Burnham PVG User Manual

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

PVG™

GAS - FIRED BOILER

As an ENERGY STAR^®Partner, Burnham Hydronics has determined that the PVG Series meets the ENERGY

STAR^®guidelines for energy efﬁciency established by the United States Environmental Protection Agency (EPA).

For service or repairs to boiler, call your heating contractor. When seeking information on

boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

Boiler Serial Number

Installation Date

PVG

Heating Contractor

Phone Number

Address

8140708R8-8/08

Price - $5.00

WARNING

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,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.

This boiler must be properly vented.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

The interior of the venting system must be inspected and cleaned before the start of the heating season

and should be inspected periodically throughout the heating season for any obstructions. A clean and

unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life

to vent safely and will contribute toward maintaining the boiler’s efﬁciency.

Installation is not complete unless a pressure relief valve is installed into the tapping located on top of

appliance. - See the Water Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start

without service. If damage due to frozen pipes is a possibility, the heating system should not be left

unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating

system to prevent damage if the boiler is inoperative.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ﬁttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the

temperature and pressure of the boiler. This boiler contains components which become very hot when

the boiler is operating. Do not touch any components unless they are cool.

Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,

carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause

death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc-

tions, including all those contained in component manufacturers manuals which are provided with the

boiler before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ﬂammable vapors or

liquids.

All cover plates, enclosures and guards must be in place at all times.

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility

of the installing contractor to see that all controls are correctly installed and are operating properly when the

installation is complete.

ꢁ

Table of Contents

I. Pre-Installation...............................6

VI. Electrical.......................................28

VII. Modular Installation ....................37

VIII. System Start-up ............................39

IX. Service ..........................................46

X. Repair Parts..................................52

II. Unpack Boiler ................................7

III. Venting...........................................8

IV. Water Piping and Trim .................20

V. Gas Piping....................................25

Figure 1: Minimum Clearances to Combustibles

I. Pre-Installation

WARNING

F. Provide combustion and ventilation air in accordance

with applicable provisions of local building codes,

or: USA - National Fuel Gas Code, NFPA 54/ANSI

Z223.1, Air for Combustion and Ventilation;

Canada - Natural Gas or Propane Installation Code,

CAN/CSA-B149.1.

If you do not follow these instructions exactly,

a ﬁre or explosion may result causing property

damage or personal injury.

DANGER

WARNING

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.

Adequate combustion and ventilation air must

be provided to assure proper combustion.

The following guideline is based on the National Fuel Gas

Code, NFPA 54/ANSI Z223.1.

1. Determine volume of space (boiler room). Rooms

communicating directly with space (through

openings not furnished with doors) are considered

part of space.

NOTICE

Due to the low water content of the boiler, mis-

sizing of the boiler with regard to the heating

system load will result in excessive boiler cycling

and accelerated component failure. Burnham

DOES NOT warrant failures caused by mis-sized

boiler applications. DO NOT oversize the boiler to

the system. Modular boiler installations greatly

reduce the likelihood of boiler oversizing.

Volume [ft³] = Length [ft] x Width [ft] x Height [ft]

2. Determine Total Input of all appliances in space.

Round result to nearest 1,000 Btu per hour (Btuh).

3. Determine type of space. Divide Volume by Total

Input.

a. If result is greater than or equal to 50 ft³ per

1,000 Btuh, space is considered an unconﬁned

space.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such

requirements, installation must conform to the National

Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/

CSA B149.1 Installation Codes.

b. If result is less than 50 ft³ per 1,000 Btuh, space

is considered a conﬁned space.

4. Determine building type. A building of unusually

tight construction has the following characteristics:

B. Appliance is design certiﬁed for installation on

combustible ﬂooring. Do not install boiler on

carpeting.

a. Walls and ceiling exposed to outside atmosphere

have a continuous water vapor retarder with a

rating of 1 perm or less with openings gasketed

and sealed, and;

C. Provide clearance between boiler jacket and

combustible material in accordance with local ﬁre

ordinance. Refer to Figure 1 for minimum listed

clearance from combustible material. Recommended

service clearance is 24 inches from left side, right

side and front. Service clearances may be reduced to

minimum clearances to combustible materials.

b. Weather-stripping has been added on openable

windows and doors, and;

c. Caulking or sealants applied in joints around

window and door frames, between sill plates and

ﬂoors, between wall-ceiling joints, between wall

panels, at plumbing and electrical penetrations,

and at other openings.

D. Install 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 boiler, water and all

additional system components.

5. For boiler located in an unconﬁned space in a

building of other than unusually tight construction,

adequate combustion and ventilation air is normally

provided by fresh air inﬁltration through cracks

around windows and doors.

E. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation

and service (circulator replacement, condensate trap,

control replacement, etc.).

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

ꢂ

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. Size each opening per

following:

space(s) of sufﬁcient volume such that combined

volume of all spaces meet criteria for unconﬁned

space. Size each opening for minimum free area

of one (1) square inch per 1,000 Btu per hour

input of all equipment in spaces, but not less than

100 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. Louvers and

grilles must be ﬁxed in open position or interlocked

with equipment to open automatically before burner

operation. Screens must not be smaller than ¼ inch

mesh.

a. Direct communication with outdoors. Minimum

free area of one (1) square inch per 4,000 Btu per

hour input of all equipment in space.

b. Vertical ducts. Minimum free area of one (1)

square inch per 4,000 Btu per hour input of all

equipment in space. Duct cross-sectional area

shall be same as opening free area.

Consider the blocking effect of louvers, grilles and

screens when calculating the opening size to provide

the required free area. If free area of louver or grille

is not known, assume wood louvers have 20-25

percent free area and metal louvers and grilles have

60-75 percent free area.

c. Horizontal ducts. Minimum free area of one (1)

square inch per 2,000 Btu per hour input of all

equipment in space. Duct cross-sectional area

shall be same as opening free area.

Alternate method for boiler located within

conﬁned space. Use indoor air if two permanent

openings communicate directly with additional

CAUTION

Avoid operating this boiler in an environment where saw dust, loose insulation ﬁbers, dry wall dust, etc.

are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and

inspected daily to insure proper operation.

II. Unpack Boiler

WARNING

CAUTION

Installation of this boiler should be undertaken

only by trained and skilled personnel from a

qualiﬁed service agency.

Do not drop boiler. Do not bump boiler jacket

against ﬂoor.

A. Move boiler to approximate installed position.

E. Tilt the boiler to its front side or back side and slide a

B. Remove all crate fasteners.

wooden slat under the three raised feet.

C. Lift and remove outside container. Save two of the

wooden slats from the container sleeve for use in Steps

E and F.

F. Tilt the boiler in the opposite direction and slide

another wooden slat under the three raised feet.

G. Slide the boiler left or right off the skid using the two

D. Remove all boiler hold-down fasteners.

wooden slats as runners.

H. Move boiler to its permanent location.

III. Venting

WARNING

Do not use this boiler with galvanized, Type ꢁ04 or Type ꢁ1ꢂ stainless steel, non metallic or any other

non ALꢀ9-4C^®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.).

This appliance needs fresh air for safe operation and must be installed so there are provisions for

adequate combustion and ventilation air.

Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation

instructions of this manual.

Do not operate appliance where gasoline or other ﬂammable vapors or liquids, or sources of hydro-

carbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used,

stored and/or present in the air.

When installing vent pipe through chimney, no other appliance can be vented into the chimney.

Do not exceed maximum vent lengths. Refer to Table 4.

Table 1: Vent System Options

Installation

Additional

Drawing and

Speciﬁcation

(See Section)

Option

Description

Vent Kit

Required

Power Vent (air from within building) the vent pipe terminates

horizontally (through a sidewall).

1. Horizontal

2. Vertical

Power Vent (air from within building) the vent pipe terminates

vertically (through the roof).

