IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR R E V OL U T ION ® GA S - F I R E D BO I L E R As an ENERGY STAR® Partner, Burnham Hydronics has determined that the Revolution Series meets the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). F o r s e r vi c e o r r e p a i r s to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r.
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. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
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. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency.
Table of Contents I. Pre-Installation................................ 6 VII. Electrical........................................ 51 II. Unpack Boiler................................. 7 VIII. Modular Installation..................... 66 III. Venting/Air Intake Piping............... 8 IX. System Start-up............................. 70 IV. Condensate Drains........................ 43 X. Service........................................... 75 V. Water Piping and Trim.................. 44 XI.
Figure 2: Dimensions
I. Pre-Installation WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. DANGER Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.
6. For boiler located within unconfined space in building of unusually tight construction or within confined space, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within twelve (12) inches of top of space. Locate remaining opening within twelve (12) inches of bottom of space. Minimum dimension of air opening is three (3) inches.
III. Venting / Air Intake Piping WARNING Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other non AL29-4C® based vent systems. Do not use a barometric damper or drafthood with this appliance. Do not use vent dampers with this boiler. Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.).
Table 1: Air Intake / Vent System Options Description Additional Vent Kit Required Part Number Installation Drawing and Specification (Section) 1. Separate Horizontal Direct Vent (sealed combustion) with both the vent pipe and air intake pipe terminating horizontally (through a sidewall) with individual penetrations for the vent and air intake piping and terminals. No See Table 2 F. 2.
Table 4: Vent/Air Intake Length 3” Air Intake Pipe (Equiv. Ft.) Model 3” Vent Pipe (Equiv. Ft.) Min. Max. Min. Max. Min. Max. RV3 & RV4 10 52 --- --- 8 50 RV5, RV6 & RV7 --- --- 10 52 8 50 A. Vent Guidelines Due to Removal of an Existing Boiler For installations not involving the replacement of an existing boiler, proceed to Step B.
5. Horizontal vent pipe must maintain a minimum ¼ inch per foot slope down towards boiler. 6. Use noncombustible ¾ inch pipe strap to support horizontal runs and maintain vent location and slope while preventing sags in pipe. Do not restrict thermal expansion or movement of vent system. Maximum support spacing is five (5) feet. Do not penetrate any part of the vent system with fasteners. 7.
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. d.
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 flue gases and/or liquid condensate will not escape. 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.
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. d. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. e. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary. f.
Figure 4: Recommended Separate Horizontal – Vent/Air Intake Installation
Figure 5: Separate Horizontal – Vent/Air Intake Terminal Configuration
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 6116062 (RV3-RV7) ------ Vent Terminal, Vertical ------ 6116061 Roof Flashing, 3” ------ 8116250 Storm Collar, 3” ------ 8116251 Description Vertical Vent Accessories (Includes items below) SEPARATE VERTICAL VENTING SYSTEM COMPONENTS Vertical Venting – 1. Do not exceed maximum vent lengths. Refer to Table 4. 2.
7. Locate air intake termination on the same roof location as the vent termination if possible, to prevent nuisance boiler shutdowns. However, boiler may be installed with vertical venting and sidewall combustion air inlet or visa versa, if installation conditions do not allow alternate arrangement. 8. Use single wall metal pipe and fittings available at most heating distributors, unless using PVC air intake kit (P/N 6116054). See Section III. K.
Figure 6: Vertical Vent Installation Figure 7: Attic Offset
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.
Figure 9: Vertical Air Intake Piping 21
H. Combination Horizontal Venting System – See Figures 10 and 11. NOTICE This vent system requires components not supplied with the boiler. 1. Do not exceed maximum vent/air intake lengths. Refer to Table 4. 2. 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. b.
c. From exterior of building, insert air box subassembly into square opening. Push air box inward until wall flange is against wall, check for level and mark the location of the four (4) securing holes on the exterior wall. Remove air box from wall. 3. Install Vent Piping. See Figure 10 and 11. a. Start at vent connector on boiler and work towards combination vent/air terminal. b. Maintain minimum 1/4 inch per foot slope down towards boiler in horizontal runs. d.
Figure 10: Combination Horizontal – Vent/Air Installation
Figure 11: Combination Horizontal – Vent/Air Terminal Installation
I. Combination Vertical Venting System – See Figures 12, 13 and 14. NOTICE This vent system requires components not supplied with the boiler.
The following parts are required for installation which are not included with this kit. Parts are supplied by others.
f. Seal vent pipe penetration through lower seal plate with RTV. 15. Install air intake piping. See Figure 12. a. Do not exceed air intake length. See Table 4. b. Use single wall metal pipe and fittings available at most heating distributors, unless using PVC air intake kit, P/N 6116054. See Section III., K. This kit will allow S & D (thin wall) PVC to be used for air intake piping. c. Air intake pipe diameter is based on boiler size.
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 exposed B-Vent must be protected with a high quality, non-latex, enamel paint.
Figure 13: Combination Vertical – Air Intake Terminal Assembly
Figure 14: Combination Vertical Vent Disc Terminal Assembly
J. Indoor Air Installation – See Figures 15, 16, 17, 18 and 19. NOTICE This vent system requires components not supplied with the boiler.
