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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
SERIES 2PV
POWER VENT
GAS - FIRED 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.
Installation Date
Boiler Model Number Boiler Serial Number
20_PV_I -_ _ _ _ 6_ _ _ _ _ _ _
Phone Number
Heating Contractor
Address
Price - $3.00
8141775R12-3/01
1
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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. DANGER CAUTION Indicates an imminently hazardous Indicates a potentially hazardous situation which, if not avoided, may result situation which, if not avoided, will result in moderate or minor injury or property in death, serious injury or substantial damage. property damage. NOTICE WARNING Indicates special instructions on
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3 Figure 1: Elevation Views
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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 D. Provide clearance between boiler jacket and installing boiler. Failure to follow all combustible material in accordance with local fire instructions in proper order can cause ordinance. See Figure 2 for minimum clearance from personal injury or death. combustible material for closet installation. For alcove
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2. Determine Total Input of all appliances in space. a. Direct communication with outdoors. Minimum Round result to nearest 1,000 Btu per hour (Btuh). 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 a. If result is greater than or equal to 50 ft³ per 1,000 in space. Duct cross-sectional area shall be same
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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 Failure to properly pipe boiler may result in Service Instructions for additional information. improper operation and damage to boiler or G. If boiler is used in connection with refrigeration systems , building. boiler must be installed with chilled medium piped in parallel with the heati
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Figure 3: Recommended Boiler Piping For Series - Loop Hot Water Heating Systems Figure 4: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems 7
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IV. Gas Piping A. Size gas piping. Design system to provide adequate 3. Install sediment trap, ground-joint union and manual gas supply to boiler. Consider these factors: shut-off valve upstream of boiler gas control valve and outside jacket. See Figure 6. 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ 4. All above ground gas piping upstream from manual psig. Actual point of delivery pressure may be less; shut-off valve must be electrically co
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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 0.5 inch w.c. Pressure Drop Length [Feet] ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1,050 175 360 680 1,400 20 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
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Table 5: Burnham Vent System Components (d) Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Burnham Burnham Adjust thermostat so appliance will operate Vent System *Cartoned Component continuously. Component Part Part (e) Test for spillage at the drafthood relief opening after Number Number 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or 3" Dia. Pipe x 1 Ft 61160112 8116135 pipe. 3" Dia
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2. Vent terminal location restricted per following: D. Install Vent Pipe, General. a. Minimum 12 inches above grade plus normally 1. Start at vent connector. Work toward vent terminal. expected snow accumulation level, or 7 feet 2. Use ¾ inch pipe strap to support horizontal runs, above grade if located adjacent to public maintain vent location and slope, and prevent sags. walkway. Do not install over public walkway Do not restrict thermal expansion movement. where local experience indicates con
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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 1. Zoning with Circulators, Domestic Hot Water jurisdiction, or in absence of such requirements the Priority. Provide DPDT relay (included with PAL). National Electrical Code, ANSI/NFPA 70, and/or the Connect coil to Alliance thermostat (prewired with CSA C22.1 Electric Code. PAL). Connect normally open contacts (
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Figure 10: Wiring Diagram VII. System Start-up 8. Open zone valve to second zone to be purged, then A. Safe operation and other performance criteria were met close first. Repeat this step until all zones have been with gas manifold and control assembly provided on purged, but always have one zone open. At boiler when boiler underwent tests specified in completion, open all zone valves. American National Standard for Gas-Fired Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13. 9. Close bib c
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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 pi
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Table 6: Gas Flow Rate in Cubic Feet per Hour Size of Gas Meter Dial Seconds for One One-Half One Two Revolution Cu. Ft. Cu. Ft. 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 Figure 16: Main Burner Flame 44 41 82 164 46 39 78 157 J. Check thermostat operation. Raise and lower 48 37 75 150 temperature setting to start and stop boiler operation. 50 36 72 144 K. Check ignition control module shut-off. Disconnect igniter/sensor cable from Ter
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Figure 17: Operating Instructions Adjust gas valve pressure regulator as necessary subsequent boiler operation. (turn adjustment screw counterclockwise to 2. Ventilate the boiler room, set the high limit to its decrease manifold pressure, or clockwise to increase maximum setting, set the thermostat to call for heat. manifold pressure). If pressure can not be attained, Allow the boiler to fire for at least an hour or until check gas valve inlet pressure. If less than minimum the odor from the cor
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TROUBLE SHOOTING GUIDE SPLIT (SEPARATE) CONTROLS, 24 VOLT OPERATION WITH ELECTRONIC IGNITION AND INTERMITTENT CIRCULATION NOTE: 1. Read Sequence of Operation prior to using Trouble Shooting Guide. See Page 14. 2. Prior to replacing a control, always check for broken wires or loose connectors that provide power to that control. 17
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Note: Minimum pilot signal should be 1.0 microamps. Disconnect Pilot Ground wire from Module and connect DC microammeter between Ground Terminal and Pilot Ground wire. 19
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Important Product Safety Information Refractory Ceramic Fiber Product Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. After this product is fired, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Precautionar
