Burnham CHG CHG150, Installation & Operation Manual

Page 1: ...ion consult a qualified installer service agency or the gas supplier This boiler requires a special venting system Read these instructions carefully before installing D N A G N I T A R E P O N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S S E I R E S G H C Y C N E I C I F F E H G I H G N I S N E D N O C R E L I O B R E T A W T O H D E R I F S A G 100343 01 3 06 ...

Page 2: ...5 VII Condensate Drain Line 20 VIII Gas Piping 22 IX System Piping 23 A General System Piping Precautions 23 B System Design 23 C Standard Piping Installation Requirements 32 D Piping For Special Situations 33 X Wiring 35 XI Start up and Checkout 39 XII Operation 44 XIII Service and Maintenance 49 XIV Troubleshooting 51 XV Parts 55 Appendix A Special Requirements For Side Wall Vented Appliances In...

Page 3: ...R SHOWN FOR PROPANE MODEL NUMBER ie CHG225LP PERFORMANCE RATINGS ARE THE SAME FOR BOTH FUELS Figure 2 1 General Configuration I Product Description The CHG is an aluminum gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180 F or less This boiler may be vented vertically or horizontally with combustion air supplied from outdoors...

Page 4: ...e the boiler to have either the DOE Heating Capacity required for the Alliance or the net rating required for the heating system whichever results in the larger boiler For systems that incorporate other indirect water heaters refer to the indirect water heater manufacturer s instructions for boiler output requirements 5 Make sure that the boiler received is configured for the correct gas natural o...

Page 5: ... BURNHAM AL29 4C ALTERNATE HEAT FAB SAF T VENT PROTECH FASNSEAL Z FLEX Z VENT III FLEX L STAR 34 VERTICAL OR HORIZONTAL AT LEAST ONE SIDE OPEN COMBUSTIBLE MATERIAL ON A MAXIMUM OF THREE SIDES 1 HORIZONTAL OR VERTICAL WITH OFFSETS ENCLOSED ON ALL FOUR SIDES 2 1 2 VERTICAL WITH NO OFFSETS Figure 4 1 Clearances To Combustible Or Non combustible Material ...

Page 6: ... 3 Divide the volume of the boiler room by the input in thousands of BTU hr If the result is less than 50 the boiler room is a confined space Example A CHG225 and a water heater are to be installed in a room measuring 6ft 3 in x 7ft with an 8 ft ceiling The water heater has an input of 30000 BTU hr Total input in thousands of BTU hr 225000 BTU hr 30000 BTU hr 1000 255 MBTU hr Volume of room 6 25 f...

Page 7: ...Confined Space Ventilation Air From Inside Step 2b If the boiler is to be placed in an unconfined space the natural infiltration into the boiler room will provide adequate air for ventilation without additional openings into boiler room ...

Page 8: ...anned vent and air intake system exactly In addition observe the following guidelines 1 Approved vent systems Use only one of the approved vent systems shown in Table 4 These systems are made of a special stainless steel alloy AL29 4C for protection against corrosive flue gas condensate They are also designed to provide a gas tight seal at all joints and seams so that flue gas does not enter the b...

Page 9: ...e Terminal Location Observe the following limitations on the vent terminal location also see Figure 6 3 Vent terminals must be at least 1 foot from any door window or gravity inlet into the building Maintain the correct clearance and orientation between the vent and air intake terminals The vent and air intake terminals must be at the same height and their center lines must be between 12 and 36 in...

Page 10: ... terminal must be at least 7 feet above a public walkway Do not install the vent terminal directly over windows or doors The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters electric meters regulators and relief equipment Do not install vent t...

