 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 6. CONTROL PANEL ASSEMBLY 100189-01 Limit, Honeywell L4080D Transformer/Relay, Honeywell 80160155U R8285D Ignition Module, Honeywell 100959-01 S8670E3003 Blower Relay, Honeywell 80160096U R8222U1006 Differential Pressure Switch 80160762 80160761 80160760 80160759 80160760 Sea Level 0’...
  • Page 63 60407044 60407054 60407064 60407074 60407084 60407094 60407032 60407042 60407052 60407062 60407072 60407082 60407092 Top Panel 101354-03 101354-04 101354-05 101354-06 101354-07 101354-08 101354-09 Front Door Jacket Cover Plate 80407001 Handle 8056184 Door Clip [2] 7041921 Bushing 8136048 81460099 Burnham Hydronics Logo...
  • Page 64 [Quantity] Part Number Description PVG-7 PVG-9 PVG-3 PVG-4 PVG-5 PVG-6 PVG-8 8. MISCELLANEOUS PARTS CARTON 80607001 Water Manifold Temperature/Pressure Gauge 100282-01 Circulator Wiring Harness 6130701 Safety Relief Valve 81660363 Boiler Drain Valve 806603061 8110701 8110702 Vent Terminal Vent Connector 8110703...
  • Page 65 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 66: Service Record

    SERVICE RECORD SERVICE PERFORMED DATE...
  • Page 67 SERVICE RECORD SERVICE PERFORMED DATE...
  • Page 68 Burnham Hydronics Repair Parts Pricing where the heat exchanger last grade boiler involved. Some states do not allow the exclusion or limitation of appeared or the current retail price of the then nearest equivalent heat exchanger.

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