1. Do not exceed maximum vent length. Refer to Table 4. Horizontal – 2. Maintain minimum ¼ inch per foot slope in horizontal runs. 3 Recommended horizontal installation consists of vent being sloped down toward boiler. See Figure 15. 4. Use appropriately designed thimbles when passing through combustible walls (thimble use optional for noncombustible walls). Insert thimble through wall from outside. Secure outside flange to wall with nails or screws, and seal with sealant material.
Figure 15: Indoor Air - Horizontal Vent Installation
Figure 16: Indoor Air - Vertical Vent Installation
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.
Figure 19: Indoor Air - Air Intake Terminal Installation
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) Description Component Part Number A 4” X 2” Single Wall Galv. Smoke Pipe 8116241 B 3” x 2” Single Wall Galv.
1. Do not exceed maximum vent/air intake length. Refer to Table 4. 2. Install vent piping for desired venting system. Refer to specific section for details for vent pipe installation. 3. Start at collar on burner enclosure (inside boiler jacket) and work towards the correct air intake terminal for installation. 4. Install two (2) foot section of single wall metal pipe (provided) onto burner enclosure collar.
Figure 21: PVC Air Intake - Separate Horizontal/Vertical Air Intake Terminal Installation Figure 22: PVC Air Intake - Combination Horizontal/Vertical Air Intake Pipe Installation 40
L. Optional Separate Horizontal Vent/Air Intake Terminal Mounting – See Figures 23, 24 and 25. 1. Do not exceed maximum vent/air intake lengths. Refer to Table 4. 2. This installation will allow a maximum of five (5) feet vertical exterior run of the vent/air intake piping to be installed on separate horizontal venting and indoor air horizontal venting. Note: Exterior run to be included in equivalent vent/ air intake lengths. 3. Install vent piping. e.
Figure 24: Optional Separate Horizontal – Air Intake Terminal Installation Figure 25: Optional Indoor Air – Vent Terminal Installation 42
IV. Condensate Drains 1. Each boiler contains two (2) condensate drain tubes. Insert both tubes into the condensate trap provided with boiler. See Figure 26. a. Ensure tubes are inserted so that tube ends contact trap bottom. Note: Wetting tubes will aid in insertion. b. Insert trap assembly into 2-1/8 inch diameter hole in base tray. Install condensate trap holding clip and secure with two (2) screws provided.
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.
E. Space heating and domestic water heating with Alliance™ water heater. Install Alliance water heater as a separate heating zone. Refer to Alliance Installation, Operating and Service Instructions for additional information. F. If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler, see Figure 27.
Figure 28: Recommended Boiler Piping For Circulator Zoned Heating Systems
Figure 29: Boiler Piping for Zone Valve Zoned Systems
VI. Gas Piping 4. Specific gravity of gas. Gas piping systems for gas with a specific gravity of 0.60 or less can be sized directly from Table 7, unless authority having jurisdiction specifies a gravity factor be applied. For specific gravity greater than 0.60, apply gravity factor from Table 6. If exact specific gravity is not shown choose next higher value. WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure.
Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Gas Pressures of 0.5 psig or Less 0.3 Inch w.c. Pressure Drop Length [Feet] 0.5 Inch w.c.
4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, NFPA 70. piping by closing boiler’s individual manual shutoff valve. 2. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. C. Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1.
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. Make sure all power is off before attempting any electrical work.
Figure 31: Internal Boiler Wiring Schematic Diagram
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).
D. 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. Use armored cable (BX) over all exposed line voltage wiring. 4. If an Alliance™ indirect water heater is used, use priority zoning except for Hydro-Air Systems. 5.
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.
Figure 33: Single Heating Zone Only Wiring Schematic
NOTICE Figure 34: Single Zone System with Packaged Alliance™ Water Heater Wiring Schematic 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 35: Circulator Zoned System Wiring Schematic
Figure 36: Zone Valve Zoned System Wiring Schematic
Figure 37: Zone Valve Zoned System Wiring Schematic
Figure 38: Different Manufacturer’s Zone Valve Connections to Honeywell R8889 61
Figure 39: Circulator Zoning with EC5000 Wiring Schematic
Figure 40: Zone Valve Zoning with EC5000 Wiring Schematic
Figure 41: Radiant Floor Circulator Zoned System with Alliance™ Water Heater
Figure 42: Radiant Floor Zone Valve Zoned System with Alliance™ Water Heater
VIII. Modular Installation A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual unless otherwise instructed in this section. 2. Consult Local Building Codes or National Fuel Gas Code, NFPA 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Module Sizing 2. The maximum air intake length for each boiler is fifty-two (52) equivalent feet. 3.
G. Electrical 1. Each boiler must be provided with a fused disconnect and service switch. 2. Install wiring in accordance with requirements of authority having jurisdiction. In the absence of such requirements, follow the National Electric Code, NFPA 70 and/or CSA C22.1 Electric Code. H. Condensate Piping 1. Each boiler requires a separate condensate drain line. Do not manifold condensate drains from multiple boilers together. 2. A common condensate pump/sump may be used.
