Burnham Revolution Installation, Operating And Service Instructions

Burnham Revolution Installation, Operating And Service Instructions

Gas- fired boiler
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Price - $5.00

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  • Page 1 ® ® As an ENERGY STAR Partner, Burnham Hydronics has determined that the Revolution Series meets the ENERGY guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). ® STAR 8140638R5-9/09 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 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 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 XI. Repair Parts ........82 V. Water Piping and Trim ....44 XII. Appendix VI. Gas Piping ........48 Low Water Cut Off .......
  • Page 6: I. Pre-Installation

    3. Determine type of space. Divide Volume by Total and accelerated component failure. Burnham Input. DOES NOT warrant failures caused by mis-sized a. If result is greater than or equal to 50 ft³ per boiler applications.
  • Page 7: Ii. Unpack Boiler

    6. For boiler located within unconfined space in Alternate method for boiler located within confined space. Use indoor air if two permanent building of unusually tight construction or within confined space, provide outdoor air through two openings communicate directly with additional space(s) of sufficient volume such that combined permanent openings which communicate directly or volume of all spaces meet criteria for unconfined by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors.
  • Page 8: Iii. Venting/Air Intake Piping

    Figure A: Burnham Vent component. Each gasket-less vent component is supplied with a clamp band and sealant. A Vent Transition Kit, part number 611630, is available that contains one clamp band and one 3 ounce tube...
  • Page 9 Gasketed Vent Terminal Horizontal (RV3 - RV7) 8116234 Disc Air Intake - 3” (RV3 - RV4) 6116045 Disc Air Intake - 4” (RV5 - RV7) 6116044 Table 3: Burnham Vent System and Air Intake System Components Equivalent Intake System Vent System Component Part Number Equivalent...
  • Page 10 1. Seal any unused openings in the common venting tions and installation inspection in your area. system. 2. The Revolution is designed to be installed as either a 2. Visually inspect the venting system for proper size Direct Vent boiler or Power Vent boiler. In the...
  • Page 11 Minimum four (4) feet horizontally from electric installing. Seal joint with RTV specified in this meters, gas meters, regulators, and relief valves. manual. This distance may be reduced if equipment is 14. Seal all Burnham Gasket-Less vent, Burnham mixed protected from damage due to condensation or vent (Gasket-Less and Gasketed) and field cut joints vapor by enclosure, overhangs, etc. using Dow Corning Silastic 732 RTV, Dow Corning e.
  • 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 fittings using an alcohol pad to remove any dirt and grease. b. Slip a locking band over female (bell) end of pipe/fitting. c. Apply a continuous ¼ inch bead of sealant around male end of joint no more than 1/8 inch from end.
  • Page 13 E. Install Vent Pipe, Burnham Gasket-Less & Gasketed Vent System. 1. Procedure for joining the male end of Burnham Gasket-Less Vent with the female end of Burnham Gasketed Vent. See Figure 3C. Figure 3C: Burnham Gasket-Less Male and Gasketed Female Vent Joint Detail a.
  • Page 14 a. Clean joints of pipe or fittings 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. Slip a locking band over female (bell) end of pipe/fitting.
  • Page 17 G. Separate Vertical Venting System - See Figures 6, 7, 8 and 9. NOTICE This vent system requires components not supplied with the boiler. Carton Part Number Component Part Number Description Vertical Vent Accessories 6116062 (RV3-RV7) ------ (Includes items below) ------ Vent Terminal, Vertical 6116061...
  • 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 flashing and storm collar.
  • Page 21 Figure 9: Vertical Air Intake Piping...
  • Page 22 H. Combination Horizontal Venting System – See Figures 10 and 11. NOTICE 1. Do not exceed maximum vent/air intake lengths. Refer to Table 4. This vent system requires components not supplied with the boiler. Install Combination Vent/Air Terminal. See Figure 11. a.
  • 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 flange is against wall, check for towards combination vent/air terminal. level and mark the location of the four (4) b.
  • Page 26 I. Combination Vertical Venting System – See Figures 12, 13 and 14. NOTICE This vent system requires components not supplied with the boiler. Vent Carton Part Number 61106012 (Includes items below) Component Part Number Description 4” X 3” Vent Pipe Reducer 8116239 Combination Vertical Vent Terminal Elbow 8116312...
  • Page 27 The following parts are required for installation which are 9. Insert vent disc terminal assembly into horizontal not included with this kit. Parts are supplied by others. leg of the remaining B-vent tee. See Figure 14. Secure terminal to tee. •...
  • Page 28 f. Seal vent pipe penetration through lower seal e. Maintain minimum of 1/4 inch per foot slope on plate with RTV. horizontal runs. Slope down towards boiler. 15. Install air intake piping. See Figure 12. f. The air intake pipe must be adequately supported with straps or supports no less than five (5) feet a.
  • Page 29 Figure 1: Combination Vertical – Vent/Air Installation Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (1) 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. NOTICE This vent system requires components not supplied with the boiler. Vent Carton (Includes items below) P/N 61106008 (RV3 - RV4) P/N 61106009 (RV-5 - RV-7) Component Part Number Description Plastic Protective Cover 8056196...
  • Page 33 Fire stop manufacturers are Air-Jet, American Metal 1. Do not exceed maximum vent length. Refer to Products, Metal-Fab, and Simpson Dura-Vent. Table 4. 11. Whenever possible install vent straight through roof. Horizontal – Refer to Figure 16 if offset is necessary. Maintain 2.
  • Page 36 Figure 1 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 (1) 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. NOTICE This vent system requires components not supplied with the boiler. Carton Part Number 6116054 (Includes items below) Component Part Number Description 4” X 2” Single Wall Galv. Smoke Pipe 8116241 3”...
  • 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. 2. Install vent piping for desired venting system. Refer 7. Maintain minimum of ¼ inch per foot slope on to specific section for details for vent pipe installa- horizontal runs.
  • Page 40 Figure 1: PVC Air Intake - Separate Horizontal/Vertical Air Intake Terminal Installation Figure : 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) 2. This installation will allow a maximum of five (5) to upper AL 29-4C ®...
  • Page 42 Figure 4: Optional Separate Horizontal – Air Intake Terminal Installation Figure 5: Optional Indoor Air – Vent Terminal Installation...
  • Page 43: Iv. Condensate Drains

