U.S. Boiler Company | IN5PV | Operating instructions | U.S. Boiler Company IN5PV Operating instructions

U.S. Boiler Company IN5PV Operating instructions
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INSTALLATION, OPERATING
AND
SERVICE INSTRUCTIONS
SERIES 2PV
GAS BOILER
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
20_PV_I-_ _ _ _
Boiler Serial Number
6_ _ _ _ _ _ _
Heating Contractor
Phone Number
Address
8141775R9-11/99
Installation Date
1
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels, or to important information concerning product life.
CAUTION
DANGER
Indicate s a po tentia lly haz ardous s ituat ion
w hich, if n ot avoided, may re sult in
mod erate o r minor in jury or prope rty
damage .
Indicates an imminently hazardous situation
wh ic h, if n ot a voi de d, will re sult in de at h,
serious injury or substantial property damage.
NOTICE
WARNING
Indicates spec ial ins tru ctions on
ins tallatio n, ope ra tion, or maintenanc e
whi ch are importan t but not re late d to
persona l injury ha zards .
In dic at es a pot ent ia ll y ha za rdo us s itu ation
which, if not avoide d, could result in death,
serious injury or substantial property damage.
Table of Contents
I.
Pre-Installation ..................................... 4
II.
Unpack Boiler ....................................... 5
III.
Water Piping ......................................... 6
IV.
Gas Piping ............................................ 8
V.
Venting ................................................. 9
VI.
Electrical ............................................. 12
VII.
System Start-up .................................. 13
VIII.
Service Instructions ............................ 20
IX.
Repair Parts ........................................ 23
2
NOTICE
USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been
specially orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National
Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers’ orifice
sizing is indicated on the rating label. High altitude boiler models are identifiable by the second
digit in the model number suffix on the rating label:
20_PV_I-__2: Less than 2000 ft. elevation
20_PV_I-__4: 2000 ft. and higher elevation, Canada
20_PV_I-__5: 2000 ft. and higher elevation, USA
Figure 1: Elevation Views
Dimensions [in inches]
A
B
C
D
Water Content
[Gallons]
203PV
20‰
14‰
10-1/16
15-5/8
3.2
265
204PV
23
17
11
15-5/8
4
309
Boiler Model
Ap prox. Shippin g
Weight (lb.)
205PV
27
21
13‰
15…
4.7
357
206PV
30…
24…
15-1/8
15…
5.5
419
3
I. Pre-Installation
C. Appliance is design certified for installation on
WARNING
combustible flooring. The boiler must not be installed
on carpeting.
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
D. Provide clearance between boiler jacket and
combustible material in accordance with local fire
ordinance. See Figure 2 for minimum clearance from
combustible material for closet installation. For alcove
installation provide top clearance of 27 inches and
right side clearance of 6 inches. Recommended service
clearance is 24 inches from left side, right side and
front. Service clearances may be reduced to minimum
clearances to combustible materials.
A. Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected and
packed. Our responsibility ceases upon delivery of
boiler to carrier in good condition. Any claim for
damage or shortage in shipment must be filed
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
E. 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.
B. Installation must conform to the requirements of the
F. Install near outside wall for through wall venting.
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/
CGA B149 Installation Codes. Where required by the
authority having jurisdiction, the installation must
conform to the Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
CSD-1.
Refer to Section V: Venting. Certified for minimum
vent length of 2 feet with one (1) elbow and maximum
vent length of 15 feet with one (1) or two (2) elbows.
WARNING
Certified as Category III appliance. Install vent
system in accordance with Section V: Venting.
Do not vent using masonry chimney, Type B gas
vent, or other Category I venting system.
G. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
H. Provide combustion and ventilation air in
accordance with applicable provisions of local building
codes, or National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Section 5.3, Air for Combustion and
Ventilation, or Sections 7.2, 7.3 or 7.4 of CAN/CGA
B149 Installation Codes.
WARNING
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.
Figure 2: Minimum Clearances to Combustible
Construction for Closet Installation
4
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).
a. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 Btu per hour
input of all equipment in space.
3. Determine type of space. Divide Volume by Total
Input.
b. Vertical ducts. Minimum free area of 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.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconfined
space.
c. Horizontal ducts. Minimum free area of 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.
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:
Alternate method for boiler located within confined
space. Use indoor air if two permanent openings
communicate directly with additional 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 1 square inch per
1,000 Btu per hour input of all equipment in
spaces, but not less than 100 square inches.
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;
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 sole plates
and floors, between wall-ceiling joints, between
wall panels, at plumbing and electrical
penetrations, and at other openings.
7. 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.
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.
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.
6. For boiler located within unconfined space in
building of unusually tight construction or within
confined space, provide outdoor air through two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 3
inches. Size each opening per following:
I. 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.
II. Unpack Boiler
CAUTION
D. Remove all boiler hold-down fasteners.
Do not drop boiler. Do not bump boiler jacket
against floor.
E. Tilt the boiler to one side and slide a wooden slat
under the two raised feet.
A. Move boiler to approximate installed position.
F. Tilt the boiler to the other side and slide another
B. Remove all crate fasteners.
wooden slat under the two raised feet.
C. Lift outside container and remove with all other inside
G. Slide the boiler forward or backward off the skid using
protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
the two wooden slats as runners.
H. Move boiler to its permanent location.
5
III. Water Piping and Trim
F. Space heating and domestic water heating with Alliance
CAUTION
water heater. Install Alliance water heater as a separate
heating zone. Refer to Alliance Installation, Operating and
Service Instructions for additional information.
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
building.
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 4.
Also consult I=B=R Installation and Piping Guides.
