U.S. Boiler Company Burnham Hydronics Revolution RV3 Page 64 Installation, Operating And Service Instructions Download

Page: 64 / 100

Figure 41: Radiant Floor Circulator Zoned System with

Alliance™ W

ater Heater

Summary of Contents for Burnham Hydronics Revolution RV3

Page 1: ...c r e l i o b o t s r i a p e r r o e c i v r e s r o F l e b a L g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b r e b m u N l...

Page 2: ...e n o h p d e t a c o l t n e m t r a p e d e r i f e h t R E G N A D n o i t a u t i s s u o d r a z a h y l t n e n i m m i n a s e t a c i d n I h t a e d n i t l u s e r l l i w d e d i o v a t o...

Page 3: ...l i b i s s o p a s i s e p i p n e z o r f o t e u d e g a m a d f I e c i v r e s t u o h t i w t r a t s e r d l u o h s s m r a l a d n a s d r a u g e f a s e t a i r p o r p p a r o r e h t a e...

Page 4: ...ing Air Intake Piping 8 IV Condensate Drains 43 V Water Piping and Trim 44 VI Gas Piping 48 Figure 1 Minimum Clearances to Combustibles VII Electrical 51 VIII Modular Installation 66 IX System Start u...

Page 5: ...5 Figure 2 Dimensions...

Page 6: ...all on level floor For basement installation provide solid base such as concrete if floor is not level or if water may be encountered on floor around boiler Floor must be able to support weight of boi...

Page 7: ...00 square inches 7 Combustion Air Ventilation Duct Louvers and Grilles Equip outside openings with louvers to prevent entrance of rain and snow and screens to prevent entrance of insects and rodents L...

Page 8: ...g u o r h t e p i p t n e v g n i l l a t s n i n e h W y e n m i h c 4 e l b a T o t r e f e R s h t g n e l e k a t n i r i a t n e v m u m i x a m d e e c x e t o n o D E C I T O N h c a e d n a n...

Page 9: ...o c d e l a e s t n e V t c e r i D a h g u o r h t y l l a t n o z i r o h g n i t a n i m r e t e p i p e k a t n i r i a d n a d n a t n e v e h t r o f s n o i t a r t e n e p l a u d i v i d n i...

Page 10: ...on venting system should be corrected so the installation conforms with the National Fuel Gas Code NFPA 54 ANSI Z223 1 When resizing any portion of the common venting system the common venting system...

Page 11: ...verhangs etc e Minimum twelve 12 inches from overhang or corner of building 10 Enclose vent passing through occupied or unoccu pied spaces above the boiler with material having a fire resistance ratin...

Page 12: ...f necessary f Slip the locking band over joint and align closest bead in locking band with bead in male end of pipe g Tighten locking band by HAND with a 5 16 nut driver until snug plus turn DO NOT SE...

Page 13: ...move any dirt and grease b Apply a continuous inch bead of sealant around male end of joint no more than 1 8 inch from end c Align weld seams in pipes and use a slight twisting motion to FULLY insert...

Page 14: ...r intake termination on the same wall as the vent termination if possible to prevent nuisance boiler shutdowns However boiler may be installed with vertical venting and sidewall combustion air inlet o...

Page 15: ...15 Figure 4 Recommended Separate Horizontal Vent Air Intake Installation...

Page 16: ...16 Figure 5 Separate Horizontal Vent Air Intake Terminal Confi guration...

Page 17: ...brace as required Refer to Figure 8 c Vertical venting requires use of the roof flashing and storm collar to prevent moisture from entering the structure d Install storm collar on vent pipe immediatel...

Page 18: ...s The complete air intake piping system must be rigid and able to withstand minor impacts without collapse 13 Inlet air pipe penetration Vertical Size roof opening to allow easy insertion of inlet pip...

Page 19: ...19 Figure 7 Attic Offset Figure 6 Vertical Vent Installation...

Page 20: ...Vent Air Termination 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 expec...

Page 21: ...21 Figure 9 Vertical Air Intake Piping...

Page 22: ...s e d u l c n i n o i t p i r c s e D r e b m u N t r a P t n e n o p m o C A g n o l 2 x e r a u q s 6 y l b m e s s A b u S x o B r i A 1 1 0 6 0 1 1 6 B e r a u q s 0 1 r e v o C l l a W r o i r e...

