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Burnham CHG150 manual

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Table of contents for the manual

  • Page 1

    Models: • CHG150 • CHG225 W ARNING : Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury , or loss of life. For assistance or additional information, consult a qualied installer , service agency or the gas supplier . This boiler requires a special venting system. Read these instructions car[...]

  • Page 2

    2 T able of Contents I. Product Description .................................................................. 3 II. Specications ........................................................................... 3 III. Before Installing ........................................................................ 4 IV . Locating The Boiler ................[...]

  • Page 3

    3 T able 2.2: Specications MODEL* NO. OF SECTIONS MAXIMUM INPUT (BTU/hr) MINIMUM INPUT (BTU/hr) D.O.E. HEA TING CAP ACITY (BTU/hr) IBR NET RA TING (BTU/hr) AFUE (%) VENT COLLAR DIAMETERS (IN.) INLET EXHAUST CHG150 3 150,000 30,000 135,000 1 17,000 93.1 4 3 CHG225 4 225,000 56,250 202,000 176,000 94.2 4 4 * MODELS SHOWN ARE FOR NA TURAL GAS. ADD [...]

  • Page 4

    4    [...]

  • Page 5

    5 T able 4.2: Clearances From V ent Piping T o Combustible Construction TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE TO COMBUSTIBLE MA TERIAL BURNHAM AL29-4C    HEA T F AB SAF-T VENT PROTECH F ASNSEAL Z-FLEX Z-VENT III FLEX-L ST AR-34 VER TICAL OR HORIZONT AL A T LEAST ONE SIDE OPEN, COMBUSTIBLE MA TERI[...]

  • Page 6

    6 W ARNING OUTDOOR COMBUSTION AIR MUST BE PIPED T O THE AIR INT AKE. NEVER PIPE COMBUSTION AIR FROM AREAS CONT AINING CONT AMINA TES SUCH AS SWIMMING POOLS AND LAUNDR Y ROOM EXHAUST VENTS. CONT AMINA TED COMBUSTION AIR WILL DAMAGE THE BOILER    [...]

  • Page 7

    7 Figure 5.1: Boiler Installed In A Conned Space, V entilation Air From Inside ?[...]

  • Page 8

    8    W ARNING   ?[...]

  • Page 9

    9 3)    4)  ?[...]

  • Page 10

    10 T able 6.2a: Summary of Horizontal V enting Options VENT OPTION # 1 2 3  5 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL DIRECT VENT HORIZONT AL DIRECT VENT (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) ILLUSTRA TED IN FIGURE 6.1 6.1 VENT PIPE STRUCTURE PENETRA TION W ALL W ALL AIR INT AKE PIPE STRUCTURE P[...]

  • Page 11

    1 1 T able 6.2b: Summary of V ertical V enting Options VENT OPTION # 6 7 CLASSIFICA TION USED IN THIS MANUAL VER TICAL DIRECT VENT VER TICAL DIRECT VENT ILLUSTRA TED IN FIGURE 6.4 6.4 VENT PIPE STRUCTURE PENETRA TION ROOF ROOF AIR INT AKE PIPE STRUCTURE PENETRA TION ROOF ROOF VENT PIPE SIZE 3” 4” AIR INT AKE PIPE SIZE 4” 4” MAXIMUM VENT PIP[...]

  • Page 12

    12 Figure 6.3a: Location of V ent T erminal Relative to Windows, Doors, Grade Figure 6.3b: Location of V ent T erminal Relative to Meters and Forced Air Inlets Figure 6.3c: Positioning V ent T erminal Under Overhangs[...]

  • Page 13

    13   [...]

  • Page 14

    14 VENT SYSTEM COMPONENT P ART NUMBER EQUIV ALENT FEET OF PIPE 3” DIA. PIPE X 1 FT .   1 4” DIA. PIPE X 1 FT . 100176-01 3” DIA. PIPE X 3 FT .   3 4” DIA. PIPE X 3 FT . 100177-01 3” DIA. PIPE X 5 FT .   5 4” DIA. PIPE X 5 FT .  3” [...]