A. Design and install boiler and system piping to prevent
oxygen contamination of boiler water.
H. If boiler is connected to heating coils located in air
CAUTION
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.
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.
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.).
Oxygen contamination sources are system leaks
requiring addition of makeup water, fittings, and oxygen
permeable materials in distribution system. Eliminate
oxygen contamination by repairing system leaks,
repairing fittings, and using nonpermeable materials in
distribution system.
Install pipe tee between circulator and boiler return along
with second tee in supply piping as shown in Figure 5.
Bypass should be same size as the supply and return lines
with valves located in bypass and supply outlet as
illustrated in Figure 5 in order to regulate water flow to
maintain higher boiler water temperatures.
B. Connect system supply and return piping to boiler. See
After the boiler is operational (reference Section VII.
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.
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.
Figure 3. Also consult I=B=R Installation and Piping
Guides. Maintain minimum ½ inch clearance from hot
water piping to combustible materials.
C. Install Circulator with flanges, gaskets and bolts
provided. Five foot circulator harness allows circulator
to be mounted on supply or return. Connect harness to
circulator and secure any excess conduit.
J. A hot water boiler installed above radiation level must be
D. Install Safety Relief Valve. See Figure 3. Safety Relief
provided with a low water cutoff device as part of
installation.
Valve must be installed with spindle in vertical position.
Installation of the relief valve must be consistant with
the ANSI/ASME Boiler and Pressure Vessel Code,
Section IV.
K. Oil, grease, and other foreign materials which
accumulate in new hot water boilers and a new or
reworked system should be boiled out, and then
thoroughly flushed. A qualified water treatment chemical
specialist should be consulted for recommendations
regarding appropriate chemical compounds and
concentrations which are compatible with local
environmental regulations.
WARNING
Safety relief valve discharge piping must be
piped near floor to eliminate potential of severe
burns. Do not pipe in any area where freezing
could occur. Do not install any shut-off valves.
L. 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.
E. Install Drain Valve in ¾" NPT connection in tee
provided. See Figure 1.
6
Figure 3: Recommended Boiler Piping For Series - Loop Hot Water Heating Systems
Figure 4: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
Figure 5: Recommended Bypass Piping
7
IV. Gas Piping
A. Size gas piping. Design system to provide adequate
3. Install sediment trap, ground-joint union and
manual shut-off valve upstream of boiler gas
control valve and outside jacket. See Figure 6.
gas supply to boiler. Consider these factors:
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 listed on
rating label.
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, ANSI/NFPA 70 and/or CSA C22
Electrical Code.
2. Maximum gas demand. Table 1 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).
C. Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
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
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
Table 1: Rated Input
Input Rate
[cubic feet per hour]
Boiler
Model
Number
Natural Gas
203PV
62
24
‰
204PV
96
38‰
‰
205PV
130
52
‰
206PV
164
LP/Propane
Gas
Connection
Size
65
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonflammable
solution. Do not use matches, candles, open flames,
or other ignition source.
‰
3. Length of piping and number of fittings. Refer to
Table 2 for maximum capacity of Schedule 40 pipe.
Table 3 lists equivalent pipe length for standard
fittings.
4. Specific gravity of gas. Gas piping systems for gas
with a specific gravity of 0.70 or less can be sized
directly from Table 2, unless authority having
jurisdiction specifies a gravity factor be applied. For
specific gravity greater than 0.70, apply gravity
factor from Table 4. If exact specific gravity is not
shown choose next higher value.
For materials or conditions other than those listed
above, refer to National Fuel Gas Code, NFPA 54/
ANSI Z223.1, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
B. Connect boiler gas valve to gas supply system.
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 and/or
CAN/CGA B149 Installation Codes.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liquefied petroleum gas.
Figure 6: Recommended Gas Piping
8
Table 2: Maximum Capacity of Schedule 40 Pipe in CFH For Gas Pressures of 0.5 psig or Less
0.3 inch w.c. Pressure Drop
Length
[Feet]
‰
10
132
20
0.5 inch w.c. Pressure Drop
1
1…
‰
1
1…
278
520
1,050
175
360
680
1,400
92
190
350
730
120
250
465
950
30
73
152
285
590
97
200
375
770
40
63
130
245
500
82
170
320
660
50
56
115
215
440
73
151
285
580
60
50
105
195
400
66
138
260
530
70
46
96
180
370
61
125
240
490
80
43
90
170
350
57
118
220
460
90
40
84
160
320
53
110
205
430
100
38
79
150
305
50
103
195
400
Table 3: Fitting Equivalent Lengths
Table 4: Specific Gravity Correction Factors
Nominal Pipe Size
Fitting
‰
1
1…
45 Ell
0.7
1
1.2
1.6
90 Ell
1.6
2.1
2.6
3.5
Tee (As Elbow)
3.1
4.1
5.2
6.9
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
0.50
1.10
1.30
1.07
0.55
1.04
1.40
1.04
0.60
1.00
1.50
1.00
0.65
0.96
1.6
0.97
0.7
0.93
1.7
0.94
0.75
0.9
0.8
0.87
V. Venting
A. General Guidelines.
1. Vent system installation must be in accordance with
National Fuel Gas Code, NFPA 54/ANSI Z221.3,
Part 7, Venting of Equipment; and/or CAN/CGA
B149 Installation Codes, Section 7, Venting
Systems and Air Supply for Appliances; or
applicable provisions of local building codes.
Contact local building or fire officials about
restrictions and installation inspection in your area.