Table ꢀ: Vent System Components Included with Boiler

Vent System Components

Part Number

Gasketed Vent Terminal 3” -Horizontal PVG-3 thru PVG-7)

Gasketed Vent Terminal 4” -Horizontal (PVG-8 & PVG 9)

8110701

8110702

Table ꢁ: Burnham Vent System Components

Equivalent

Vent System Component Part Number

Feet of Pipe

3” Dia. Pipe x 1 Ft

4” Dia. Pipe x 1 Ft

3” Dia. Pipe x 3 Ft

4” Dia. Pipe x 3 Ft

3” Dia. Pipe x 5 Ft

4” Dia. Pipe x 5 Ft

3” Dia. Pipe x Adjustable

8116296U

100176-01

8116298U

100177-01

8116300U

100178-01

8116319U

Equal to

Installed Length

(1.06 TO 1.64)

4” Dia. Pipe x Adjustable

100179-01

3” Dia. 90° Elbow

8116294U

100180-01

8116292U

100181-01

8116302U

100182-01

8116304U

100183-01

8116116

4” Dia. 90° Elbow

3” Dia. 45° Elbow

4” Dia. 45° Elbow

3” Dia. Horizontal Drain Tee

4” Dia. Horizontal Drain Tee

3” Dia. Vertical Drain Tee

4” Dia. Vertical Drain Tee

3” Single Wall Thimble

4” Single Wall Thimble

3” Double Wall Thimble

4” Double Wall Thimble

7½

---

100184-01

8116115

100185-01

Table 4: Vent Length

3” Vent Pipe

(Equiv. Ft.)

Min. Max.

4” Vent Pipe

(Equiv. Ft.)

Model

Min.

---

Max.

---

PVG-3 & PVG-4

PVG-5 & PVG-6

PVG-7

---

PVG-8 & PVG-9

---

A. Vent Guidelines Due to Removal of an Existing

Boiler

B. General Guidelines

1. Vent system installation must be in accordance

with National Fuel Gas Code, NFPA 54/ANSI

Z221.3 or applicable provisions of local building

codes. Contact local building or ﬁre ofﬁcials about

restrictions and installation inspection in your area.

For installations not involving the replacement of an

existing boiler, proceed to Step B.

When an existing boiler is removed from a common

venting system, the common venting system is likely

to be too large for proper venting of the remaining

appliances. At the time of removal of an existing

boiler, the following steps shall be followed with each

appliance remaining connected to the common venting

system placed in operation, while the other appliances

remaining connected to the common venting system are

not in operation:

2. Refer to the appropriate drawings in this section of

this manual to determine the proper conﬁguration of

venting system. See Table 1.

3. This appliance requires a Special Gas Vent. The

productisdesignedtouseBurnhamsuppliedAL29-4C^®

StainlessSteelventsystemcomponents.Thefollowing

manufacturers offer similar AL 29-4C^®components

and are approved for use with this product. Heat-Fab

Inc.-Saf-T-Vent(800-772-0739);Flex-LInternational

Inc. - Star-34 (800-561-1980); Z-Flex U. S., Inc.

- Z-Vent (800-654-5600); and Protech Systems, Inc.-

FasNSeal™ (800-766-3473) or equivalent. The use

of these alternate manufacturer’s venting systems will

require adapters to connect to the Burnham supplied

vent connector and vent terminal. These adapters are

notsuppliedwiththisunitandshouldbeobtainedfrom

the supplier of the alternate manufacturer’s venting

system. See Table 3 for complete list of Burnham

Vent System Components.

1. Seal any unused openings in the common venting

system.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion, and other

deﬁciencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the common

venting system are located and other spaces of the

building. Turn on clothes dryers and any appliance

not connected to the common venting system.

Turn on any exhaust fans, such as range-hoods and

bathroom exhausts, so they will operate at maximum

speed. Do not operate a summer exhaust fan. Close

ﬁreplace dampers.

4. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope away from boiler.

5. 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.

4. Place in operation the appliance being inspected.

Follow the Lighting (or Operating) Instructions.

Adjust thermostat so appliance will operate

continuously.

6. Vent length restrictions are based on equivalent

length of vent pipe (total length of straight pipe

plus equivalent length of ﬁttings). Maximum

vent lengths are listed in Table 4. Do not exceed

maximum vent lengths. Table 3 lists equivalent

lengths for ﬁttings. Do not include vent terminals in

equivalent feet calculations.

5. Test for spillage at the draft hood relief opening

after ﬁve (5) minutes of main burner operation. Use

the ﬂame of a match or candle, or smoke from a

cigarette, cigar or pipe.

6. After it has been determined that each appliance

remaining connected to the common venting system

properly vents when tested as outlined above, return

doors, windows, exhaust fans, ﬁreplace dampers and

any other gas burning appliance to their previous

conditions of use.

7. Provide and maintain vent pipe minimum clearances

to combustible materials. Vent pipe minimum

clearance to combustible material is four (4) inches

when vent is installed in a fully enclosed (chase)

application or three (3) inches when vent is installed

with at least one side open, similar to a joist bay

application. Use double wall thimble [Burnham

Part No. 8116115 (3”), 100185-01 (4”)] when

penetrating a combustible wall.

7. Any improper operation of the common 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 should be resized to approach the minimum

size as determined using the appropriate tables in

Part II in the National Fuel Gas Code, NFPA 54/

ANSI Z223.1.

8. Do not install venting system components on

the exterior of the building except as speciﬁcally

required by these instructions. The vent termination

location is restricted as follows:

a. Minimum twelve (12) inches above grade plus

normally expected snow accumulation level, or

seven (7) feet above grade if located adjacent

to public walkway. Do not install over public

walkway where local experience indicates

appliance ﬂue gas vapor or condensate creates a

nuisance or hazard.

requires a minimum installed length of 12¾ inch

and can adjust across a 7 inch gap up to a maximum

of 19¾ inch long. (Note for the adjustable pipe

the installed length should be measured from the

centerline of the bead on the male end of the ﬁrst

pipe to the end of the female pipe excluding the

locking band of the second pipe with a single

gasket.) Only in the event the adjustable length pipe

is not sufﬁcient a standard length pipe may be cut

using the procedure outlined below for the Gasket-

Less Vent System.

b. Minimum three (3) feet above any forced air

inlet located within ten (10) feet.

c. Minimum four (4) feet below, four (4) feet

horizontally from, or four (4) feet above any

door, window, or gravity air inlet.

WARNING

d. Minimum four (4) feet horizontally from electric

meters, gas meters, regulators, and relief valves.

This distance may be reduced if equipment is

protected from damage due to condensation or

vapor by enclosure, overhangs, etc.

Never exceed maximum installed length of 19¾

inches for adjustable length pipe.

Risk of ﬂue gas leakage is possible.

e. Minimum twelve (12) inches from overhang or

corner of building.

NOTICE

9. Enclose vent passing through occupied or

unoccupied spaces above the boiler with material

having a ﬁre resistance rating of at least equal to the

rating of the adjoining ﬂoor or ceiling. Maintain

minimum clearances to combustible materials. See

Figure 1.

Cut must be square with pipe and ﬁled or

sanded smooth before joining. Carefully ensure

roundness of cut pipe by hand with gloves before

installing. Seal joint with RTV speciﬁed in this

manual.

Note: For one or two family dwellings, ﬁre

resistance rating requirement may not need to be

met, but is recommended.

C. Install Vent Pipe, Burnham Gasketed Vent System.

1. Procedure for Joining Burnham Gasketed Vent Pipe

and Fittings. See Figure 3.

10. Plan venting system to avoid possible contact with

plumbing or electrical wires. Start at vent connector

on top of boiler and work towards vent terminal.

a. Wipe the male end of each joint using an alcohol

pad to remove any dirt and grease.

b. Align weld seams in pipes and use a slight

twisting motion to FULLY insert male end into

female end of joint. Ensure bead in male end

of pipe is below locking band and rest against

the end of the female pipe. Verify the factory-

installed gasket is not dislodged or cut.

11. Once a vent pipe manufacturer and system is chosen

never mix and match vent systems.

12. If a non-standard length pipe is required:

Gasketed Vent System: The use of the adjustable

length pipe (P/N 8116319U) is recommended to

complete a non-standard pipe length. This pipe

Figure ꢁ: Burnham Gasketed Vent Joint Detail

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!

4. Use appropriate 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 ID, OD and vent holes with

sealant material. Install inside ﬂange to inside wall,

secure with nails or screws, and seal with sealant

material.

d. Once the installation is complete, operate

appliance and inspect all joints to ensure that ﬂue

gases and/or liquid condensate will not escape.

5. For noncombustible wall application when thimble

is not used, size opening such that bell with locking

band attached cannot pass through.

D. Horizontal Venting System. See Figures 4, 4A and 5.

Vent Piping –

1. This boiler is supplied with components as standard

equipment for installation of the separate horizontal

venting system.

6. Join vent terminal to vent pipe. See Figure 5.

7. Insert vent pipe through thimble/opening from

outside and join to vent system. Apply sealant

between vent pipe and opening/thimble to provide

weathertight seal.

