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U.S. Boiler Company Burnham Hydronics Revolution RV3, Инструкция по установке, эксплуатации и обслуживанию

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23

c.  From exterior of building, insert air box sub-

assembly into square opening.  Push air box 
inward until wall fl ange 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.

d.  Drill four (4) pilot holes, properly sized for the 

non-corrosive fasteners (stainless steel, brass, or 
aluminum) to be used to secure the wall fl ange to 
the exterior wall.  (Securing screws not supplied 
with kit.)

e.  Attach four (4) 1/2 inch long threaded aluminum 

spacers to the outer fl anges of the exterior wall 
fl ange with four (4) number 10 - 32 x 1/4 inch 
stainless steel machine screws provided.        
(See Figure 11.)

f.  Apply a 1/4 inch thick continuous bead of 

silicone caulk to perimeter of exterior wall 
fl ange’s back surface to provide a weathertight 
seal.

g.  Reinstall air box sub-assembly into opening in 

exterior wall and secure to wall.

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h.  Apply a bead of silicone caulk to perimeter of 

wall fl ange, where the wall and fl ange join.  Use 
a tool or your fi nger and apply pressure while 
smoothing caulking to provide a weathertight 
seal.

i.  From interior of building, insert end panel with 

collar and vent pipe assembly into open end of 
air box sub-assembly.  (See Figure 11.)

j.  Secure end panel to air box sub-assembly with 

shipping screw and thirteen (13) number 8 sheet 
metal screws provided.

k.  From exterior of building, position 10 inch 

square exterior wall cover over exterior wall 
fl ange.  Insert 3 inch diameter vent pipe into 
center opening in terminal cover.  Align four (4) 
holes on cover with 1/2 inch long threaded 
spacers on wall fl ange.  Secure terminal cover 
with four (4) number 10  - 32 x 1/4 inch stainless 
steel machine screws provided.

l.  Apply a bead of silicone caulk to perimeter of 

plate-seal and around pipe. Secure plate-seal to 
exterior cover with six (6) #8 stainless steel sheet 
metal screws provided.  Smooth caulk around 
plate-seal and pipe to provide weathertight seal.

m. Install Vent Terminal supplied 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 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.

c.  Recommended horizontal installations consists 

of vent being sloped toward boiler.

d.  Use 3/4 inch pipe strap to support horizontal runs 

and maintain vent location and slope.  Maximum 
support spacing is fi ve (5) feet.

e.  Install vent piping to connect vent connector on 

boiler and combination vent/air terminal.  
Reference Section B - General Venting Guide-
lines for proper procedure for joining pipe and 
fi ttings.

f.  Connect vent piping to combination vent/air 

terminal.  See Figure 10.

4. 

Install Air Intake Piping

.  See Figures 10 and 11.

a.  Do not exceed air intake length.  See Table 4.

b.  Use single wall metal pipe and fi ttings available 

at most heating distributors, unless using PVC 
air intake kit (P/N 6116054), see Section III. H.  
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.

 

RV3 - RV4 – uses 3 inch diameter piping*

 

RV5 - RV7 – uses 4 inch diameter piping

*  The PVC air intake kit (P/N 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 combination vent/
air terminal.

e.  Maintain minimum of 1/4 inch per foot slope on 

horizontal runs.  Slope down towards boiler.

f.  The air intake pipe must be adequately supported 

with straps or supports no less than fi ve (5) feet 
apart on horizontal runs.  The complete air intake 
piping system must be rigid and able to with-
stand minor impacts without collapse.

g.  Connect Air Intake Piping to Combination Vent/

Air Terminal.  See Figure 10.

NOTE: When installing 3 inch diameter air intake 
piping for a RV3 or RV4 application, the use of a    4 
inch x 3 inch reducer will be required to connect air 
intake piping to combination vent/air terminal.  
(Reducer included with combination horizontal 
venting kit).

h.  Seal all joints airtight, using silicone caulk or 

self-adhesive aluminum tape.

Содержание Burnham Hydronics Revolution RV3

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 5: ...5 Figure 2 Dimensions...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 71: ...71 Figure 45 Operating Instructions...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 80: ...80 Revolution Troubleshooting Tree...

Страница 81: ...81 Revolution Troubleshooting Tree...

Страница 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...

Страница 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...

Страница 84: ...84...

Страница 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...

Страница 86: ...86...

Страница 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...

Страница 88: ...88...

Страница 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...

Страница 90: ...90...

Страница 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...

Страница 92: ...92...

Страница 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...

Страница 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...

Страница 95: ...95 SERVICE RECORD DATE SERVICE PERFORMED...

Страница 96: ...96 SERVICE RECORD DATE SERVICE PERFORMED...

Страница 97: ...97 SERVICE RECORD DATE SERVICE PERFORMED...

Страница 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...

Страница 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...

Страница 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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