Saf-T-Vent, Flex-L International Inc., - Star-34,
Protech Systems, Inc. - FasNSeal™, and Z-Flex U. S.,
Inc. - Z-Vent. 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 not supplied
with this unit and should be obtained from the
supplier of the alternate manufacturer's venting
system. See Table 5 for complete list of Burnham
Vent System Components.
2. This appliance requires a Special Gas Vent. Use
Vent Connector and Vent Terminal in Vent
Accessory Carton provided with boiler (See Repair
Parts, Key No. 8). The product is designed to use
Burnham supplied AL 29-4C® Stainless Steel vent
system components. The following manufacturers
offer similar AL 29-4C® components and are
approved for use with this product: Heat-Fab Inc. -
WARNING
Do not use this appliance with nonmetallic vent
systems such as Hart & Cooley Ultravent, Plexco
Plexvent, or Selkirk-Metalbestos Sel-Vent.
9
continuously.
Table 5: Burnham Vent System Components
Vent System
Component
Burnham
*Car toned
Part
Number
Burnham
Component
Part
Number
3" Dia. P ipe x 1 Ft
611 60112
8116135
3" Dia. P ipe x 3 Ft
61160101
8116058
3" Dia. P ipe x 4 Ft
**
8116176
3" Dia. P ipe x 5 Ft
6116 0111
8116059
3" Dia . 90 E lbow
61160121
8116060
3" Dia . 45 E lbow
61160131
8116061
(e) Test for spillage at the drafthood relief opening
after 5 minutes of main burner operation. Use the
flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
(f) 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.
(g) 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.
* Com plete with Locking B and(s )
* * 61160 33 Contains (4 ) 4 ft. l engths
61160 40 Contains (2 ) 4 ft. l engths
3. Minimum vent length requirement is 2 feet of pipe
and one (1) elbow. Maximum vent length is 15 feet
with one (1) or two (2) elbows.
B.
C. Install Vent Connector.
4. Do not install venting system components on the
exterior of the building except as specifically
required by these instructions.
Removal of Existing Boiler. For installations not
involving the replacement of an existing boiler,
proceed to Step C.
1. Remove vent connector from vent accessory carton.
2. Remove gaskets, orifice plate and hardware from
blower outlet flange.
3. Assemble orifice plate gaskets, orifice plate, and
vent connector. See Figure 7.
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:
4. Secure vent connector with washers and locknuts.
(a) Seal any unused openings in the common venting
system.
(b) 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.
(c) 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.
(d) Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
Figure 7: Vent Connector Installation
10
D. Install Vent Pipe, General.
2. Vent terminal location restricted per following:
a. Minimum 12 inches above grade or normally
expected snow accumulation level, or 7 feet
above grade if located adjacent to public
walkway. Do not install over public walkway
where local experience indicates condensate or
vapor from Category III appliances creates a
nuisance or hazard.
1. Start at vent connector. Work toward vent terminal.
2. Use ¾ inch pipe strap to support horizontal runs,
maintain vent location and slope, and prevent sags.
Do not restrict thermal expansion movement.
Maximum support spacing is 5 feet.
3. Provide minimum 5 inch clearance to combustible
materials. Use thimble when penetrating
combustible wall.
a. 203PV and 204PV - Single wall thimble,
Burnham Part No. 8116116. Other wall thimble
manufacturers are American Metal Products,
Hart & Cooley, and Metal Fab.
b. 205PV and 206PV - Double wall thimble,
Burnham Part No. 8116115 (accomodates 5" to
8¾" wall thickness). Another wall thimble
manufacturer is Hart & Cooley.
4. Cut pipe to length using hacksaw with minimum 32
teeth per inch or circular saw with metal abrasive
wheel. Remove bead end only - bell end accepts
next fitting or pipe. Cut must be square with pipe.
Scrape off burrs with sharp edged tool.
Figure 8: Typical Joint Detail
Note: If remaining pipe (less bell) must be used,
beaded end of mating pipe/fitting must be crimped.
b. Minimum 3 feet above any forced air inlet
located within 10 feet.
c. Minimum 4 foot below, 4 foot horizontally
from, or 1 foot above any door, window, or
gravity air inlet.
d. Minimum 4 feet horizontally from, and in no
case above or below, unless a 4-foot horizontal
distance is maintained, from electric meters, gas
meters, regulators and relief equipment.
e. Minimum 12 inches from overhang or corner.
5. Seal all joints using Dow Corning Silastic 732
RTV, Dow Corning Silastic 736 RTV, Polybac
#500 RTV, or Sil-bond RTV 4500 (Acetoxy). Do
not use other adhesives or sealants.
6. Procedure for joining pipe and fittings. See Figure 8.
a. Clean pipe or fitting. Remove all dirt and grease.
b. Slip locking band over pipe/fitting bell.
3. Use wall thimble when passing through
combustible outside wall (thimble use optional for
noncombustible wall). Insert thimble through wall
from outside. Secure outside flange to wall with
nails or screws, and seal with adhesive material.
Install inside flange to inside wall, secure with nails
or screws, and seal with adhesive material.
c. Apply continuous ¼ inch bead of sealant around
bead end of pipe/fitting no more than 1/8 inch
from end.
d. Insert pipe/fitting into bell. Smooth sealant for
continuous seal around gap between bead and
bell. Apply additional sealant if necessary.
e. Slip locking band over joint and tighten. Do not
secure joint with sheet metal screws or pop rivets.
4. For noncombustible wall when thimble is not used,
size opening such that bell with locking band
attached cannot pass through.
E. Horizontal (Through Wall) Vent Installation.
5. Join vent terminal to vent pipe. Cut vent pipe to
locate vent terminal 3 inches (minimum) and 6
inches (recommended) from wall when joined to
inside vent piping. See Figure 9. Vent terminal
clearance to vinyl wall surfaces is 6 inches.
