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™ ® 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...
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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.
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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.
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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.
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...
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.
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.
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...
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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.
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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...
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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.
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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.
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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.
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.
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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.
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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.
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.
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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.
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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.
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.
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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...
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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.
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NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below.
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Figure 0: Different Manufacturer’s Zone Valve Connections to Honeywell R8889...
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.
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.
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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.
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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-...
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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.
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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.
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.
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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.
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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...
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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...
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[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...
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[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...
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[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”...
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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.
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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.