Page 23: ...plied with boiler P N 8116308 to vent pipe penetrating through terminal cover Join terminal and pipe with locking band and seal with RTV see Figure 3 3 Install Vent Piping See Figure 10 and 11 a Start...

Page 24: ...24 Figure 10 Combination Horizontal Vent Air Installation...

Page 25: ...25 Figure 11 Combination Horizontal Vent Air Terminal Installation...

Page 26: ...e V n o i t a n i b m o C 3 1 0 6 0 1 1 6 D c s i D r e n n I e k a t n I r i A 0 3 2 6 1 1 8 E 4 r e t p a d A e k a t n I r i A r e w o L n o i t a n i b m o C 0 5 0 6 1 1 6 F e t a l P l a e S r e...

Page 27: ...vent terminal elbow Refer to Sections C through E for proper procedures for joining vent pipe and fittings 9 Insert vent disc terminal assembly into horizontal leg of the remaining B vent tee See Figu...

Page 28: ...6116054 if used will increase air intake pipe diameter to 4 inch d Start at collar on burner enclosure inside boiler jacket and work towards the air intake adapter on the interior B vent tee s horizo...

Page 29: ...ir 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...

Page 30: ...30 Figure 13 Combination Vertical Air Intake Terminal Assembly...

Page 31: ...31 Figure 14 Combination Vertical Vent Disc Terminal Assembly...

Page 32: ...P t n e n o p m o C A r e v o C e v i t c e t o r P c i t s a l P 6 9 1 6 5 0 8 7 9 1 6 5 0 8 B 0 9 e k a t n I r i A m u n i m u l A w o b l E 4 2 2 6 1 1 8 3 2 0 4 0 1 1 8 4 C w o b l E e p i P t n...

Page 33: ...to air intake opening in jacket top panel See Figure 19 NOTE RV3 RV4 uses 4 inch cap RV5 RV7 uses 5 inch cap 1 Do not exceed maximum vent length Refer to Table 4 Horizontal 2 Maintain minimum inch per...

Page 34: ...34 Figure 15 Indoor Air Horizontal Vent Installation...

Page 35: ...35 Figure 16 Indoor Air Vertical Vent Installation...

Page 36: ...al 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...

Page 37: ...37 Figure 19 Indoor Air Air Intake Terminal Installation...

Page 38: ...4 2 6 1 1 8 C r e c u d e R e p i P e l a M 3 x e l a m e F 4 4 6 1 6 1 1 8 D r e c u d e R e p i P e l a m e F 3 x e l a M 4 9 3 2 6 1 1 8 E g n i t t i F D S n i a r D r e w e S g n i l p u o C b u...

Page 39: ...4 or 4 inch diameter two 2 foot section of single wall metal pipe RV5 RV7 See Figure 20 a Secure with three 3 self drilling sheetmetal screws provided 7 Maintain minimum of inch per foot slope on hori...

Page 40: ...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: ...so that elbow leg is opposite the building s exterior surface L Optional Separate Horizontal Vent Air Intake Terminal Mounting See Figures 23 24 and 25 e If installation requires indoor air install A...

Page 42: ...42 Figure 24 Optional Separate Horizontal Air Intake Terminal Installation Figure 25 Optional Indoor Air Vent Terminal Installation...

Page 43: ...t o n o D g n i p i p e t a s n e d n o c f o e z i s e c u d e r t o n o D r e h t e g o t g n i p i p 2 Pipe condensate trap to a floor drain or condensate pump sump 3 Use PVC or CPVC for condensate...

Page 44: ...r h t w o l f t c e r r o c e r u s s e r p e h t r o t a l u c r i c m e t s y s e h t g n i z i s d n a d r a o b e s a b s r o t a i d a r l l a f o p o r d g n i p i p g n i t c e n n o c l l a d...

Page 45: ...hot water boiler is just above the highest water containing cavity of the boiler that is a hot water boiler must be full of water to operate safely Figure 27 Recommended Piping for Combination Heatin...

Page 46: ...46 Figure 28 Recommended Boiler Piping For Circulator Zoned Heating Systems...

Page 47: ...47 Figure 29 Boiler Piping for Zone Valve Zoned Systems...

Page 48: ...ific gravity of gas Gas piping systems for gas with a specific gravity of 0 70 or less can be sized directly from Table 7 unless authority having jurisdiction specifies a gravity factor be applied For...