  • Page 15

    15    ?[...]

  • Page 16

    16 2)    ®  ?[...]

  • Page 17

    17 Figure 6.7b: Star-34 Connections l)  Cuttheexcessjoinerbandsothatitlaysatinthebeadedchannel(Fig6.7b). m) Filltheinletofthebeadedchannelwithsilicone.Smooththesiliconeoverthechannelinletaswellasthe  siliconebetween[...]

  • Page 18

    18 Figure 6.8: Z-V ent III Connection to V ent Collar  ?[...]

  • Page 19

    19 Figure 6.9: SAF-T V ent Ezseal Connection to V ent Collar 7)     [...]

  • Page 20

    20 Figure 6.10: FasNSeal Connection to V ent Collar  1)  ?[...]

  • Page 21

    21 W ARNING BOILER CONDENSA TE IS CORROSIVE. ROUTE CONDENSA TE DRAIN LINE IN A MANNER SUCH THA T ANY CONDENSA TE LEAKAGE WILL NOT CAUSE PROPER TY DAMAGE. SOME JURISDICTIONS MA Y REQUIRE THA T CONDENSA TE BE NEUTRALIZED PRIOR T O DISPOSAL. Figure 6.1 1: Condensate Piping Arrangement[...]

  • Page 22

    22   [...]

  • Page 23

    23   CAUTION THE HEA T EXCHANGER USED IN THE CHG IS MADE FROM A SPECIAL ALUMINUM ALLOY .    [...]

  • Page 24

    24   [...]

  • Page 25

    25 Figure 8.3: Piping Method #1 - Heat + Indirect W ater Heater Figure 8.2: Piping Method #1 - Heat Only[...]

  • Page 26

    26 Figure 8.4b: Piping Method #1 - Indirect W ater Heater Loop Piping (Shaded) Figure 8.4a: Piping Method #1 - Secondary Loop Piping (Shaded)[...]

  • Page 27

    27 T able 8.5: Pipe and Circulator Sizing for Boiler Loop BOILER MODEL (a)    PIPE SIZE FLOW CIRCULA TOR MODEL BOILER LOOP MAX EqUIV ALENT LENGTH (in NPT) (GPM)  CHG150 1 1/4     CHG150 1 1/4    224 CHG225 1 1/4 12.0  [...]

  • Page 28

    28                           [...]

  • Page 29

    29 Figure 8.8: Piping Method #2 - Heat Only Figure 8.9: Piping Method #2 - Heat + Indirect W ater Heater[...]

  • Page 30

    30 Figure 8.10a: Piping Method #2 - Secondary Loop Piping (Bolded) Figure 8.10b: Piping Method #2 - Primary Loop Piping (Bolded)[...]

  • Page 31

    31 Figure 8.10c: Piping Method #2 - Indirect W ater Heater Loop Piping (Bolded) Figure 8.1 1: Piping Method #3 - Direct Connection of Boiler to Heating System[...]

  • Page 32

    32  ?[...]

  • Page 33

    33  ?[...]

  • Page 34

    34 Figure 8.14: Chiller Piping Figure 8.13: Isolation of the Boiler From Oxygenated W ater with A Plate Heat Exchanger[...]

  • Page 35

    35      [...]

  • Page 36

    36 Figure 9.1: Wiring Connections Diagram[...]

  • Page 37

    37 Figure 9.2: Ladder Diagram[...]

  • Page 38

    38 Figure 9.3: Wiring of Isolation Relay for Control of T wo Heating Circulators[...]

  • Page 39

    39    ?[...]

  • Page 40

    40 [...]

  • Page 41

    41   [...]

  • Page 42

    42 Figure 10.2: Gas V alve Detail   ?[...]

  • Page 43

    43        ?[...]

  • Page 44

    44   [...]

  • Page 45

    45   [...]