Figure 43: Modular Boiler Piping
Figure 44: Alternate Modular Boiler Piping
IX. System Start-up A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas-Fired LowPressure Steam and Hot Water Boilers, ANSI Z21.13. B. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. C.
Figure 45: Operating Instructions 71
Figure 47A: 40mm Main Burner Flame Figure 47B: 1 Inch Main Burner flame Figure 46: Sequence of Operation Figure 48: Pilot Burner Flame DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. 8. Purge gas line of air. H. Follow Operating Instructions to place boiler in operation. See Figure 45. 72 I. Sequence of Operation. See Figure 46. If boiler fails to operate properly, see Troubleshooting Tree in Section X: Service. J. Check pilot burner flame. See Figure 48.
K. Check main burner flame. See Figures 47A and 47B. Flame should have clearly defined inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping. L. Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. M. Check ignition control module shut-off. Disconnect pilot lead wires from gas valve. If burners do not shutdown, determine cause of malfunction. Replace necessary items and check operation. N.
Figure 49: Variable Speed Control Sequence of Operation Figure 50: Internal Primary / Secondary Piping 74
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. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
4. Pipe must be supported at minimum five (5) foot intervals and must not sag. 10. Connect Silicone Tubing between Pressure Fittings on Canopy Assembly and Pressure Switch. Route through bushings in Vestibule Panel . See Figure 51. 5. All vent joints must be secure and watertight. 11. Install Jacket Top Rear Panel. 6. All air intake joints must be secure and airtight. Horizontal vent tee drain or vertical vent tee drain (if used) must have minimum 6 inch trap and allow condensate to flow freely.
Figure 53: Cleaning Boiler Flue Passages
Table 11: Pilot Burner Location 1” Burners Boiler Model 40mm Burners Main Burner with 60° Pilot Bracket Pilot Burner Located Between Main Burners * Main Burner with 41° Pilot Bracket Pilot Burner Located Between Main Burners * RV3 1 1&2 1 1&2 RV4 2 2&3 2 2&3 RV5 3 3&4 2 2&3 RV6 4 4&5 3 3&4 RV7 6 6&7 3 3&4 * Main burners numbered left to right as viewed from front of boiler. E. Main Burners and Firebox. 1. Vacuum firebox. Exercise care - do not damage base insulation. 2.
First measure the temperature using the thermometer and then measure the resistance of the sensor at the control. The wires from the sensor must not be connected to the control while the test is performed. Using Table 13, estimate the temperature measured by the sensor. The sensor and thermometer readings should be close. If the test meter reads a very high resistance, there may be a broken wire, a poor wiring connection or a defective sensor.
Revolution Troubleshooting Tree 80
Revolution Troubleshooting Tree 81
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.
[Quantity] Part Number Key No. Description RV3 RV4 RV5 RV6 RV7 [1] 6170603 [1] 6170604 [1] 6170605 [1] 6170606 [1] 6170607 [4] 7171703 [5] 7171703 [2] 80861043 (19” Lg) [2] 80861044 (22” Lg) 1.
[Quantity] Part Number Key No. Description RV3 RV4 RV5 RV6 RV7 2.
[Quantity] Part Number Key No. Description RV3 RV4 RV5 RV6 RV7 [1] 71806032 [1] 71806042 [1] 71806052 [1] 71806062 [1] 71806072 [1] 71806063 [1] 71806073 3.
[Quantity] Part Number Key No. Description RV3 RV4 RV5 RV7 RV6 4. BURNER ASSEMBLIES 4A 4B 4C 4D Gas Valve (Natural Gas), Honeywell VR8204C6000 [1] 81660176 ----- Gas Valve (Natural Gas), Honeywell VR8304P4298 ----- [1] 81660177 Gas Valve (LP Gas), Honeywell VR8204C6018 [1] 81660180 ----- Gas Valve (LP Gas), Honeywell VR8304P4280 ----- [1] 81660181 Nipple, 1/2” x 3” Lg. [1] 71806033 [1] 71806043 Nipple, 3/4” x 3” Lg.
[Quantity] Part Number Key No.
Key No. [Quantity] Part Number Description RV3 RV4 RV5 RV6 RV7 6.
[Quantity] Part Number Key No. Description 7. MISCELLANEOUS PARTS VENT CARTON (Includes Items Below) 94 RV3 RV4 RV5 RV6 [1] 6050605 [1] 6050606 [1] 6116045 [1] 60116044 7A Air Intake Assembly, 3” or 4” Dia.
SERVICE RECORD DATE SERVICE PERFORMED 95
SERVICE RECORD DATE 96 SERVICE PERFORMED
SERVICE RECORD DATE SERVICE PERFORMED 97
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. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
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 A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.
Limited Warranty Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water or steam boiler or U.S. Boiler Company, Inc. supplied parts and/or accessories manufactured and shipped on or after July 1, 2008: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE BOILERS AND PARTS / ACCESSORIES SUPPLIED BY U.S. BOILER COMPANY, INC. U.S. Boiler Company, Inc.