1. Maintain minimum ¼ inch per foot slope in
horizontal runs. Slope pipe down toward vent
terminal.
CAUTION
6. 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.
Moisture and ice may form on surfaces around
vent terminal. To prevent deterioration, surfaces
should be in good repair (sealed, painted etc.)
11
Figure 9: Recommendations for Thimble and Wall Penetration
VI. Electrical
A. General. Install wiring and ground boiler in
Instructions.
accordance with requirements of authority having
jurisdiction, or in absence of such requirements the
National Electrical Code, ANSI/NFPA 70, and/or the
CSA C22.1 Electric Code.
1. Zoning with Circulators, Domestic Hot Water
Priority. Provide DPDT relay (included with PAL).
Connect coil to Alliance thermostat (prewired with
PAL). Connect normally open contacts (red and
white wires in PAL control harness) to transformer
terminals 'R' and 'Y'. Disconnect yellow circulator
wire. Connect normally closed contacts (violet
wires in PAL boiler harness) to yellow relay wire
and yellow circulator wire.
B. Install thermostat. Locate on inside wall approximately
4 feet above floor. Do not install on outside wall, near
fireplace, or where influenced by drafts or restricted air
flow, hot or cold water pipes, lighting fixtures,
television, or sunlight. Allow free air movement by
avoiding placement of furniture near thermostat.
2. Zoning with Circulators, Nonpriority. Connect
Alliance circulator zone control (or red and white
wires in PAL control harness) to transformer
terminals 'R' and 'Y'.
C. Wire thermostat. Provide Class II circuit between
thermostat and boiler. Run wires through grommet in
Jacket Left Side Panel. Set thermostat heat anticipator
to 0.6 amps. See Figure 10.
3. Zoning with Zone Valves. Connect Alliance
thermostat to zone valve. Connect zone valve end
switch to relay terminals 'R' and 'G'. See Paragraph
F.
D. Wire boiler. Boiler is rated for 120 VAC, 60 hertz, less
than 12 amperes. Provide individual branch circuit with
fused disconnect. Connect to black and white wires and
green ground screw. See Figure 10.
F. For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance.
E. Alliance water heater (if used). See Figure 10. Also refer
to Alliance Installation, Operating and Service
12
Figure 10: Wiring Diagram
VII. System Start-up
A. Safe operation and other performance criteria were
8. Open zone valve to second zone to be purged, then
close first. Repeat this step until all zones have been
purged, but always have one zone open. At
completion, open all zone valves.
met with gas manifold and control assembly provided
on boiler when boiler underwent tests specified in
American National Standard for Gas-Fired LowPressure Steam and Hot Water Boilers, ANSI Z21.13.
9. Close bib cock, continue filling system until
pressure gauge reads 12 psi. Close fill valve.
B. Fill heating system with water and vent air from
system. Use the following procedure on a Series Loop
System equipped with zone valves. See Figure 3.
Note: If makeup water line is equipped with
pressure reducing valve, system will automatically
fill to 12 psi. Leave globe valve open.
1. Close isolation valve in boiler supply piping.
10.Open isolation valve in boiler supply piping.
2. Isolate all circuits by closing zone valves or
balancing valves.
11.Remove hose from bib cock.
3. Attach hose to bib cock located just below isolation
valve in boiler supply piping. Terminate hose in
five gallon bucket at a suitable floor drain or
outdoor area).
C. Check main burners. See Figure 11. Rear of burner
must be in vertical slot in rear of burner tray. Front of
burner must be seated on orifice.
4. Starting with one circuit, open zone valve.
5. Open bib cock.
6. Open fill valve. Makeup water line should be
located directly above isolation valve in boiler
supply piping.
7. Allow water to overflow from bucket until
discharge from hose is bubble free for 30 seconds.
13
Figure 11: Main Burner Installation
Figure 12: Gas Valve Pressure Tap
D. 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.
See Figure 12.
3. For natural gas fired boiler, temporarily turn off all
other gas-fired appliances.
E. Follow Operating Instructions to place boiler in
operation. See Figure 17.
F. Sequence of Operation. See Figure 14. If boiler fails
to operate properly, see Troubleshooting Tree on pages
17-18.
G. Check gas piping and connections between Gas
Valve and Manifold, Orifices and Pilot Tubing. Use
soap solution or other approved method. See Figure 13.
H. Check pilot burner flame. See Figure 15. Flame
should be steady, medium hard blue enveloping 3/8 to
½ inch of sensing probe.
I. Check main burner flame. See Figure 16. Flame
should have clearly defined inner cone with no yellow
tipping. Orange-yellow streaks should not be confused
with true yellow tipping.
Figure 13: Schematic Pilot and Gas Piping
Figure 14: Sequence of Operation
14
Figure 15: Pilot Burner Flame
Table 6: Gas Flow Rate in Cubic Feet per Hour
Size of Gas Meter Dial
Seconds
for One
Revolution
One-Half
Cu. Ft.
One
Cu. Ft.
Two
Cu. Ft.
30
60
120
240
32
56
113
225
34
53
106
212
36
50
100
200
38
47
95
189
40
45
90
180
42
43
86
172
44
41
82
164
temperature setting to start and stop boiler operation.
46
39
78
157
K. Check ignition control module shut-off. Disconnect
48
37
75
150
50
36
72
144
52
35
69
138
54
33
67
133
56
32
64
129
58
31
62
124
60
30
60
120
Figure 16: Main Burner Flame
J. Check thermostat operation. Raise and lower
igniter/sensor cable from Terminal 9 (SPARK). Gas
valve should close and pilot and main burners should
extinguish.