Page 49: ...heating value of your gas 3 Install sediment trap ground joint union and manual shut off valve upstream of boiler gas control valve and outside jacket See Figure 30 h t g n e L t e e F p o r D e r u s...

Page 50: ...eration 1 Protect boiler gas control valve For all testing over psig boiler and its individual shutoff valve must be disconnected from gas supply piping For testing at psig or less isolate boiler from...

Page 51: ...e n o H t i m i l e r u t a r e p m e t r e t a w l a n o i t i d d a n a l l a t s n i s r u c c o s i h t f I s a e r i W l a u n a m s i h t f o n o i t c e S m i r T d n a g n i p i P r e t a W e...

Page 52: ...52 Figure 31 Internal Boiler Wiring Schematic Diagram...

Page 53: ...E C I T O N l l e w y e n o H e h t f o e r i w e u l b t i u c r i c 1 B h t i w s e i r e s n i l l a t s n i d e s u s i t i m i l m e t s y s l a n o i t i d d a n a f I t e k c a j r e l i o b e...

Page 54: ...ntrol system Locate the group of two 2 thermostat wires black and black inside the boiler jacket at the top not in the boiler junction box Connect wires from these boiler wire leads to the H1 and H2 t...

Page 55: ...r o f g n i n o z y t i r o i r p e d i v o r p l l i w r e h t e g o t l o r t n o c h c a e f o s l a n i m r e t C d n a B A e h t g n i r i w y b s 9 8 8 8 R l a n o i t i d d a t c e n n o c d e...

Page 56: ...56 Figure 33 Single Heating Zone Only Wiring Schematic...

Page 57: ...Wiring Schematic E C I T O N l l e w y e n o H e h t f o e r i w e u l b t i u c r i c 1 B h t i w s e i r e s n i l l a t s n i d e s u s i t i m i l m e t s y s l a n o i t i d d a n a f I t e k c...

Page 58: ...58 Figure 35 Circulator Zoned System Wiring Schematic...

Page 59: ...59 Figure 36 Zone Valve Zoned System Wiring Schematic...

Page 60: ...60 Figure 37 Zone Valve Zoned System Wiring Schematic...

Page 61: ...61 Figure 38 Different Manufacturer s Zone Valve Connections to Honeywell R8889...

Page 62: ...62 Figure 39 Circulator Zoning with EC5000 Wiring Schematic...

Page 63: ...63 Figure 40 Zone Valve Zoning with EC5000 Wiring Schematic...

Page 64: ...64 Figure 41 Radiant Floor Circulator Zoned System with Alliance Water Heater...

Page 65: ...65 Figure 42 Radiant Floor Zone Valve Zoned System with Alliance Water Heater...

Page 66: ...ing Section of this manual for Air Intake Guidelines and Options 2 The maximum air intake length for each boiler is fifty two 52 equivalent feet 3 Locate air intake termination on the same wall as the...

Page 67: ...t pump sump manufacturer for compatibility of materials of construction with flue gas conden sate If a common pump sump is used individual boiler drain lines must be connected such that one drain pipe...

Page 68: ...68 Figure 43 Modular Boiler Piping...

Page 69: ...69 Figure 44 Alternate Modular Boiler Piping...

Page 70: ...l i o b e h t t a h t 1 Close full port ball valve in boiler supply piping 2 Isolate all zones by closing zone valves or shut off valves in supply and return of each zone s IX System Start up 3 Attac...

Page 71: ...71 Figure 45 Operating Instructions...

Page 72: ...u o s n o i t i n g i r e h t o r o 8 Purge gas line of air H Follow Operating Instructions to place boiler in operation See Figure 45 Figure 47A 40mm Main Burner Flame I Sequence of Operation See Fi...

Page 73: ...k gas meter for at least 30 seconds Use Table 10 to determine gas flow rate in Cubic Feet per Hour G N I N R A W l l i w e t a r t u p n i s a g t s u j d a y l r e p o r p o t e r u l i a F e h t f o...

Page 74: ...74 Figure 49 Variable Speed Control Sequence of Operation Figure 50 Internal Primary Secondary Piping...

Page 75: ...e d n a d e l l i k s y b d e r i a p e r d n a d e c i v r e s e b y l n o t s u m r e l i o b s i h T s n a i c i n h c e t s l e d o m l a c i t n e d i h t i w d e c a l p e r e b t s u m y e h t...