  • Page 46

    46 Figure 1 1.2: Basic Menu T ree[...]

  • Page 47

    47     ?[...]

  • Page 48

    48 Figure 1 1.4: Outdoor Reset Curve 7)   ?[...]

  • Page 49

    49  IMPOR T ANT W ARRANTY DOES NOT COVER BOILER DAMAGE OR MALFUNCTION IF THE FOLLOWING STEPS ARE NOT PERFORMED A T THE INTER V ALS SPECIFIED. 1) Continuously   ?[...]

  • Page 50

    50     ?[...]

  • Page 51

    51    A.  CONDITION POSSIBLE CAUSES Display Blank, Fan off, L WCO lights off • No 120V AC Power at boiler . Check [...]

  • Page 52

    52 B.   [...]

  • Page 53

    53 C.    ?[...]

  • Page 54

    54 SER VICE RECORD DA TE SER VICE PERFORMED[...]

  • Page 55

    55   All CHG Series 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 ([...]

  • Page 56

    56 CHG REPLACEMENT P ARTS LIST KEY DESCRIPTION CHG150 CHG225 BURNHAM P ART # QUANTITY BURNHAM P ART # QUANTITY 3 #8-32 x 1/4” H.W .H. Screw 100401-01 2 100401-01 2 4 Front Door Panel 100402-01 1 100402-02 1 5 #6-32 Hex Nylon Insert LockNut 100403-01 4 100403-01 4 6 Control Chassis Assembly 100404-01 1 100404-01 1 7 .125” ID x .250”OD Silicone[...]

  • Page 57

    57 CHG REPLACEMENT P ARTS LIST KEY DESCRIPTION CHG150 CHG225 BURNHAM P ART # QUANTITY BURNHAM P ART # QUANTITY 47 Nylon Glide Foot 1”Dia x 3/4” Long 100444-01 4 100444-01 4 48 Combination Base / Rear Panel 100445-01 1 100445-02 1 49 V esibule T op Panel Assembly 100446-01 1 100446-02 1 50 V ent Seal Gasket 100447-01 1 100447-02 1 51 V ent Adapt[...]

  • Page 58

    58[...]

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    59[...]

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    60[...]

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    61[...]

  • Page 62

    62 CHG REPLACEMENT P ARTS LIST KEY DESCRIPTION CHG150 CHG225 BURNHAM P ART # QUANTITY BURNHAM P ART # QUANTITY 89 #6-32 x 13mm Hex x 92mm, Long Standoff 100488-01 2 100488-01 2 90 M6 x 1.0 x 75mm, Hex Head Screw 100489-01 16 100489-01 16 91 Manifold Seal Ring, EPDM 100490-01 8 100490-01 8 92 M6 x 1.0 x 30mm, SS Hex Socket Set Screw 100491-01 6 1004[...]

  • Page 63

    63[...]

  • Page 64

    64 CHG REPLACEMENT P ARTS LIST KEY DESCRIPTION CHG150 CHG225 BURNHAM P ART # QUANTITY BURNHAM P ART # QUANTITY Not Shown 1 1-1/2” Releasable Nylon Cable Wire T ie 100533-01 1 100533-01 1 Not Shown 6” Nylon Wire T ie 100534-01 10 100534-01 1 1 Not Shown 1-5/8” Hole Plug 100535-01 1 100535-01 1 Not Shown 5mm x 20mm Fast Acting, Ceramic T ube, 5[...]

  • Page 65

    65[...]

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    66[...]

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    67[...]

  • Page 68

    68         IMPOR T ANT [...]

  • Page 69

    69 SER VICE RECORD DA TE SER VICE PERFORMED[...]

  • Page 70

    70 SER VICE RECORD DA TE SER VICE PERFORMED[...]

  • Page 71

    71 SER VICE RECORD DA TE SER VICE PERFORMED[...]

  • Page 72

    9 EARSIN3ERVICE        3ERVICE#HARGE ASOF 2ETAIL0RICE .O #HARGE      [...]