L. Check low water cutoff (if used). Drain boiler water
below LWCO set point. Burners should extinguish.
M. Check limit.
1. Adjust thermostat to highest setting.
a. Boiler must not be overfired. 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.
2. Observe temperature gauge. When temperature is
indicated, adjust limit to setting below observed
temperature. Main burners and pilot burner should
extinguish and blower stop.
3. Adjust limit to setting above observed temperature.
Ignition sequence should begin.
b. Increase input rate if less than 98% of rating
label 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:
4. Adjust thermostat to lowest setting. Adjust limit to
desired setting.
N. Adjust gas input rate to boiler (Natural Gas).
i.
1. Adjust thermostat to highest setting.
Remove Main Burners per procedure in
Section VIII: Service.
ii. Remove gas orifices. Drill one (1) drill size
larger (drill size is stamped on orifice, or
see Key No. 4D).
2. Check manifold gas pressure. Manifold pressure is
listed on rating label. Adjust gas valve pressure
regulator as necessary (turn adjustment screw
counterclockwise to decrease manifold pressure, or
clockwise to increase manifold pressure). If
pressure can not be attained, check gas valve inlet
pressure. If less than minimum gas supply pressure
listed on rating label, contact gas supplier for
assistance.
iii. Reinstall gas orifices and main burners.
Measure input rate.
6. Recheck Main Burner Flame.
7. Adjust thermostat to normal setting.
8. Return other gas-fired appliances to previous
conditions of use.
3. Clock gas meter for at least 30 seconds. Use Table 6
to determine gas flow rate in Cubic Feet per Hour.
O. Adjust gas input rate to boiler (LP/Propane).
4. Determine Input Rate. Multiply gas flow rate by gas
heating value.
1. Adjust thermostat to highest setting.
2. Check manifold pressure. Adjust gas valve pressure
regulator to obtain 10 inches w.c. manifold
5. Compare measured input rate to input rate listed on
rating label.
15
Figure 17: Operating Instructions
pressure. Adjust gas valve pressure regulator as
necessary (turn adjustment screw counterclockwise
to decrease manifold pressure, or clockwise to
increase manifold pressure). If pressure can not be
attained, check gas valve inlet pressure. If less than
minimum gas supply pressure listed on rating label,
contact gas supplier for assistance.
subsequent boiler operation.
2. Ventilate the boiler room, set the high limit to its
maximum setting, set the thermostat to call for
heat. Allow the boiler to fire for at least an hour or
until the odor from the cornstarch has dissipated.
3. Return the high limit and thermostat to their
desired settings.
3. Recheck Main Burner Flame
Q. Review User's Information Manual and system
4. Adjust thermostat to normal setting.
operation with owner or operator.
P. COMBUSTION CHAMBER BURN-OFF
R. Post instructions near boiler for reference by owner
1. The mineral wool combustion chamber panels
contain a cornstarch based binder that must be
burned out at installation to prevent odors during
and service personnel. Maintain instructions in legible
condition.
16
17
18
19
VIII. Service
A. General. Inspection and service should be conducted
5. Using flashlight, examine all flue passageways.
annually. Turn off electrical power and gas supply
while conducting service or maintenance. Follow
instructions TO TURN OFF GAS TO APPLIANCE.
See Figure 17.
a. If passageways are free of soot and obstruction,
replace canopy, secure and seal using kit
available from Burnham Distributors, Part No.
6111716.
b. If passageways need cleaning, remove burners
as described in Paragraph F below. Using long
handle wire or bristle flue brush and vacuum,
brush flueways thoroughly from top of boiler as
illustrated in Figure 19. Replace canopy and seal
using kit available from Burnham Distributors,
Part No. 6111716.
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.
B. Inspect Housekeeping. Boiler area must be clear and
WARNING
free from combustible materials, gasoline and other
flammable vapors and liquids. Remove obstructions to
the flow of combustion and ventilation air.
Canopy must be resealed with RTV-732 Silicone
Rubber Sealant (500 F Intermittent Duty).
C. Service Low water cutoff (if so equipped). Follow
6. Reinstall jacket top panel, vent pipe and vent
connector in reverse manner. Reconnect electrical
connector to blower.
instructions provided with low water cutoff
D. Inspect Vent System for obstructions in vent pipe,
soot accumulation, deterioration of pipe or joints, and
proper support:
F. Clean Main Burners and Firebox.
1. To remove burners for cleaning, changing orifice
plugs, or repairs:
1. Remove vent connector and vent pipe. See Figure
19.
a. Remove jacket Front Panel.
2. Remove all obstructions. Check and clean vent
terminal screens.
b. Disconnect pilot tubing at gas valve.
3. Remove soot accumulations with wire brush and
vacuum.
c. Disconnect igniter/sensor cable and ground wire
at Ignition Module.
4. Replace deteriorated parts.
d. Disconnect Flame Rollout Switch wires.
5. Repair deteriorated joints. See Section V: Venting,
Paragraph D.6.
e. Remove Burner Access Panel.
f. Mark Pilot Main Burner location on Manifold.
E. Inspect Boiler Flue Passages for blockage or soot
g. Hold burner on throat. Lift slightly to clear
orifice. Pull burner from combustion chamber.
See Figure 11. Pilot Main Burner can only be
removed by lifting at 45° angle after adjacent
burner to right is removed.
accumulation. See Figure 19.
1. Disconnect vent connector from blower discharge
flange.
2. Remove sheet metal screws securing Jacket Top
Panel. Lift panel and rotate about relief valve
piping until top of boiler is exposed. If piping or
wall prevent full rotation of top panel for access to
canopy, cut slot into relief valve opening and
remove top panel.