Page 11: ... ROOF ROOF VENT PIPE SIZE 3 4 AIR INTAKE PIPE SIZE 4 4 MAXIMUM VENT PIPE LENGTH CHG150 49 5 FT N R CHG225 N R 47 FT MAXIMUM INTAKE PIPE LENGTH CHG150 52 FT N R CHG225 N R 52 FT EXHAUST TERMINAL RODENT SCREEN BY VENT SYSTEM MANUFACTURER SAME DIAMETER AS VENT SYSTEM SEE TABLE 6 5 AIR INTAKE TERMINAL 4 180 ELBOW 4 180 ELBOW VENT MATERIAL APPROVED VENT SYSTEM SHOWN IN TABLE 6 5 AIR INTAKE MATERIAL GAL...

Page 12: ... Figure 6 3a Location of Vent Terminal Relative to Windows Doors Grade Figure 6 3b Location of Vent Terminal Relative to Meters and Forced Air Inlets Figure 6 3c Positioning Vent Terminal Under Overhangs ...

Page 13: ... least 12 The bottom of the air inlet terminal must be at least 12 above the normal snow accumulation that can be expected on the roof The air intake terminal must be located on the roof and must be no further than 24 horizontally from the exhaust pipe 8 Wall thimbles Wall thimbles are required where the vent pipe passes through combustible walls with less than the required clearance shown in Tabl...

Page 14: ...ll Thimble 100184 01 3 Double Wall Thimble 8116115 4 Double Wall Thimble 100185 01 Table 6 6 Vent Air Intake Fitting Equivalent Length VENT FITTING EQUIVALENT LENGTH ft 3 90 ELBOW 5 5 3 45 ELBOW 4 0 4 90 ELBOW 8 0 4 45 ELBOW 4 5 Table 6 5a Alternate Vent Systems and Vent Components MANUFACTURER VENT SYSTEM SIZE WALL THIMBLES HORIZONTAL TERMINATION VERTICAL TERMINATION HEAT FAB SAF T VENT EZ SEAL 3...

Page 15: ...rom 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 appliances to their previous condition of use g Any improper operation of the common venting system should be corrected so the installation conform...

Page 16: ...ly of Flex L Intl Star 34 Vent System a Star 34 General Notes Do not cut Star 34 vent components Support horizontal piping sections at intervals of 48 or less Vertical venting systems must be supported by at least one Star 34 Fire stop An additional vertical support is required after any offset Orient Star 34 components so that the arrows on the piping labels are in the direction of flue gas flow ...

Page 17: ...nstallation instructions b Start assembly of the vent system at the boiler Remove the hose clamp shipped on the CHG vent collar Bend the three hose clamp tabs on this collar outward slightly c Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler Remove dirt grease and moisture from the surfaces to be sealed Dry surfaces or allow to dry thoro...

Page 18: ...port An additional vertical support is required after any offset b Connection to Boiler Start assembly of the vent system at the boiler Remove the hose clamp shipped on the CHG vent collar Bend the three hose clamp tabs on this collar outward slightly Cut the male spigot off of the first piece of pipe Fig 6 9 If necessary crimp the cut end of the pipe so that it can be inserted at least 1 into the...

Page 19: ... a gasket in the female end of the pipe for a proper seal d Align the longitudinal seam of both pipes Insert the male end of the second pipe into the female end of the first pipe until the bead on the male end contacts the flare on the female end e Tighten the locking band with a nut driver f Repeat d and e for the remaining FasNSeal components g Allow the silicone to cure per the silicone manufac...

Page 20: ...ot use metallic pipe or fittings in the condensate drain line Do not route the drain line through areas that could be damaged by leaking condensate c Some jurisdictions may require that the condensate be neutralized before being disposed of Dispose of condensate in accordance with local codes d Do not route or terminate the condensate drain line in areas subjected to freezing temperatures e If the...

Page 21: ...ORROSIVE ROUTE CONDENSATE DRAIN LINE IN A MANNER SUCH THAT ANY CONDENSATE LEAKAGE WILL NOT CAUSE PROPERTY DAMAGE SOME JURISDICTIONS MAY REQUIRE THAT CONDENSATE BE NEUTRALIZED PRIOR TO DISPOSAL Figure 6 11 Condensate Piping Arrangement ...