2. Do not exceed maximum vent lengths. Refer to

Table 4.

3. Recommended horizontal installation consists of

vent being sloped down ¼ inch per foot away from

boiler. See Figures 4 and 4A.

1ꢀ

1ꢁ

E. Vertical Venting System - See Figures 6, 7 and 8.

NOTICE

Roof penetrations require the use of roof ﬂashing

and storm collar - not supplied with boiler.

Maintain minimum clearance to combustible

materials.

Vent Piping –

1. Do not exceed maximum vent lengths. Refer to

Table 4.

6. Install Vent Terminal.

a. Size roof opening to maintain minimum

clearance from combustible materials.

2. Installation of a vertical vent tee 8116304U is

required on all vertical vent applications. See

Figures 6 and 7. Attach vertical vent drain tee

directly to elbow or horizontal pipe from an elbow

immediately after vent connector.

b. Extend vent pipe to maintain minimum vertical

and horizontal distance of twelve (12) inches

from roof surface. Allow additional vertical

distance for expected snow accumulation.

Provide brace as required. Refer to Figure 8.

3. Slope horizontal runs minimum ¼ inch per foot.

Slope towards vertical vent drain tee. Position weld

seams in vent pipes, in all horizontal runs, at the top

to avoid condensate from lying on the seams.

c. Install storm collar on vent pipe immediately

above ﬂashing. Apply Dow Corning Silastic 732

RTV Sealant between vent pipe and storm collar

to provide weathertight seal.

4. Install ﬁre stops where vent passes through ﬂoors,

ceilings or framed walls. The ﬁre stop must close

the opening between the vent pipe and the structure.

d. Attach vent terminal.

5. Whenever possible, install vent straight through

the roof. Refer to Figure 7 if offset is necessary.

1ꢂ

F. Optional Exterior Separate Horizontal Vent Terminal Mounting – See Figure 9.

b. After penetrating wall/thimble, install an

1. Do not exceed maximum vent lengths. Refer to

Table 4.

AL 29-4C^®90° elbow so that elbow leg is in the

up direction.

2. This installation will allow a maximum of seven

(7) feet vertical exterior run of the vent piping to be

installed .

c. Install maximum of ﬁve (5) feet of AL 29-4C^®

vent pipe. Refer to Sections C through E for

proper procedures for joining vent pipe and

ﬁttings.

d. Install AL 29-4C^®45° elbow to upper AL 29-4C^®

90° elbow so that leg of 45° is in down direction

(see Figure 9).

NOTICE

Exterior run to be included in equivalent vent

lengths.

f. Install vent terminal.

3. Install vent piping.

g. Brace piping if required.

a. Install vent piping for desired venting system.

Refer to speciﬁc section for details for vent pipe

installation.

Figure 9: Horizontal Vent Terminal Installation (3” Vent [left view] or 4” Vent [right view])

IV. Water Piping and Trim

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and

can lead to boiler failure. Burnham’s Standard Warranty does not cover problems caused by oxygen

contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water and

frequent water additions.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply

or return piping. The minimum safe water level of a

water boiler is at the uppermost top of the boiler; that is,

it must be full of water to operate safely.

1. There are many possible causes of oxygen

contamination such as:

a. Addition of excessive make-up water as a result

of system leaks.

What Kind

b. Absorption through open tanks and ﬁttings.

c. Oxygen permeable materials in the distribution

system.

The PVG boiler is designed to accept the wiring of the

Safgard Model 1100-H4 LWCO (P/N 100592-01). This

is a probe type LWCO. The factory wiring is designed

to allow simple “Plug-in” installation of the wiring.

2. In order to insure long product life, oxygen sources

must be eliminated. This can be accomplished by

taking the following measures:

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

a. Repairing system leaks to eliminate the need for

addition of make-up water.

b. Eliminating open tanks from the system.

c. Eliminating and/or repairing ﬁttings which allow

oxygen absorption.

d. Use of non-permeable materials in the

distribution system.

e. Isolating the boiler from the system water by

installing a heat exchanger.

f. Use properly designed and operating air

elimination devices in water piping.

B. Low Water Cut Off (LWCO) on Hot Water Boilers

(Optional)

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.

LWCO Location

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch

connection must have a minimum diameter to prevent

bridging between the probe and the tee. Also, the run

of the tee must have a minimum diameter to prevent

the end of the probe from touching or being located too

close to the inside wall of the run of the tee.

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.

baseboard on the same ﬂoor level as the boiler). In

addition, some jurisdictions require the use of a LWCO

with a hot water boiler.

Ideally, manual shutoff valves should be located

above the LWCO and the boiler to allow for servicing.

This will allow probe removal for inspection without

draining the heating system. Many probe LWCO

manufacturers recommend an annual inspection of the

probe.

ꢀ0

How to Wire

Ensure power is turned off to boiler.

Locate the LWCO jumper wire in the factory wiring

harness. Remove the jumper wire and install

the LWCO wiring from LWCO Model 1100-H4

(P/N 100592-01) into the plug of the PVG factory

wiring.

WARNING

Pressure relief valve discharge piping must be

piped such that the potential of severe burns

is eliminated. DO NOT pipe in any area where

freezing could occur. DO NOT install any shut-off

valves, plugs or caps. Consult Local Codes for

proper discharge piping arrangement.

How to Test

Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand

by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by ﬁlling the system.

The boiler should attempt to operate once the water

level is above the LWCO.

F. 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.

G. 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 10.

NOTICE

Ensure the location of the LWCO in the piping will

allow for connection of the LWCO wiring harness

to the factory wiring of the PVG.

H. If boiler is connected to heating coils located in

air handling units where they may be exposed to

refrigerated air, boiler piping must be equipped with

ﬂow control valves to prevent gravity circulation of

boiler water during operation of cooling system.

C. Connect system supply and return piping to

boiler. See Figures 11 and 12. Maintain minimum ½

inch clearance from hot water piping to combustible

materials.

NOTICE

Burnham recommends sizing the system

circulator to supply sufﬁcient ﬂow (GPM) to allow a

ꢀ0°F temperature differential in the system. When

sizing the system circulator, the pressure drop of

all radiators, baseboard and radiant tubing and all

connecting piping must be considered.

D. Install circulator with ﬂanges, gaskets and bolts

provided. Circulator harness allows circulator to be

mounted on supply or return. Connect harness to

circulator and secure any excess conduit.

E. Install supply manifold, pressure/temperature gauge

and pressure relief valve.

Figure 10: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

See Figure 10A. Pressure Relief Valve must be installed

with spindle in vertical position. Installation of the

relief valve must comply with the ASME Boiler and

Pressure Vessel Code, Section IV.

I. Use a boiler bypass if the boiler is to be operated

in a system which has a large volume or excessive

radiation where low boiler water temperatures may be

encountered (i.e. converted gravity circulation system,

etc.).

ꢀ1

Figure 10A: Supply Water Manifold Piping

Install pipe tee between circulator and boiler return

J. After the boiler and system have been cleaned and

ﬂushed, and before reﬁlling the entire system add

appropriate water treatment chemicals, if necessary, to

bring the pH between 7 and 11.

along with second tee in supply piping as shown in

Figure 11 or 12. Bypass should be same size as the

supply and return lines with valves located in bypass

and supply outlet as illustrated in Figure 11 or 12 in

order to regulate water ﬂow to maintain higher boiler

water temperatures.

After the boiler is operational (reference Section VIII.

System Start-Up) set by-pass and boiler supply valves

to half throttle position to start. Operate boiler until

system water temperature reaches normal operating

range.

K. If it is required to perform a long term pressure

test of the hydronic system, the boiler should ﬁrst be

isolated to avoid a pressure loss due to the escape of air

trapped in the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must ﬁrst be removed from the

boiler.

Adjust valves to provide 180° to 200°F supply water

temperature. Opening the boiler supply valve will raise

system temperature, while opening the by-pass valve

will lower system supply temperature.

A loss of pressure during such a test, with no visible

water leakage, is an indication that the boiler contained

trapped air.

ꢀꢀ

ꢀꢁ

ꢀ4

V. Gas Piping

WARNING

Table 7 for maximum capacity of Schedule 40 pipe.

Table 8 lists equivalent pipe length for standard

ﬁttings.

Failure to properly pipe gas supply to boiler may

result in improper operation and damage to the

boiler or structure. Always assure gas piping is

absolutely leak free and of the proper size and

type for the connected load.

4. Corrections for the speciﬁc gravity of natural gas

can be found in Table 6.