2. Brush top of burners with a soft bristle brush. See
Figure 19. Vacuum burners.
3. Check orifices. Drilled passageways must be free of
lint or dirt.
4. Vacuum tip of Pilot Burner.
3. Disconnect blower connection from wiring harness
in vestibule.
5. Clean firebox by vacuuming. Exercise care not to
disturb insulation inside base.
4. Remove bolts securing canopy to boiler sections.
Cut silastic sealant around base of canopy, pry
canopy from boiler sections and remove canopy/
blower assembly from boiler.
6. Install burners by reversing procedure used to
remove burners. Burner with pilot assembly must
be in same location as original installation. See
Table 7. Burners must be properly located on
20
Table 7: Pilot Burner Location
Boiler
Model
Main Burner with
60 Pilot Bracket *
Pilot Burner Located
Between Main Burners
*
203PV
1
1&2
204PV
2
2&3
205PV
3
3&4
206PV
4
4&5
Figure 18: Spark Gap Setting
* Main burners numbered left to right as viewed from front of
boiler
support bracket at rear of burner. See Figure
11. Slide burner over orifice.
7. Reconnect pilot gas supply, igniter/sensor
cable, and ground wire. Reinstall Burner
Access Panel. Reconnect Flame Rollout
Switch wires.
G. Check operation. Follow steps D through O
from Section VII: System Start-up.
H. Removal or replacement of pilot assembly or
pilot assembly parts. If pilot assembly, sensor
or pilot orifice need replacing, remove main
burner with pilot using procedure described in
Paragraph F.1.
1. To replace orifice.
a. Disconnect pilot tubing. Pilot orifices
screw into Pilot Burner. Replace with
Honeywell 388146NE (Natural Gas) or
Honeywell 388146KP (LP/Propane).
b. Reconnect pilot tubing and check for
leaks.
2. To adjust or check spark gap between
electrode and hood on Honeywell Q348A
intermittent pilot. See Figure 18.
a. Use round wire gauge to check spark
gap.
b. Spark gap should be 1/8 inch for
optimum performance.
3. To replace complete pilot assembly.
a. Remove two machine screws holding
pilot burner to pilot bracket.
b. Disconnect pilot tubing.
c. Disconnect all other leads to pilot.
d. Select pilot assembly with identical
model number, reconnect leads and pilot
tubing. Resecure to pilot bracket.
4. Reinstall main burner following procedure
described in Paragraph F.
Figure 19: Flueway Cleaning
21
Table 8: Minimum Suction Pressure
Boiler Model
Minimum Suction Pressure
203PV
-0.50 inches w.c.
204PV
-0.50 inches w.c.
205PV
-0.80 inches w.c.
206PV
-0.80 inches w.c.
I. Lubrication. There are no parts requiring lubrication
by service technician or owner. Circulator bearings are
water lubricated. Blower motor bearings are factory
sealed.
Figure 20: Procedure for Measuring Fan Suction
Pressure
22
IX. Repair Parts
All Series 2PV 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 your Burnham Regional Sales Office as listed below.
B urnh am Corpo rati on Regional Offices
A. B urnham Cor poration - Centr al & Wes tern R egio ns C. Burnham Corporation - M etropolitan Region
P.O. Box 3079
P.O. Box 3079
La ncast er, PA 17604 -3079
Lancas ter, PA 17604-3079
P hone: (717) 481 -8400
Phone: (717) 481-8400
FAX : (717) 481 -8408
FA X: (717) 481-8409
B. B urnham S ales Cor poration - Nort heast Region
19 -27 M yst ic Av enue
Som erv ille, M A 02145
P hone: (617) 625 -9735
FAX : (617) 625 -9736
D. B urnham Co rporat ion - Mid-A tlant ic Region
P.O. Box 3079
La ncast er, PA 17604 -3079
P hone: (717) 481 -8400
FAX : (717) 481 -8409
Contact Regional Office Indicat ed f or y our S tate
Al abam a
A
Ne bra ska
A
Oreg on
A
Ala ska
A
N eva da
A
P enns yl van ia
D
Arizo na
A
New Ha mps hire
B
Rh ode Isla nd
B
Arkan sas
A
Ne w Jersey
S outh Caroli na
A
Cal iforn ia
A
Atlan tic, Burlin gton, Camd en,
S outh Dakota
A
Col ora do
A
Ca pe May, C umbe rla nd,
Tennes s ee
A
Conn ecticut
B
Glou cester, M erc er,
Te xas
A
Del aware
D
Monm outh, Oce an, S ale m
Utah
A
Fl ori da
A
Co unties
Ve rm ont
B
Ge org ia
A
A ll other Co unties
Hawa ii
A
New Mexico
Ida ho
A
Ne w York
Ill inois
A
Alb any, Fulton , M ontgom ery,
India na
A
Re nss ela er, S ara to ga,
D
C
A
Virgin ia
Arling to n,Acco mac k,Cl arke,
Fairfax,Frederick,Fauq uier,
D
Lo udoun ,North ampto n a nd
Prince Wil liam Co unties
B
Io wa
A
S ch enec tady, S cho harie,
Kan sas
A
Warre n, Was hingto n Co unties
K entuc ky
A
All Other Co unties
Loui sia na
A
Mai ne
A ll other Co unties
A
Was hing ton
A
C
Wash ington , D.C.