Page 22: ...pstream of all gas controls Install the factory provided manual shut off valve outside the jacket with a ground joint union as shown The boiler and its gas connection must be leak tested before placing the boiler in operation When doing this the boiler and its individual shut off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of 1...

Page 23: ... 10 kw 34 MBTU PER END SECTION WITH LOAD BASED ON NET CALORIC VALUE THIS EQUATES TO 75 000 BTU HR GROSS CALORIC INPUT FOR CENTER SECTION AND 37 500 BTU HR GROSS CALORIC INPUT FOR AN END SECTION MAXIMUM ALLOWABLE DELTA T BETWEEN SUPPLY AND RETURN DURING OPERATION IS 45 F AT MAXIMUM LOAD AND 63 F AT MINIMUM LOAD THE PRODUCT SHALL AT ALL TIMES BE FILLED WITH CLEAN POTABLE WATER THE ONLY ALLOWABLE ADD...

Page 24: ...ater connections are smaller than the pipe size called for in column a reduce the pipe size at the indirect water heater connections To size the circulator a Count all fittings in the planned Indirect Water Heater Loop the indirect water heater loop consists of the shaded piping in Figure 8 4b In doing so you will be counting some piping and fittings which are common to the heating system secondar...

Page 25: ...25 Figure 8 3 Piping Method 1 Heat Indirect Water Heater Figure 8 2 Piping Method 1 Heat Only ...

Page 26: ...26 Figure 8 4b Piping Method 1 Indirect Water Heater Loop Piping Shaded Figure 8 4a Piping Method 1 Secondary Loop Piping Shaded ...

Page 27: ...GPM ft HEAD ft CHG150 1 1 4 8 0 3 0 AL26A AL40A ALG40 ALG50 Taco 007 26 CHG150 1 1 4 8 0 3 0 AL26A AL40A ALG40 ALG50 Taco 0010 165 CHG150 1 1 4 8 0 5 0 AL53A AL79A Taco 0010 96 CHG150 1 1 4 10 0 5 0 ALG79 NOTE 1 Taco 0010 38 CHG225 1 1 4 9 0 3 0 AL26A AL40A ALG40 ALG50 Taco 007 90 CHG225 1 1 4 9 0 5 0 AL53A AL79A Taco 0010 97 CHG225 1 1 4 10 0 5 7 ALG79 ALG100 NOTE 2 Taco 0010 60 Note 1 ALG100 or ...

Page 28: ...l these equivalent lengths and add them to the total length of straight pipe measured in step a The result is the total equivalent length of the primary loop c Using Table 8 5 find the boiler size being installed and select a boiler primary circulator that shows a maximum equivalent length column d in excess of the total equivalent length calculated in Step b 3 Indirect Water Heater Loop Piping If...

Page 29: ...29 Figure 8 8 Piping Method 2 Heat Only Figure 8 9 Piping Method 2 Heat Indirect Water 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 Water Heater Loop Piping Bolded Figure 8 11 Piping Method 3 Direct Connection of Boiler to Heating System ...

Page 32: ...ded pipe If the relief valve discharge is not piped to a drain it must terminate at least 6 inches above the floor Do not run relief valve discharge piping through an area that is prone to freezing The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris 2 The fitting in which the gauge relief valve and LWCO are to be mounted must n...

Page 33: ...ulator zone systems through zones that are not calling for heat 10 Isolation Valves Recommended Isolation valves are useful when the boiler must be drained as they will eliminate having to drain and refill the entire system 11 Drain Valve Required The drain valve is installed on the return tee located in the lower vestibule compartment as shown in Figure 8 2 12 Low Water Cut off Required The low w...

Page 34: ...34 Figure 8 14 Chiller Piping Figure 8 13 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger ...