Table 6: Speciﬁc Gravity Correction Factors for

An additional gas pressure regulator may be

needed. Consult gas supplier.

Natural Gas

Speciﬁc

Gravity

Correction

Factor

Speciﬁc

Gravity

Correction

Factor

A. Size gas piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

---

0.85

0.90

1.00

1.10

1.20

1.30

1.40

0.81

0.82

0.78

0.74

0.71

0.68

0.66

1. Allowable pressure drop from point of delivery to

boiler. Maximum allowable system pressure is ½

psig. Actual point of delivery pressure may be less;

contact gas supplier for additional information.

Minimum gas valve inlet pressure is stamped on

the rating label located in the boiler’s vestibule

compartment.

---

0.60

0.65

0.70

0.75

0.80

1.00

0.96

0.93

0.90

0.87

2. Maximum gas demand. Refer to the boiler’s input as

printed on its rating label. Also consider existing and

expected future gas utilization equipment (i.e. water

heater, cooking equipment).

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, NFPA54/ANSI

Z223.1, or size system using standard engineering

methods acceptable to authority having jurisdiction.

3. Length of piping and number of ﬁttings. Refer to

Table 5: Gas Ratings

Boiler

Model

Number Gas Pressure

Natural/LP

Maximum

Minimum Natural

Gas Pressure

(in. w.c.)

Minimum LP

Gas Pressure

(in. w.c.)

Natural

Manifold

Pressure

(in. w.c.)

Manifold

Pressure

(in. w.c.)

Inlet to Gas Valve Inlet to Gas Valve

PVG-3

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

4.5

11.5

3.5

10.5

NOTICE

PVG boilers built for altitudes greater than 4,999 feet above sea level need to be specially oriﬁced to adjust for

changes in atmospheric conditions. The PVG boiler “H” Model has been certiﬁed to operate in atmospheric

conditions from 5,000 to 10,000 feet above sea level. Input is derated by 10% for applications at 5,000 feet

above sea level, and ꢀ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.

For applications above 10,000 feet, consult the manufacturer.

ꢀ5

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

[Feet]

132

278

190

152

130

115

105

1¼

1,050

730

590

500

440

400

370

350

320

305

175

120

1¼

1,400

950

770

660

580

530

490

460

430

400

100

520

350

285

245

215

195

180

170

160

150

360

250

200

170

151

138

125

118

110

103

680

465

375

320

285

260

240

220

205

195

* 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.

2. Use thread (joint) compounds (pipe dope) resistant

B. Connect boiler gas valve to gas supply system.

to action of liqueﬁed petroleum gas.

3. Install sediment trap, ground-joint union and manual

shut-off valve upstream of boiler gas control valve

and outside jacket. See Figure 13.

WARNING

Failure to use proper thread compounds on all

gas connectors may result in leaks of ﬂammable

gas.

WARNING

Gas supply to boiler and system must be

absolutely shut off prior to installing or servicing

boiler gas piping.

1. Use methods and materials in accordance with local

plumbing codes and requirements of gas supplier. In

absence of such requirements, follow National Fuel

Gas Code, NFPA 54/ANSI Z223.1.

Figure 1ꢁ: Recommended Gas Piping

Table 8: Equivalent Lengths of Standard Pipe Fittings & Valves

VALVES FULLY OPEN

Pipe

Size

I.D.

Inches

Swing

Check

90°

Elbow

45°

Elbow

90° Tee, Flow

Through Run Through Branch

90° Tee, Flow

Gate

Globe

Angle

½”

¾”

0.622

0.824

1.049

1.380

0.35

0.44

0.56

0.74

18.6

23.1

29.4

38.6

9.3

4.3

5.3

6.8

8.9

1.6

2.1

2.6

3.5

0.78

0.97

1.23

1.60

1.0

1.4

1.8

2.3

3.1

4.1

5.3

6.9

11.5

14.7

19.3

1”

1¼”

ꢀꢂ

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.

at ½ psig or less, isolate boiler from gas supply

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.

DANGER

1. Protect boiler gas control valve. For all testing over

½ psig, boiler and its individual shutoff valve must

be disconnected from gas supply piping. For testing

Do not use matches, candles, open ﬂames or

other ignition source to check for leaks.

ꢀ7

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. Make sure all power is off before attempting any

electrical work.

Each boiler must be protected with a properly sized over-current device.

Never jump out or make inoperative any safety or operating controls.

The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with

a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls

used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

service switch such that the boiler can be shut-off

without exposing personnel to danger in the event of

an emergency. Connect the main power supply and

ground to the three (3) boiler wires (black, white and

green) located in the junction box at the inside top of

the boiler jacket. If a low water cutoff is to be used,

connect the low water cutoff so that all 120V power

to boiler is interrupted if the low water cutoff’s switch

opens.

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in

the absence of such requirements, follow the National

Electrical Code, NFPA 70, and/or CSA C22.1 Electrical

Code.

B. A separate electrical circuit must be run from

the main electrical service with an over-current

device/disconnect in the circuit. A service switch is

recommended and may be required by some local

jurisdictions. Install the service switch in the line

voltage “Hot” leg of the power supply. Locate the

C. Refer to Figures 14 and 15 for details on the internal

boiler wiring.

NOTICE

This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler.

This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the

limit control. Certain Local Codes require an additional water temperature limit. In addition, certain types

of systems may operate at temperatures below the minimum set point of the limit contained in the boiler.

If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat) located in the system

piping as shown in the Water Piping and Trim Section of this manual. Wire as indicated in the Electrical

Section of this manual.

NOTICE

All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.

ꢀ8

ꢀ9

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

ꢁ0

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. Single Zone Heating System – Refer to Figure 16 of this manual for the electrical diagram for this type of system.

Set the thermostat heat anticipator to 0.60 amps.

6. Single Zone Heating System with Alliance™ Water Heater - Refer to Figure 17 of this manual for the electrical diagram

for this type of system.

Set the thermostat heat anticipator to 0.60 amps.

7. Conventional Circulator Zoned System – Refer to Figure 18 of this manual for the electrical diagram for this type of

system.

Read, understand and follow all of the instructions provided with the Honeywell R8888 control.

Connect the thermostat of each zone and the circulator for that zone to R8888 panel. If an Alliance™ indirect water

heater is used, connect the Alliance™ thermostat and circulator to the Zone 1 terminals of the R8888.

Set the thermostat heat anticipator to 0.12 amps.

NOTICE

The Honeywell R8888 Control is available in a three (ꢁ) zone Model (R8888A) and a four (4) zone Model

(R8888B). Up to four (4) R8888’s may be used together to provide control for up to twelve (1ꢀ) individual

zones. Only one (1) zone, the ﬁrst zone of the main control, will provide priority circulation. If more than

four (4) zones are required, connect additional R8888’s by wiring the A, B, and C terminals of each control

together. Each R8888 requires a 120 volt power supply. If more than one (1) R8888 is used, set the panel

type switch to “main” on the ﬁrst R8888 and set the panel type switch to “expansion” on the second, third

or fourth R8888.

8. Conventional Zone Valve Zoned System – Refer to Figure 19. Wiring to the most popular models of zone valves is given

in Figure 20.

Connect the thermostat of each zone and the zone valve for that zone to the R8889 control. If an Alliance™ indirect water

heater is used, connect the Alliance™ thermostat and zone valve to the “zone 1” terminals of the R8889.

Set the thermostat heat anticipator to 0.12 amps.

NOTICE

The Honeywell R8889 Control is available in two three (ꢁ) zone models and two four (4) zone models.

Burnham recommends using Model R8889A for three (ꢁ) zone systems and Model R8889B for four (4) zone

systems. Models R8889C and R8889D have less load capacity and may not operate with certain types of

zone valves. Up to four (4) R8889’s may be used together to provide up to sixteen (1ꢂ) individual zones.

Only one (1) zone, the ﬁrst zone of the main control will provide priority zoning for the Alliance indirect

water heater. If more than four (4) zones are required, connect additional R8889’s by wiring the A, B and

C terminals of each control together. Each R8889 requires a 120 volt power supply. If more than one (1)

R8889 is used, set the panel type switch to “main” on the ﬁrst R8889 and set the panel type switch to

“expansion” on the second, third or fourth R8889.

ꢁ1

ꢁꢀ

NOTICE

If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing

below.

ꢁꢁ

ꢁ4

ꢁ5

Figure ꢀ0: Different Manufacturer’s Zone Valve Connections to Honeywell R8889

ꢁꢂ

VII. Modular Installation

A. General Guidelines

E. Gas Piping

1. Refer to National Fuel Gas Code, Local Codes and

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.