D
N orth Caroli na
A
West Virgin ia
D
B
No rth Dak ota
A
Wisc onsin
A
M aryla nd
D
Oh io
Wyomi ng
A
Ma ss ach use tts
B
A th ens , B elm ont, Gall ia,
Michig an
A
J effe rson, Lawrenc e, M eig s,
Min nes ota
A
Mo nro e, an d Was hing ton
M issis sip pi
A
Co unties
M iss ouri
A
A ll other Co unties
Monta na
A
Cana da
A
D
Okl ahom a
A
A
23
1.
Section Assembly ............................... 25
2.
Canopy/Blower Assembly .................. 25
3.
Base Assembly Group ........................ 26
4.
Manifold and Main Burners ............... 27
5.
Pilot Burner and Gas Valve ............... 28
6.
Jacket .................................................. 29
7.
Miscellaneous Trim and Controls ...... 31
8.
Vent Accessory Carton ....................... 31
SERVICE SCHEDULE
DATE
SERVICE PERFORMED
24
Key
No.
[Quantity] Part Number
Descr iption
1. Section Assembly
203PV
204PV
205PV
206PV
617 170321
617 170421
617 170521
617 170621
2. Canopy/Blower Assembly
2A
Cano py
[1] 61117034
[1] 61117044 [1] 61117054 [1] 61117064
2B
Carriage Bolt, …-20 x 1"
2C
Wash er, …, SA E
2D
Nut,…-20, Heav y Hex
2E
Blower Mou ntin g Gasket [Inc luded in Key No. 2F]
[1] 8 206048
[1] 8 206049
2F
Blo wer
[1] 6111714
[1] 6111715
2G
Orific e Plate Gas ket [(2) Inc luded in Key No. 2F]
[2] 8 206042
[2] 8 206035
2H
Orifice Plate
2J
Pressure Fitting, Dwy er A 308
2K
Hex Nut, 1/4-20, B rass [(4) Included in Key No. 2F]
2L
Hex Loc knut, …-20
2M
Flue B affle
[2] Common Hardwa re
[10] Common Hardwa re
[2] Common Hardwa re
[1] 71117035
[1] 71117045 [1] 71117055 [1] 71117065
[1] 822657
[4] 80 860424
[4] Common Hardwa re
No t Applicable
25
Key
No.
[Quantity] Part Number
Description
203PV
204PV
205PV
206PV
Bas e A ssem bly, Complete
[1] 618 600391
[1] 618 600491
[1] 618 600591
[1] 618 600691
3A
Base Tray Assemb ly
[1] 718 600391
[1] 718 600491
[1] 718 600591
[1] 718 600691
3B
Ba se Wrapp er
[1] 7186 00311
[1] 7186 00411
[1] 7186 00511
[1] 7186 00611
3B1
B ase End Insulation
3B2
B ase Rear Ins ulation
3C
3. Base Assembly Group
3
[2] 720601
[1] 72 060035
[1] 72 060045
[1] 72 060055
[1] 72 060065
Ba se Fr ont Panel As semb ly
[1] 618 600341
[1] 618 600441
[1] 618 600541
[1] 618 600641
3D
Burner Tray
[1] 718 600305
[1] 718 600405
[1] 718 600505
[1] 718 600605
3E
Base Leg Assemb ly
3E1
B ase Leg
3E2
Nylo n Glide
[4] 6 186001
[4] 71 860021
8 186006
3F
Bu rner Ac cess P anel
[1] 718 600361
[1] 718 600461
[1] 718 600561
3G
J ack et Attachme nt Bracket, Le ft
[1] 704 60011
3H
Jac ket A ttac hment B rac ket, Right
[1] 70 460012
3J
Cerafelt Gas ket, ‰" x 2"
Johns-Mans ville CRF-400
3K
Scr ew, S elf-Ta pping Ty pe F, Phill ips Pan
Head, …-20 x ‰", Plated
3L
Sc rew, Self Tapping, 5/16-18 x 1…"
3M
Washer, 5/16, US S
[4] Common Hardwa re
3N
Washer, Loc k, US S
[4] Common Hardwa re
3P
Nut, Hex, 5/16-18, B ras s
3R
Sc rew, S heet M etal , Phillips Head, #8 x ‰"
[1] 6 206002
[20] 80 860700
[4] 80 860717
[4] 80 860403
[2] Common Hardwa re
26
[1] 718 600661
[ Quant ity] Part Num ber
K ey No.
Description
203PV
204PV
205PV
206PV
[2] 8 236099
[4] 8 236099
[6] 8 236099
[8] 8 236099
4 . Ma n ifo ld a n d Ma in Bu rn e rs
4A
Main Burn er
4B
Mai n Bur ner with 60 Pilot Brac ket
4C
M anifold
[1] 8 236098
[1] 82 260033 [1] 82 260043 [1] 82 260053 [1] 82 260063
4D (Natural
Ga s Only )
Main Burner Orifice, #44, Orange
4D
(LP/Propane
Only )
Main Burner Orifice, #55 , Green
4E
S crew, Ma chine, #1 0-32 x 3/16"
[2] 80 860800
4F
Scr ew, S elf-Ta pping Ty pe F, Phill ips Pan
Head, 1/4-20 x 1/2", Plated
[4] 80 860700
M ain B urner Orific e, #45, Pi nk
Main Burner Or ifi ce, 1.25mm , Purple
27
[3] 822712
-----
-----
-----
-----
[5] 8 22711
[7] 8 22711
[9] 8 22711
[3] 822708
-----
-----
-----
-----
[5] 822705
[7] 822705
[9] 822705
[Quantity] Part Number
Key
Des cription
No.