Page 35: ...5 and 6 the boiler will adjust the target space heating set point supply water temperature downwards as the outdoor air temperature increases If used this sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house Avoid placing this sensor in areas where it may be covered with ice or snow In general locations where the senso...

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 Two Heating Circulators ...

Page 39: ...tructions before attempting to fire boiler Make sure that the silicone cure time called for in the vent assembly instructions has passed before firing boiler 5 Inspect all line voltage wiring for loose or uninsulated connections 6 Remove the dust cap from the condensate trap Fig 6 11 Add water to the trap until water runs out the condensate drain Reinstall the dust cap NOTE SAFE LIGHTING AND OTHER...

Page 40: ...40 CHG Series Lighting and Operating Instructions ...

Page 41: ...n are needed it will be necessary to press the reset button to restart the boiler Once a flame has been established for the first time subsequent calls for burner operation should result in a flame on the first try 9 Inspect the flame visible through the window On high fire the flame should be stable and mostly blue Fig 10 1 No yellow tipping should be present however intermittent flecks of yellow...

Page 42: ...s been driven to high fire After this happens allow the boiler to operate for approximately 5 minutes before taking combustion readings b To lock the boiler in low fire simultaneously press and hold the Mode button and button until the display flashes L indicating that the boiler has been driven to low fire After this happens allow the boiler to operate for approximately 5 minutes before taking co...

Page 43: ...the appropriate circulators also start and stop in response to the thermostats 14 As shipped the heating and indirect water heater set point supply temperatures are both set to 180 F If necessary adjust these to the appropriate settings for the type of system to which this boiler is connected See the Operation Section of this manual for information on how to do this 15 Adjust the heating and indir...

Page 44: ... safety controls including the low water cut off and safety limit are connected into the MCBA The MCBA uses input from all of these controls to either shut down the boiler when an unsafe condition exists or in some cases to correct the problem 2 The display panel has three primary modes of operation These are Standby Mode Displays boiler s current status This is the default operating mode Paramete...

Page 45: ... boiler supply temperature will exceed 180 F and there is a possibility that the safety temperature limit will open If this happens the boiler will shut down and a b26 error will appear on the display The boiler will resume normal operation without manual intervention when the safety limit closes this behavior is common on conventional boilers Information mode is used to view various temperatures ...

Page 46: ...46 Figure 11 2 Basic Menu Tree ...

Page 47: ...ply water target temperature increases For example if the outdoor air temperature is 30 F the set point temperature for the supply water is 140 F 5 An indirect water heater thermostat can be connected between terminals 7 and 8 on the terminal strip When this thermostat closes the central heating circulator will be turned off and the DHW circulator will be turned on 6 An external limit control can ...

Page 48: ...fan ignition speed setting If the flame fails to prove the control module will attempt to light the burner 4 more times If a flame is still not established the control will lockout e Once the flame stabilization period has ended the MCBA allows the burner to modulate The actual firing rate is dependent upon the measured current and recent differences between the set point temperature and the suppl...

Page 49: ...o verify they are free from leaks Call the service technician to make repairs if required 3 Required Annual Inspections and Service In addition to the inspections listed above the following shall be performed by a service technician once every year a Test the low water cutoff by pressing the Test button located at its end The yellow light should come on and E12 should flash on the display Push the...

Page 50: ... remove accumulation of any loose particulate from the pins and heat transfer surfaces Clean the casting pins by flushing with clean water using a standard garden spray nozzle Do not use any cleaning agents or solvents A soft nylon brush may be used in accessible area Remove inspection cover and inspect Condensate collector sump Drain and flush the condense collector and condensate drain as requir...

Page 51: ...ded Display reads U 125 continuously Fan running Defective AT250 transformer Blown F3 fuse in MCBA see Figure 13 2 for location Replace with 4A slow blow fuse provided Boiler not responding to call for heat Status code on display 0 see Figure 11 1 Boiler is not seeing call for heat Check thermostat or zone wiring for loose connection miswiring or defective thermostat zone control Boiler fires but ...