Tables 7 and 8 for gas pipe sizing.

Table 9: Modular Boiler Water Manifold Sizing

2. Consult Local Building Codes or National Fuel Gas

Code, NFPA 54/ANSI Z222.3 for restrictions and

instructions on modular boiler installations.

Recommended Minimum

Combined Output

Common Water Manifold

(MBH)

Size (NPT)

< 166

< 260

< 550

< 900

< 2000

1¼”

1½”

2”

B. Module Sizing

Burnham recommends sizing each boiler in a modular

system to provide 20 % of the combined heating load

where ever possible.

2½”

3”

C. Venting

1. Each boiler must have an individual vent pipe.

Refer to Venting Section of this manual for venting

guidelines and options.

2. Each boiler must be piped as shown in Figure 13.

WARNING

Do not manifold vent pipes together.

If gas pressure in the building is above ½ psig,

an additional gas pressure regulator is required.

Using one additional regulator for multiple

boilers may result in unsafe boiler operation.

The additional regulator must be able to properly

regulate gas pressure at the input of the smallest

boiler. If the regulator cannot do this, two or

more additional regulators are required. Consult

regulator manufacturer and/or local gas supplier

for instructions and equipment ratings.

2. The maximum vent length for each boiler is ﬁfty

(50) equivalent feet.

3. The minimum horizontal distance between vent

terminations is one (1) foot. Additional horizontal

distance is desirable to avoid frost damage to the

building. Vent terminations must be at least twelve

(12) inches above the ground plus the expected

snow accumulation.

F. Electrical

CAUTION

1. Each boiler must be provided with a fused

disconnect and service switch.

Installing multiple vent terminations close

together promotes frost buildup on buildings.

To minimize this possibility, extend the distance

from the building to the end of the vent

termination and increase the horizontal distance

between terminations.

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.

G. Modular Boiler Control Systems

4. Multiple vertical vent pipes may be piped through

a common conduit or chase so that one roof

penetration may be made. Each vent termination

must be one (1) foot from other terminations.

Contact a controls manufacturer such as Honeywell or

Tekmar to properly apply a modular control system.

Common systems may use outdoor temperature, return

water temperature or both to stage the boilers.

D. Water Piping (See Table 9 and Figure 21)

Installing a low water cutoff in the system piping of

modular systems is strongly recommended and may be

required by Local Codes.

ꢁ7

ꢁ8

VIII. System Start-up

4. Starting with one circuit at a time, open zone valve

or shut-off valve in system supply and return piping.

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 Low-

Pressure Steam and Hot Water Boilers, ANSI Z21.13.

5. Open hose bib.

6. Open ﬁll valve (Make-up water line should be

located directly after full port ball valve in system

supply piping between air scoop and expansion

tank).

B. Verify that the venting, water piping, gas piping and

electrical system are installed properly. Refer to

installation instructions contained in this manual.

7. Allow water to overﬂow from bucket until discharge

from hose is bubble free for 30 seconds.

C. Conﬁrm all electrical, water and gas supplies are

turned off at the source and that vent is clear of

obstructions.

8. Close the opened zone valve or shut-off valve for

the zone being purged of air, then open the zone

valve or shut-off valve for the next zone to be

purged. Repeat this step until all zones have been

purged. At completion, open all zone valves or

shut-off valves.

D. Conﬁrm that all manual shut-off gas valves between

the boiler and gas source are closed.

WARNING

9. Close hose bib, continue ﬁlling the system until the

pressure gauge reads 12 psi. Close ﬁll valve.

Completely read, understand and follow all

instructions in this manual before attempting

start up.

(Note - If make-up water line is equipped with

pressure reducing valve, system will automatically

ﬁll to 12 psi. Follow ﬁll valve manufacturer’s

instructions).

E. Fill entire heating system with water and vent air

from system. Use the following procedure on a Series

Loop or multi-zoned system installed as per Figure 11

or 12 to remove air from system when ﬁlling.

10.Open isolation valve in boiler supply piping.

11.Remove hose from hose bib.

F. Conﬁrm that the boiler and system have no water

WARNING

leaks.

The maximum operating pressure of this boiler

is ꢁ0 psig. Never exceed this pressure. Do not

plug or change pressure relief valve.

G. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot)

from gas supplier.

2. Connect manometer to pressure tap on gas valve.

Use 1/8 NPT tapping provided.

NOTICE

If it is required to perform a long term pressure

test of the hydronic system, the boiler should

ﬁrst be isolated to avoid a pressure loss due to

the escape of air trapped in the boiler.

3. Temporarily turn off all other gas-ﬁred appliances.

4. Turn on gas supply to the boiler gas piping.

5. Conﬁrm that the supply pressure to the gas valve is

14 in. w.c. or less. Refer to Table 5 for minimum

supply pressure.

To perform a long term pressure test including

the boiler, ALL trapped air must ﬁrst be removed

from the boiler.

6. Open the ﬁeld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

A loss of pressure during such a test, with no

visible water leakage, is an indication that the

boiler contained trapped air.

7. Using soap solution, or similar non-combustible

solution, electronic leak detector or other approved

method. Check that boiler gas piping valves, and

all other components are leak free. Eliminate any

leaks.

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).

DANGER

3. Attach a hose to the vertical hose bib located prior to

the full port ball valve in the system supply piping.

(Note - Terminate hose in ﬁve gallon bucket at a

suitable ﬂoor drain or outdoor area).

Do not use matches, candles, open ﬂames or

other ignition source to check for leaks.

8. Purge gas line of air.

ꢁ9

Figure ꢀꢀ: Operating Instructions

numbers in the wiring ladder diagrams. The yellow

LED indicates the status of the ﬂame, see Table 11.

The green LED indicates the status of the system,

see Table 12. See Figure 23 for LED locations. See

Figure 24 for Troubleshooting Guide.

H. Operating Instructions

1. Follow Operating Instructions to place boiler in

operation. See Figure 22.

2. Electronic Ignition Modules with LED indicators.

Table 10 cross-references the ignition module

terminal designations to the ignition terminal

Table 10: Ignition Module Terminal

Cross-Reference

Ignition Module

Wiring Ladder Diagram

Terminal Designation

Terminal Number

MV/PV

GND

24V (GND)

24V

SPARK

Figure ꢀꢁ: LED Locations

TABLE 11: Yellow LED Flame Codes

Yellow LED

Indicates

Recommended Service Action

Flash Code^a

Heartbeat

Normal Flame Signal

N/A

Weak Flame Signal -

System will operate reliably but ﬂame signal is

less than desired.

Note: This indication may ﬂash temporarily

during or shortly after lightoff on some appli-

cations.

Perform routine maintenance to

assure optimum ﬂame signal.

Marginal Flame Signal (less than 1.1 µA) -

System may not operate reliably over time.

Service call recommended.

Note: This indication may ﬂash temporarily

during or shortly after lightoff on some appli-

cations.

Check gas supply, pilot burner, ﬂame

sense wiring, contamination of ﬂame

rod, burner ground connection.

No Flame or Flame Signal -

Below minimum threshold for system opera-

tion.

OFF

N/A

^aFlash Code Descriptions

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- The ﬂash code number signiﬁes that the LED ﬂashes X times at 2Hz, remains off for two

seconds, and then repeats sequence.

Table 1ꢀ: Green LED Status Codes

Green LED

Flash Code

Indicates

Next System Action

Recommended Service Action

(X + Y)^a

OFF

No “Call for Heat”

N/A

None

Startup - Flame sense

calibration

Flash Fast

Heartbeat

Normal operation

If system fails to light on next trial

for ignition check gas supply, pilot

burner, spark and ﬂame sense wir-

ing, ﬂame rod contamination or out

of position, burner ground connec-

tion.

5 minute Retry Delay-

Pilot ﬂame not detected

during trial for ignition

Initiate new trial for ignition after retry

delay completed.

If system fails to light on next trial

for ignition check gas supply, pilot

burner, ﬂame sense wiring, ﬂame

rod contamination, burner ground

connection.

Initiate new trial for ignition. Flash

code will remain through the ignition

trial until ﬂame is proved.