203PV
204PV
205PV
206PV
5 . Pi lo t Bu r n e r a nd G a s Va l v e
P ilo t A sse mb ly, N atural Ga s, Ho ney we ll Q34 8A133 3
[1] 8 236104
Pil ot As sem bly, LP Ga s, Ho ney we ll Q34 8A 134 1
[1] 8 236107
5A
P ilo t Or ifi ce , N atural Ga s Ho neywe ll 38 814 6NE
5B
Incl uded with Key No.5A
Pi lo t Or ific e, L P/P ro pan e Hon ey wel l 388 146 KP
5C
Co mp re ssio n Nut/Fi tting , 1 /8" OD x … NP T
5D
Pi lot Tu bin g, 1/8 " OD x 3 0"
Included with Key No.5A and 5E
[1] 82 36110
Gas Va lv e, ‰ x ‰, Natura l Ga s, Ho ney we ll V R82 04C 600 0
[1] 81 660176
Gas Va lv e, ‰ x ‰, LP/Pr opa ne, Ho neywe ll V R82 04C 601 8
[1] 81 660180
5E
5F
Ig nite r/S en so r Ca ble , 3 6", Hon ey wel l 394 800 -3 6
[1] 8 236084
5G
Gr ound Wire As semb ly
[1] 6 136054
28
Key
No.
[ Quant ity] Part Number
Description
203PV
204PV
205PV
206PV
[1] 604 170312
[1] 604 170412
[1] 604 170512
[1] 604 170612
6. Jacket
6A
Jac ket Wrap-A-Rou nd Pan el (1)
6B
Jac ket Uppe r Ves tibu le Pan el (1)
[1] 6041 703221
[1] 6041 704221
[1] 6041 705221
[1] 6041 706221
6C
Ja cket Lower Ves tibule P anel
[1] 6041 703222
[1] 6041 704222
[1] 6041 705222
[1] 6041 706222
6D
J ack et Top Panel (1) (2)
[1] 604 170334
[1] 604 170434
[1] 604 170534
[1] 604 170634
6E
Jac ket Fr ont Remov able Do or
[1] 604 170344
[1] 604 170444
[1] 604 170544
[1] 604 170644
6F
Jack et Lower Front P anel
[1] 604 170313
[1] 604 170413
[1] 604 170513
[1] 604 170613
6G
Screw, S heet M etal, #8 x ‰"
6H
S nap B ushing , Heyc o SB -1093-15
[2] 8 136257
6J
S nap B ushing , Heyc o SB -2000-26
[1] 8 136266
6K
Snap Bushi ng, Heyco S B-437 -5
[1] 8 136048
6L
B urnham Logo Plate
[20] Common Hardwa re
[1] 81 460107
(1) For boilers installed in Canada , indicate ’For Canada’ whe n ord ering.
(2) For bo ilers ins tall ed in California, in dicate ’For California’ whe n ord ering.
29
30
[Quantity] Part Number
Key No. Description
203PV
204PV
205PV
206PV
7. Miscellaneous Trim and Controls
7A
Safety Relief Valve, 30 psi,
Conbraco 10-408-05
7B
Limit, Honeywell L40 80D1036
7B1
Im mersion Well, ‰ NPT
7B2
Im mersion Well,
(Dual Limit Only)
7B3
Lim it Honeywell L4080 B1212 (Dual Limit Only )
7C
Transformer/Relay, Honeywell R82 85D5001
[1] 80 160155U
7C1
Relay, DPS T, Honeywell R82 22U1006
[1] 80 160096U
7C2
Junc tio n Box, 4" x 4" x 1‰"
[1] 8 136259
7D
Flame Rollout Switch
[1] 80 160044
7D1
Flam e Rollout Switch Bracket
[1] 7 186018
7E
NPT,
[1] 81 660319
[1] 80 160156
Included with 7B
NPT, Honeywell 1238 70A
[1] 80 160426
[1] 80 160474
Suction Pressure S witch
[1] 80 160180
[1] 80 160181
Sili cone Tubing, 1/8" x 11"
Silicone Tubing, 1/8" x 12‰"
7E1
9016001 (Specify L ength)
Silicone Tubing, 1/8" x 13-5 /8"
Silicone Tubing, 1/8" x 15…"
7F
Ignition Module, Ho neywell S8670E1007
[1] 80 160108
7G
Temperatu re-Pres sure Gauge
[1] 8 056164U
Circu lator with Gaskets, Bell & Gossett NFR-22
[1] 8 056174
Circulator with Gaskets, Grun dfos UP 15-42F
[1] 8 056173
Circulator with Ga skets , Taco 007F
[1] 8 056170
Circulator with Gaskets, Taco 0010
[1] 8 056176
7H
Ga sket, B ell & Gossett NFR-22 (SLC-3 0)
[2] 806 602029
Gasket, Grundfos 510179
[2] 806 602016
Gasket, Taco ’00 ’ Seri es
[2] 806 602006
7J
Flange, 1… NPT
[2] 806 602013
7 J1
Screw, Cap Hex Head, 7/16-14 x 1‰"
[4] Common Hardwa re
7 J2
Nut, Hex, 7 /16-14
[4] Common Hardwa re
7K
Drain Valve,
7H1
NP T, Conbraco 31-606-02
[1] 8066 03011
[Quant ity] Part Num ber
K ey No.
Description
203PV
8. Vent Accesso ry Carto n
204PV
205PV
611170322
611170522
[1] 8116102
[1] 8116103
8A
Vent Connector
8B
Vent Terminal
[1] 8116063
8C
Locking Band
[1] 8116101
8D
Silico ne Se alant, 3 oz . tube, Dow
Corning Silastic 732 RTV, or Sil-Bond
RTV 4500 (Ac etoxy)
[1] 8 056052
31
206PV
32
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