    IV. Condensate Drains 2. Pipe condensate trap to a floor drain or condensate 1. Each boiler contains two (2) condensate drain tubes. 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. Ensure tubes are inserted so that tube ends 4. Consult local authorities regarding disposal of flue contact trap bottom.
  • Page 44: V. Water Piping And Trim

    WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. The Revolution boiler contains internal controls and piping to control water temperature. Do not pipe system with a bypass. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure.
  • 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 thoroughly flushed. A local qualified water treatment Operating and Service Instructions for additional...
  • Page 48: Vi. Gas Piping

    VI. Gas Piping 4. Specific gravity of gas. Gas piping systems for gas WARNING with a specific gravity of 0.60 or less can be sized directly from Table 7, unless authority having Failure to properly pipe gas supply to boiler may jurisdiction specifies a gravity factor be applied. For result in improper operation and damage to the specific gravity greater than 0.60, apply gravity boiler or structure. Always assure gas piping is factor from Table 6. If exact specific gravity is not absolutely leak free and of the proper size and shown choose next higher value.
  • Page 49 Table : Maximum Capacity of Schedule 40 Pipe in CFH* For Gas Pressures of 0.5 psig or Less 0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop Length [Feet] ½ 1¼ ½ 1¼ ¾ ¾ 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; contact 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: Vii. Electrical

    VII. 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 53 NOTICE If an additional system limit is used, install in series with B1 circuit (blue wire) of the Honeywell L8148 Aquastat (located inside boiler jacket). Figure 3: 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 “expansion” on the second, third or fourth R8889. 9. Burnham EC5000 Circulator Zoned System – Refer to Figure 39 of this manual for the electrical diagram for this type of system. Wire the system as indicated in that diagram. Refer to the manual provided with the Burnham EC5000 Control for control operation and setup details.
  • Page 57 NOTICE If an additional system limit is used, install in series with B1 circuit (blue wire) of the Honeywell L8148 Aquastat (located inside boiler jacket).
  • Page 61 Figure 38: Different Manufacturer’s Zone Valve Connections to Honeywell R8889...
  • Page 66: Viii. Modular Installation

    Module Sizing Table 9: Modular Boiler Water Manifold Sizing Burnham recommends sizing each boiler in a modular Recommended Minimum Combined Output system to provide 20 % of the combined heating load Common Water Manifold (MBH) where ever possible.
  • Page 67 condensate. If a common pump/sump is used, Electrical individual boiler drain lines must be connected such 1. Each boiler must be provided with a fused that one drain pipe cannot back feed into another disconnect and service switch. boiler drain. 2.
  • Page 70: Ix. System Start-Up

    IX. System Start-up 3. Attach a hose to the vertical hose bib located prior to Safe operation and other performance criteria were the full port ball valve in the system supply piping. met with gas manifold and control assembly provided (Note - Terminate hose in five gallon bucket at a on boiler when boiler underwent tests specified in suitable floor drain or outdoor area).
  • Page 71 Figure 45: Operating Instructions...
  • Page 72 Figure 4A: 40mm Main Burner Flame Figure 47B: 1 Inch Main Burner flame Figure 46: Sequence of Operation Figure 48: Pilot Burner Flame DANGER Sequence of Operation. See Figure 46. If boiler fails Do not use matches, candles, open flames or to operate properly, see Troubleshooting Tree in Section other ignition source to check for leaks.
  • Page 73 Do not reduce more than 0.3 inch w.c. If boiler is still overfired, . Check thermostat operation. Raise and lower contact your Burnham distributor or Regional temperature setting to start and stop boiler operation. Office for replacement Gas Orifice. Check ignition control module shut-off. Disconnect b.
  • Page 74 Figure 49: Variable Speed Control Sequence of Operation Figure 50: Internal Primary / Secondary Piping...
  • Page 75: X. Service