Recycle- Flame failed

during run

If situation self corrects within 10

Check for pilot ﬂame. Replace gas

valve if pilot ﬂame present. If no

pilot ﬂame, cycle “Call for Heat.” If

error repeats, replace control.

seconds, control returns to normal

sequence. If ﬂame out of sequence re-

mains longer than 10 seconds, control

goes to Flash code 6+4 (see below)

Flame sensed out of

sequence

Check ﬂame sense lead wire for

damage or shorting. Check that

the fault corrects, control resumes nor- ﬂame rod is in proper position.

mal operation after a one minute delay. Check ﬂame rod ceramic for cracks,

damage or tracking.

Control remains in wait mode. When

Flame sense leakage to

ground

Check transformer and AC line for

Control remains in wait mode. When

proper input voltage to the control.

Low secondary voltage

supply- (below 15.5 Vac)

the fault corrects, control resumes nor-

Check with full system load on the

mal operation after one minute delay.

transformer.

Check gas supply, pilot burner, spark

5 minute Retry Delay-

On every third retry on

same “Call for Heat”

Initiate new trial for ignition after retry

delay completed.

and ﬂame sense wiring, ﬂame rod

contamination or out of position,

burner ground connection.

6 + 2

6 + 3

6 + 4

On every 6th ﬂame

failure during run on the

same “Call for Heat”

Check gas supply, pilot burner, ﬂame

sense wiring, contamination of ﬂame

rod, burner ground connection.

5 minute retry delay, then initiate new

trial for ignition.

Control waits until ﬂame is no longer

sensed and then goes to soft lockout.

Flash code continues. Control auto

Check for pilot ﬂame. Replace gas

valve if pilot ﬂame present. If no

pilot ﬂame, cycle “Call for Heat.” If

Flame sensed out of

sequence- longer than

10 seconds

resets from soft lockout after one hour. error repeats, replace control.

Soft lockout due to error

detected during self

check sequences

Control auto resets from soft lockout

after one hour.

Reset by cycling “Call for Heat.” If

error repeats, replace the control

^aFlash Code Descriptions:

Flash Fast: rapid blinking

Heartbeat: Constant ½ second bright, ½ second dim cycles.

A single ﬂash code number signiﬁes that the LED ﬂashes X times at 2Hz, remains off for two seconds, and then

repeats the sequence.

X + Y ﬂash codes signify that the LED ﬂashes X times at 2Hz, remains off for two seconds, ﬂashes Y times at 2

Hz, remains off for three seconds, and then repeats the sequence.

4ꢀ

Honeywell Electronic Ignition Troubleshooting Guide

Figure ꢀ4: Troubleshooting Guide

4ꢁ

Figure 26: 1 Inch Main Burner ﬂame

Figure ꢀ7: Pilot Burner Flame

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. Check low water cutoff (if so equipped).

1. Adjust thermostat to highest setting.

2. With boiler operating, open drain valve and slowly

drain boiler.

Figure 25: Sequence of Operation

3. Main burners and pilot burner will extinguish and

blower will stop when water level drops below low

water cutoff probe. Verify limit, thermostat or other

controls have not shut off boiler.

I. Sequence of Operation. See Figure 25. If boiler fails

to operate properly, see Troubleshooting Tree in Section

IX: Service.

J. Check pilot burner ﬂame. See Figure 27. Flame

should be steady, medium hard blue enveloping 3/8 to

½ inch of sensing probe.

4. Adjust thermostat to lowest setting. Reﬁll boiler.

O. Check limit.

1. Adjust thermostat to highest setting.

K. Check main burner ﬂame. See Figures 26. Flame

should have clearly deﬁned inner cone with no yellow

tipping. Orange-yellow streaks should not be confused

2. Observe temperature gauge. When temperature is

indicated, adjust limit to setting below observed

with true yellow tipping.

temperature. Main burners and pilot burner should

extinguish, and blower should stop.

ii. Remove gas oriﬁces. Drill one (1) drill size

larger (drill size is stamped on oriﬁce, or see

Section X: Repair Parts).

iii. Reinstall gas oriﬁces and main burners.

Measure input rate.

3. Adjust limit to setting above observed temperature.

Ignition sequence should begin.

4. Adjust thermostat to lowest setting. Adjust limit to

desired setting.

6. Recheck Main Burner Flame.

7. Return other gas-ﬁred appliances to previous

P. Adjust gas input rate to boiler.

conditions of use.

1. Adjust thermostat to highest setting.

Q. Review User’s Information Manual and system

2. Check manifold gas pressure. See Table 5 or rating

label located in the boiler’s vestibule compartment.

Adjust gas valve pressure regulator as necessary

(turn adjustment screw counterclockwise to

decrease manifold pressure, or clockwise to increase

manifold pressure). If pressure cannot be attained,

check gas valve inlet pressure. If less than minimum

indicated in Table 5 or boiler’s rating label, contact

gas supplier for assistance.

operation with owner or operator.

Table 1ꢁ: Gas Flow Rate in Cubic Feet

Per Hour

Seconds

for One

Revolution

Size of Gas Meter Dial

One-Half

One

Two

Cu. Ft.

3. Clock gas meter for at least 30 seconds. Use Table

13 to determine gas ﬂow rate in Cubic Feet per

Hour.

120

113

106

100

240

225

212

200

189

180

172

164

157

150

144

138

133

129

124

120

WARNING

Failure to properly adjust gas input rate will result

in over ﬁring or under ﬁring of the appliance.

Improper and unsafe boiler operation may result.

4. Determine Input Rate. Multiply gas ﬂow rate by gas

heating value.

5. Compare measured input rate to input rate stated on

rating plate.

a. Boiler must not be over ﬁred. Reduce input rate

by decreasing manifold pressure. Do not reduce

more than 0.3 inch w.c. If boiler is still overﬁred,

contact your Burnham distributor or Regional

Ofﬁce for replacement Gas Oriﬁce.

b. Increase input rate if less than 98% of rating

plate input. Increase manifold gas pressure no

more than 0.3 inch w.c. If measured input rate is

still less than 98% of rated input:

i. Remove Main Burners per procedure in

Section IX: Service.

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. Never modify,

remove or tamper with any control device.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.

If any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this

manual.

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires

are reconnected properly.

Never jump out or bypass any safety or operating control or component of this boiler.

Read, understand and follow all the instructions and warnings contained in ALL of the component

instruction manuals.

Assure that all safety and operating controls and components are operating properly before placing

the boiler back in service.

4. Pipe must be supported at minimum ﬁve (5) foot

A. General. Inspection and service should be conducted

annually. Turn off electrical power and gas supply while

conducting service or maintenance. Follow instructions

TO TURN OFF GAS TO APPLIANCE. See Figure 22.

intervals and must not sag.

5. All vent joints must be secure and watertight.

6. All 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. To Clean:

B. Low water cutoff (if so equipped).

Probe Type (Annual Service). Probe type LWCO

should be removed once a year, examined and

cleaned of any dirt accumulations to assure proper

operations. Do not attempt to repair mechanisms in the

ﬁeld. Complete replacement mechanisms, including

necessary gaskets and installation instructions, are

available from the manufacturer.

a. Disconnect drain tube from drain ﬁtting.

b. Flush drain tube with water. Fill trap with water.

c. Securely fasten drain tube to drain ﬁtting,

providing gas-tight and watertight seal.

7. If pipe must be disassembled for removal of

obstructions or resealing of joint, see Section III,

Paragraph C.

C. Vent System. Inspect for obstructions, soot

accumulation, proper support, and deterioration of pipe,

ﬁttings, and joints.

D. Boiler Flue Passages. Inspect for blockage or soot

accumulation.

1. Clean terminal screens. Terminals must be free of

obstruction, undamaged, with screens securely in

place.

1. Remove Main Burners. See Figure 30.

a. Remove front door.

2. Terminal and wall thimbles (if used) must be

weathertight.

b. Disconnect pilot tubing and pilot lead wires at

the gas valve.

3. Pipe must be full round shape, and show no damage

from impact or excessive temperature.

c. Remove wires to Flame Roll-out Switch.

d. Remove Burner Access Panel.

4ꢂ

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. Disconnect Vent Connector and Vent Pipe from

Blower Outlet.

3. Remove Jacket Top Panel.

4. Disconnect the Black and Gray Silicone Tubing

from the Canopy.

5. Disconnect Wiring Harness from Blower Motor.

6. Remove Canopy/Blower Assembly.

Figure ꢀ9: Blower Vent Connector Assembly

a. Loosen the (4) screws from Canopy.

7. Remove Flue Gas Bafﬂes. Inspect Flue Gas Bafﬂes

for deterioration.