Page 52: ...ed b 24 MCBA is reading a return sensor temperature higher than the supply sensor temperature Condition must be present for at least 75s for this error code to appear Flow through boiler reversed Verify correct piping and pump orientation No boiler water flow Verify that system is purged of air and that appropriate valves are open Sensor wiring reversed Supply or return sensor defective b 25 Suppl...

Page 53: ...ess and check for 24VAC across AT140 transformer E 13 E 14 E 15 E 16 E 17 Internal control failure Reset the control If problem reoccurs replace the MCBA E 18 MCBA supply sensor detected temperatures in excess of 200 F for an extended period of time See possible causes for b18 error Also check safety limit for proper operation E 19 MCBA return sensor detected temperatures in excess of 200 F for an...

Page 54: ...54 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 55: ... 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 ...

Page 56: ...t Washer 80860635 4 80860635 4 22 Inspection Port Window 100420 01 1 100420 01 1 23 Upper Vestibule Door 100421 01 1 100421 02 1 24 Partition 100422 01 1 100422 02 1 25 10 x 1 2 Truss Hd Screw 100423 01 21 100423 01 21 26 Shutter Bushing for 875 Hole 100424 01 2 100424 01 2 27 Flat Wire Clip Ribbon Cable 100425 01 2 100425 01 2 28 Right Side Panel Assembly 100426 01 1 100426 01 1 29 5 16 ID Cable ...

Page 57: ...2 x 3 16 Ground Screw 100464 01 1 100464 01 1 68 Control Chassis 100465 01 1 100465 01 1 69 4 X 4 J Box 100466 01 1 100466 01 1 70 4 X 4 J Box Cover Plate 100467 01 1 100467 01 1 71 Resistor Clamp 312 Dia 100468 01 1 100468 01 1 72 Terminal Block 375 c c 9 Pole 100469 01 1 100469 01 1 73 Pressure Switch 100470 01 1 100470 01 1 74 40VA Transformer LWCO Power Supply 100471 01 1 100471 01 1 75A Boile...

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Page 62: ...0507 01 1 100507 01 1 107 Sight Glass Gasket 5mm 100508 01 2 100508 01 2 109 Ignition Electrode 100509 01 1 100509 01 1 110 Ignition Electrode Gasket 5mm 100510 01 1 100510 01 1 111 Exhaust Pipe Lip Ring Seal 100511 01 1 100511 02 1 112 Burner Hood 100512 01 1 100512 02 1 113 Burner 100513 01 1 100513 02 1 114 Burner Hood Seal 100514 01 1 100514 02 1 115 Burner Air Distributor Plate 100515 01 1 10...

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Page 64: ...0535 01 1 Not Shown 5mm x 20mm Fast Acting Ceramic Tube 5 Amp Fuse 100536 01 1 100536 01 1 Not Shown 5mm x 20mm Time Delay Glass Tube 4 Amp Fuse 100537 01 1 100537 01 1 Not Shown 1 2 NPT x 3 1 2 Nipple 806600188 1 806600188 NA Not Shown 1 2 NPT 90 Elbow 100539 01 1 100539 01 NA Not Shown Violet Jumper Wire 100540 01 1 100540 01 1 Not Shown X5 Plug 100541 01 1 100541 01 1 Not Shown Outdoor Sensor 1...

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Page 68: ...a product approved air intake must be used Installation shall be in strict compliance with the manufacturer s instructions A copy of the installation instructions shall remain with the appliance or equipment at the completion of the installation d A metal or plastic identification plate shall be mounted at the exterior of the building four feet directly above the location of the vent terminal The ...

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Page 72: ...9EARS IN 3ERVICE 3ERVICE HARGE AS OF 2ETAIL 0RICE O HARGE ...