    X. 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. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service.
  • 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 five (5) foot intervals and must not sag.
  • Page 78 Table 11: Pilot Burner Location 1” Burners 40mm Burners Boiler Model Main Burner with Pilot Burner Located Main Burner with Pilot Burner Located 60° Pilot Bracket 41° Pilot Bracket Between Main Burners * Between Main Burners * 1 & 2 1 &...
  • Page 79 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. Using Table 13, estimate the temperature measured by representative.
  • Page 80 Revolution Troubleshooting Tree...
  • Page 81 Revolution Troubleshooting Tree...
  • Page 82: Xi. Repair Parts

    All Revolution ® 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 [Quantity] Part Number Description 1. SECTION AND WATER PIPING ASSEMBLY Section Assembly, Complete 6170603 6170604 6170605 6170606 6170607 [1] 7170601 Left End Section Center Section 7171703 7171703 7171703 7171703 7171703 [1] 71717021 Right End Section Tie Rod, 1/4” -20 80861042 80861043 80861040 80861041...
  • Page 85 [Quantity] Part Number Description . BLOWER OUTLET ORIFICE / VENT CONNECTOR ASSEMBLY Canopy 6110603 6110605 6110607 6110604 6110606 [50”] [56”] [60”] [66”] [72”] Cerafelt, 1/2 Thick x 1 Wide 9206005 9206005 9206005 9206005 9206005 Left End Flue Cover 61106032 61106042 61106052 61106062 61106072...
  • Page 87 [Quantity] Part Number Description 3. BASE ENCLOSURE ASSEMBLY [1] 71806032 [1] 71806042 [1] 71806052 [1] 71806062 [1] 71806072 Base Tray Base Leg Assembly [6] 6186001 [6] 71860021 Base Leg [6] 8186006 Nylon Glide Base Wrapper [1] 71806033 [1] 71806043 [1] 71806053 [1] 71806063 [1] 71806073 Burner Tray (1 Inch Main Burners)
  • Page 89 [Quantity] Part Number Description 4. BURNER ASSEMBLIES Gas Valve (Natural Gas), Honeywell [1] 81660176 ----- VR8204C6000 Gas Valve (Natural Gas), Honeywell ----- [1] 81660177 VR8304P4298 Gas Valve (LP Gas), Honeywell [1] 81660180 ----- VR8204C6018 Gas Valve (LP Gas), Honeywell ----- [1] 81660181 VR8304P4280 Nipple, 1/2”...
  • Page 91 [Quantity] Part Number Description 5. JACKET PARTS Complete Jacket Assembly (less control panel) 60406037 60406047 60406057 60406067 60406077 Jacket Rear / Right Side Panel, Insulated 60406035 60406045 60406055 60406065 60406075 Jacket Vestibule Panel, Insulated 60406036 604060346 60406056 60406076 60406066 Control Panel, Insulated [1] 60406005 [1] 60406002 Jacket Left Side Panel...
  • Page 93 [Quantity] Part Number Description 6. MISCELLANEOUS TRIM AND CONTROLS Boiler Circulator Control, Burnham VS3000 [1] 8010601 Burnham VS3000 / 3001 Clear Cover [1] 8010603 Aquastat, Honeywell :8148E1299, with [1] 61306002 harness Blower Relay, Honeywell R8222U1006 [1] 80160096U Ignition Module, Honeywell S8670E3003...
  • Page 94 [Quantity] Part Number Description . MISCELLANEOUS PARTS VENT CARTON [1] 6050605 [1] 6050606 (Includes Items Below) Air Intake Assembly, 3” or 4” Dia. [1] 6116045 [1] 60116044 Holding Clip, condensate Trap [1] 70906001 Sheet Metal Screw, #8 x 1/2” [2] 80860000 Nipple, 3/4”...
  • Page 95: Service Record

    SERVICE RECORD SERVICE PERFORMED DATE...
  • Page 96 SERVICE RECORD SERVICE PERFORMED DATE...
  • Page 97 SERVICE RECORD SERVICE PERFORMED DATE...
  • Page 98 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 99: Low Water Cut Off

    XII. Low Water Cut Off (LWCO) on Hot Water Boilers WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When manufacturers recommend an annual inspection of the probe.
  • Page 100 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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