E. Main Burners and Firebox.

8. Inspect ﬂue passages. Clean with ﬂue brush. See

1. Vacuum ﬁrebox. Exercise care - do not damage base

Figure 30.

insulation.

9. Inspect heating surface in combustion chamber.

Clean with straight handle wire brush.

2. Clean main burners. Brush top of burners with soft

bristle brush. See Figure 30. Vacuum to remove any

dirt and lint.

10. Install Flue Gas Bafﬂes.

11. Replace Canopy Assembly and seal.

3. Vacuum tip of pilot burner.

12. Connect Silicone Tubing between Pressure Fittings

on Canopy Assembly and Pressure Switch. Route

through bushings in Vestibule Panel . See Figure

28.

4. Check gas oriﬁces for lint and dirt. Clean as

necessary.

5. Install main burners by reversing procedure to

remove burners.

13. Install Jacket Top Rear Panel.

a. Pilot burner must be installed in original

location. See Table 14.

14. Connect vent system. See Figure 29.

15. Connect Blower Motor Wiring Harness

b. Main burners must be properly secured in burner

tray slot at rear of ﬁrebox and over gas oriﬁce.

See Figure 30.

c. Pilot gas supply and pilot lead wires must be

reconnected.

d. Burner access panel must be securely in place.

e. Reconnect Flame Roll-out wires.

F. Check operation. Follow steps G through P from

Section VIII: System Start-up.

G. Procedure for measuring differential pressure (See

Figure 31).

1. With boiler off, remove Gray and Black Hoses at

differential pressure switch.

2. With tees and ¼ inch aluminum stubs, connect water

manometer as shown with additional tubing.

Figure ꢀ8: Silicone Tubing Assembly

Table 14: Pilot Burner Location

Boiler Model

PVG-3

Main Burner with Pilot Bracket

Pilot Burner Located Between Main Burners *

2 & 3

3 & 4

4 & 5

5 & 6

6 & 7

7 & 8

8 & 9

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

* Main burners numbered left to right as viewed from front of boiler.

3. Start boiler and read Pressure on Manometer

when boiler water temperature reaches operating

temperature. Refer to Table 15 for minimum

readings.

NOTE: If switch drops-out before boiler reaches

temperature or if pressure differential readings are

below minimums shown in Table 15, check for

cracks in hose or contact your nearest Burnham

representative.

4. Stop boiler, remove manometer and reconnect hoses

to differential pressure switch. See Figures 28 and

31.

Figure ꢁ1: Differential Pressure Measurement

Table 15: Differential Pressure Switch Settings

Minimum Differential Pressure

Boiler Model

Sea Level to 4,999 Ft.

1.32” w.c.

5,000 - 10,000 Ft. Elevation

PVG-3

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

.80” w.c.

.65” w.c.

.35” w.c.

.30” w.c.

.35” w.c.

1.17” w.c.

.88” w.c.

.80” w.c.

.88” w.c.

XI. Repair Parts

All PVG 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.

5ꢀ

[Quantity] Part Number

Key

No.

Description

PVG-3

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

1. CASTING ASSEMBLY

Section Assembly

61707031

61707041

61707051

61707061

71707001

61707071

61707081

61707091

1A Left End Section

1B Center Section

1C Right End Section

1D Slip Nipple, #3

[1]

[2]

[3]

[4]

[5]

[6]

[7]

71707003

71707002

[4]

[6]

[8]

[10]

[12]

[14]

[16]

806600009 806600009 806600009 806600009 806600009 806600009 806600009

[2]

71107002

[3]

71107002

[4]

71107002

[5]

71107002

[6]

71107002

[7]

71107002

[8]

71107002

1E Flue Gas Bafﬂe

[2]

Tie Rod, ¼” -20

100109-01

100108-05

100108-07

100108-13

100108-14

100108-15

100108-16

1G Hex Nut, ¼” -20

[4] 80860407

5ꢁ

[Quantity] Part Number

PVG-5 PVG-6 PVG-7

Key

No.

Description

PVG-3

PVG-4

PVG-8

PVG-9

2. BASE ASSEMBLY

2A Base Wrapper

71807031 71807041 71807051 71807061 71807071 71807081 71807091

2B Base Tray

71807032 71807042 71807052 71807062 71807072 71807082 71807092

2C Burner Tray Assembly

2D Base Front Panel

61807031 61807041 61807051 61807061 61807071 61807081 61807091

71807035 71807045 71807055 71807065 71807075 71807085 71807095

2E Burner Access Panel

2F Cerafelt Gasket 1/2” x 2”

2G Cerafelt Gasket 1/2” x 2”

2H Base Side Insulation

2J Base Rear Insulation

2K Base Front Insulation

2L Base Leg Assembly

71807036 71807046 71807056 71807066 71807076 71807086 71807096

6206002

[2] 72007001

72007031 72007041 72007051 72007061 72007071 72007081 72007091

72007032 72007042 72007052 72007062 72007072 72007082 72007092

[4] 6186001

[18] 80860700

80160044

2M Self Tapping Screw, 1/4” -20 x 1/2”

2N Flame Roll-out Switch

2P Sheet Metal Screw, #8 x 3/4”

2Q Self Tapping Screw, 10-32 x 3/8”

80860030

[5] 80860705

[6] 80860705

[4] 80860717

[7] 80860705

Self Tapping Screw Hex Cap,

5/16 - 18 x 1-1/4”

[Quantity] Part Number

PVG-5 PVG-6 PVG-7

Key

No.

Description

PVG-3

PVG-4

PVG-8

PVG-9

3. BASE ASSEMBLY

3A Burner Cover (Natural Gas Only) 102033-03 102033-04 102033-05 102033-06 102033-07 102033-08 102033-09

3B Manifold Support Bracket

718070001

[2] 80860000

[6] 80860705

3C Sheet Metal Screw, #8 x 1/2”

3D Self Tapping Screw, 10-32 x 3/8”

5ꢂ

[Quantity] Part Number

PVG-5 PVG-6 PVG-7

Key

No.

Description

PVG-3

PVG-4

PVG-8

PVG-9

4. FAN/CANOPY ASSEMBLY

Canopy Assembly - Sea Level

61107031 61107041 61107051 61107061 61107071 61107081 61107091

Canopy Assembly - High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092

4B Cerafelt

9206005

[4] 80861512

[4] 808600141

8206085

4C U-Clip

4D Sheet Metal Screw, #10 x 1”

4E Fan Gasket

4F Fan

81161512

4G Lock Washer, #10

4H Machine Screw, #10-24 x 2-1/2”

[4] 80860636

[4] 808608982

[Quantity] Part Number

PVG-5 PVG-6 PVG-7

Key

No.

Description

PVG-3

PVG-4

PVG-8

PVG-9

5. BURNER ASSEMBLY

Gas Valve (Natural Gas),

Honeywell VR8204P1171

81660282

N/A

Gas Valve (Natural Gas),

Honeywell VR8304P4496

N/A

81660146

N/A

81660283

N/A

Gas Valve (LP Gas),

Honeywell VR8204C3015

Gas Valve (LP Gas),

Honeywell VR8304P4280

81660181

Nipple, ½” NPT x Close

806600040

N/A

806600022

N/A

Nipple, ¾” NPT x Close

Union, ½” NPT

806604023

N/A

Union, ¾” NPT

806604001

---

½” Gas Manifold

82207031 82207041 82207051 82207061

---

¾” Gas Manifold

---

82207071 82207081 82207091

[4]

822710

[6]

822710

[8]

822710

[10]

822710

[12]

822710

[14]

822710

[16]

822710

Burner Oriﬁces - Natural Gas #47

[4]

822792

[6]

822792

[8]

822792

[10]

822792

[12]

822792

[14]

822792

[16]

822792

Burner Oriﬁces - LP Gas 1.20 mm

Pilot Assembly - Natural Gas

8236163

8236164

Pilot Assembly - LP Gas

5G Pilot Burner

100147-01

[9]

[3]

[5]

[7]

[11]

[13]

[15]

5H Main Burner

100146-01 100146-01 100146-01 100146-01 100146-01 100146-01 100146-01

5J Pilot Tubing

8236122

5K Self Tapping Screw, ¼ - 20 x ½”

[6] 80860700

[Quantity] Part Number

Key

No.