Page 76: ...es at the gas valve d Remove wires to Flame Roll out Switch RV3 RV6 only e Remove Burner Access Panel f Mark location of Main Burner with Pilot Bracket on gas manifold g Hold Main Burner on throat Lif...

Page 77: ...77 Figure 53 Cleaning Boiler Flue Passages...

Page 78: ...ps G through Q from Section IX System Start up G PROCEDURE FOR MEASURING DIFFERENTIAL PRESSURE See Figure 54 1 With boiler off remove Gray and Black Hoses at differential pressure switch Figure 54 Dif...

Page 79: ...nected 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...

Page 80: ...80 Revolution Troubleshooting Tree...

Page 81: ...81 Revolution Troubleshooting Tree...

Page 82: ...h 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...

Page 83: ...0 0 0 0 6 6 0 8 B 1 e l f f a B s a G e u l F 2 1 0 0 6 0 1 1 7 3 1 0 0 6 0 1 1 7 4 1 0 0 6 0 1 1 7 5 1 0 0 6 0 1 1 7 6 1 0 0 6 0 1 1 7 C 1 e g u a G e r u s s e r P p m e T U 9 6 1 6 5 0 8 1 D 1 4 x...

Page 84: ...84...

Page 85: ...7 1 3 6 0 6 0 1 1 7 A N G 2 n o i s n e t x E e e T r o t c e n n o C t n e V 6 0 6 0 1 1 8 1 H 2 p a r T e t a s n e d n o C 1 0 0 6 0 6 0 6 1 J 2 p a r T e t a s n e d n o C p i l C g n i d l o H 1...

Page 86: ...86...

Page 87: ...a P s s e c c A r e n r u B 1 3 0 6 0 1 2 7 1 1 4 0 6 0 1 2 7 1 1 5 0 6 0 1 2 7 1 1 6 0 6 0 1 2 7 1 1 7 0 6 0 1 2 7 1 P 3 h c t i w S t u O l l o R e m a l F 4 4 0 0 6 1 0 8 1 Q 3 h c t i w S t u O l...

Page 88: ...88...

Page 89: ...2 1 5 0 7 2 2 8 7 5 0 7 2 2 8 9 s a G P L e u l B 4 6 3 4 0 7 2 2 8 2 1 E 4 t f 0 0 0 5 t f 1 0 0 2 e d u t i t l A h g i H r e n r u B m m 0 4 s e c i f i r O r e n r u B n i a M s a G l a r u t a N...

Page 90: ...90...

Page 91: ...c a J 1 1 3 0 6 0 4 0 7 1 1 4 0 6 0 4 0 7 1 1 5 0 6 0 4 0 7 1 1 6 0 6 0 4 0 7 1 1 7 0 6 0 4 0 7 F 5 l e n a P p o T t n o r F t e k c a J 1 3 3 0 6 0 4 0 7 1 3 4 0 6 0 4 0 7 1 3 5 0 6 0 4 0 7 1 3 6 0...

Page 92: ...92...

Page 93: ...h c t i w S e r u s s e r P l a i t n e r e f f i D 2 3 3 5 9 5 2 0 2 S I l l e w y e n o H t F 0 0 0 2 l e v e L a e S 1 1 8 8 0 6 1 0 6 6 7 6 5 9 5 2 0 2 S I l l e w y e n o H n o i t a v e l E t F...

Page 94: ...r o 3 y l b m e s s A e k a t n I r i A 5 4 0 6 1 1 6 1 4 4 0 6 1 1 6 1 B 7 p a r T e t a s n e d n o C p i l C g n i d l o H 1 0 0 6 0 9 0 7 1 C 7 x 8 w e r c S l a t e M t e e h S 0 0 0 0 6 8 0 8 2...

Page 95: ...95 SERVICE RECORD DATE SERVICE PERFORMED...

Page 96: ...96 SERVICE RECORD DATE SERVICE PERFORMED...

Page 97: ...97 SERVICE RECORD DATE SERVICE PERFORMED...

Page 98: ...ve gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wa...

Page 99: ...to connect the probe LWCO to the supply or return piping as shown below LWCO Location manufacturers recommend an annual inspection of the probe How to Wire LWCO s are available in either 120 VAC or 24...

Page 100: ...remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS 03 03 S...

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

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Summary of Contents for Burnham Hydronics Revolution RV3

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