Description

PVG-3

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

6. CONTROL PANEL ASSEMBLY

6A Limit, Honeywell L4080D

100189-01

80160155U

Transformer/Relay, Honeywell

R8285D

Ignition Module, Honeywell

S8670E3003

100959-01

Blower Relay, Honeywell

R8222U1006

80160096U

Differential Pressure Switch

Sea Level 0’ - 4999’

80160762

80160759

80160761

80160763

80160760 80160759

80160760

80160764

High Altitude - 5000’ - 10,000’

80160764 80160765

8136259

6F Junction box

ꢂ0

[Quantity] Part Number

Key

No.

Description

PVG-3

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

7. JACKET PARTS

7A Left Side Panel

7B Right Side Panel

7C Rear Panel

7D Vestibule Panel

7E Top Panel

60407002

60407001

60407033 60407043 60407053 60407063 60407073 60407083 60407093

60407034 60407044 60407054 60407064 60407074 60407084 60407094

60407032 60407042 60407052 60407062 60407072 60407082 60407092

7F Front Door

101354-03 101354-04 101354-05 101354-06 101354-07 101354-08 101354-09

7G Jacket Cover Plate

7H Handle

80407001

8056184

7J Door Clip

[2] 7041921

8136048

7K Bushing

7L Burnham Logo

81460099

ꢂ1

[Quantity] Part Number

Key

No.

Description

PVG-3

PVG-4

PVG-5

PVG-6

PVG-7

PVG-8

PVG-9

8. MISCELLANEOUS PARTS CARTON

8A Water Manifold

80607001

8056169

8B Temperature/Pressure Gauge

8C Circulator Wiring Harness

8D Safety Relief Valve

8E Boiler Drain Valve

8F Vent Terminal

6130701

81660363

806603061

8110701

8110703

8110702

8110704

8G Vent Connector

ꢂꢀ

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.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective 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.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF

and crystalline silica are not classified as hazardous wastes in the United

States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing

difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

ꢂꢁ

Limited Warranty

FOR RESIDENTIAL CAST IRON WATER BOILERS

for its intended purposes and its maintenance accordance with U. S.

Subject to the terms and conditions set forth below, U.S. Boiler™

Co., Inc. Lancaster, pennsylvania hereby extends the following limited

warranties to the original owner of a residential grade water boiler

manufactured and shipped on or after July 1,1991:

Boiler Co., Inc. recommendations and hydronics industry standards.

These warranties will be inapplicable if the residential grade water boiler

is used or operated over its rated capacity, is subjected to unauthorized

modiﬁcation, or is damaged as a result of being otherwise improperly

operated or serviced including, but not limited to, damage from any of the

following: operation with insufﬁcient water, allowing the boiler to freeze,

subjecting the boiler to ﬂood conditions, and operation with unapproved

water or fuel additives which cause deposits or corrosion.

ONEYEAR LIMITED WARRANTY

ON RESIDENTIAL GRADE WATER BOILERS

U.S. Boiler Co., Inc. warrants to the original owner that its residential

grade water boilers comply at the time of manufacture with recognized

hydronic industry standards and requirements then in effect and will be

free of defects in material and workmanship under normal usage for a

period of one year from the date of original installation. If any part of a

water boiler is found to be defective in material or workmanship during

this one year period, U.S. Boiler Co., Inc. will, at its option, repair or

replace the defective part.

5. Removal and Installation: These warranties do not cover expenses

of removal or reinstallation. The owner is responsible for the cost of

removing and reinstalling any defective part and its replacements and all

labor and material connected therewith.

6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach

of these warranties is limited to the repair or replacement of its parts in

accordance with the terms and conditions of these warranties.

LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER

U.S. Boiler Co., Inc. warrants to the original owner that the heat

exchanger of its residential grade water boilers will remain free from

defects in material and workmanship under normal usage for the

lifetime of the original owner at the original place of installation. If a

claim is made under this warranty during the ﬁrst ten years from the

date of original installation, U.S. Boiler Co., Inc. will, at its option, repair

or replace the heat exchanger. If a claim is made under this warranty

after the expiration of ten years from the date of original installation,

U.S. Boiler Co., Inc. will, at its option and upon payment of the pro-rated

service charge set forth below, repair or replace the heat exchanger.

The service charge applicable to a heat exchanger warranty claim is

based upon the number of years the heat exchanger has been in service

and will be determined as a percentage of the retail price of the heat

exchanger model involved at the time the warranty claim is made as

follows:

7. Limitation of Damages: Under no circumstances shall U.S. Boiler Co.,

Inc. be liable for incidental, indirect, special or consequential damages

of any kind whatsoever under these warranties, including, but not limited

to, injury or damage to persons or property and damages for loss of use,

inconvenience or loss of time. U.S. Boiler Co., Inc. liability under these

warranties shall under no circumstances exceed the purchase price paid

by the owner for the residential grade water boiler involved. Some states

do not allow the exclusion or limitation of incidental or consequential

damages, so the above limitation or exclusion may not apply to you.

8. Limitation of Warranties: These warranties set forth the entire

obligation of U.S. Boiler Co., Inc. with respect to any defect in a

residential grade water boiler and U.S. Boiler Co., Inc. shall have no

express obligations, responsibilities or liabilities of any kind whatsoever

other than those set forth herein. These warranties are given in lieu of all

other express warranties.

Years

In Service

ALL AppLICABLE ImpLIED WARRAnTIES, If Any, InCLUDIng

Any WARRAnTy of mERChAnTABILITy oR fITnESS foR A

pARTICULAR pURpoSE ARE ExpRESSLy LImITED In DURATIon

To A pERIoD of onE yEAR ExCEpT ThAT ImpLIED WARRAnTIES,

If Any, AppLICABLE To ThE hEAT ExChAngER In A RESIDEnTIAL

gRADE WATER BoILER ShALL ExTEnD To ThE oRIgInAL

oWnER foR ThE LIfETImE of ThE oRIgInAL oWnER AT ThE

oRIgInAL pLACE of InSTALLATIon. SomE STATES Do no ALLoW

LImITATIon on hoW Long An ImpLIED WARRAnTy LASTS, So

ThE ABovE LImITATIon mAy noT AppLy To yoU.

1-10

Service Charge

as % of

Retail Price

Charge

Years

In Service

25 and

above

Service Charge

as % of

Retail Price

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to

complete and mail the attached Warranty Card within ten days after the

installation of the boiler, although failure to comply with this request will

not void the owner’s rights under these warranties.

noTE: If the heat exchanger model involved is no longer available

due to product obsolescence or redesign, the value used to establish

the retail price will be the published price as shown in the Burnham

hydronics Repair parts price Sheet where the heat exchanger last

appeared or the current retail price of the then nearest equivalent heat

exchanger.

Upon discovery of a condition believed to be related to a defect in

material or workmanship covered by these warranties, the owner should

notify the installer, who will in turn notify the distributor. If this action is

not possible or does not produce a prompt response, the owner should

write to U.S. Boiler Co., Inc., Burnham hydronics, at p.o. Box 3079,

Lancaster, pA 17604, giving full particulars in support of the claim.

ADDITIONAL TERMS AND CONDITIONS

1. Applicability: The limited warranties set forth above are extended

only to the original owner at the original place of installation within the

United States and Canada. These warranties are applicable only to

water boilers designated as residential grade by U.S. Boiler Co., Inc. and

installed in a single or two-family residence and do not apply to steam

boilers of any kind or to commercial grade boilers.

The owner is required to make available for inspection by U.S. Boiler

Co., Inc. or its representative the parts claimed to be defective and, if

requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S.

Boiler Co., Inc. at the above address for inspection or repair. In addition,

the owner agrees to make all reasonable efforts to settle any disagree-

ment arising in connection with a claim before resorting to legal remedies

in the courts.

2. Components manufactured by others: Upon expiration of the

one year limited warranty on residential grade water boilers, all boiler

components manufactured by others but furnished by U.S. Boiler Co.,

Inc. (such as oil burner, circulator and controls) will be subject only to the

manufacturer’s warranty, if any.

ThIS WARRAnTy gIvES yoU SpECIfIC LEgAL RIghTS AnD

yoU mAy ALSo hAvE oThER RIghTS WhICh vARy fRom STATE

To STATE.

3. proper Installation: The warranties extended by U.S. Boiler Co., Inc.

are conditioned upon the installation of the residential grade water boiler

in strict compliance with U.S. Boiler Co., Inc. installation instructions.

U. S. Boiler Co., Inc. speciﬁcally disclaims liability of any kind caused by

or relating to improper installation.

4. proper Use and maintenance:The warranties extended by U.S. Boiler

Co., Inc. conditioned upon the use of the residential grade water boiler

03/03

ꢂ4

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