00
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-_ _ _ _
6_ _ _ _ _ _ _
Heating Contractor
Phone Number
Address
8141775R9-11/99
Installation Date
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
NOTICE
WARNING
Table of Contents
I.
Pre-Installation ..................................... 4
II.
III.
IV.
V.
Venting ................................................. 9
VI.
Electrical ............................................. 12
VII.
VIII.
IX.
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
Water Content
[Gallons]
203PV
20
14
10-1/16
15-5/8
3.2
265
204PV
23
17
11
15-5/8
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
I. Pre-Installation
C. Appliance is design certified for installation on
WARNING
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.
WARNING
Adequate combustion and ventilation air must
be provided to assure proper combustion.
CAUTION
CAUTION
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.
Figure 3: Recommended Boiler Piping For Series - Loop Hot Water Heating Systems
Boiler
Model
Number
Natural Gas
203PV
62
24
204PV
96
38
205PV
130
52
206PV
164
LP/Propane
Gas
Connection
Size
65
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
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
45 Ell
0.7
1.2
1.6
90 Ell
1.6
2.1
2.6
3.5
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.
WARNING
Do not use this appliance with nonmetallic vent
systems such as Hart & Cooley Ultravent, Plexco
Plexvent, or Selkirk-Metalbestos Sel-Vent.
continuously.
Vent System
Component
Burnham
*Car toned
Part
Number
Burnham
Component
Part
Number
611 60112
8116135
61160101
8116058
**
8116176
6116 0111
8116059
61160121
8116060
61160131
8116061
B.
10
CAUTION
11
VI. Electrical
A. General. Install wiring and ground boiler in
Instructions.
E. Alliance water heater (if used). See Figure 10. Also refer
to Alliance Installation, Operating and Service
12
13
14
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
46
39
78
157
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
M. Check limit.
1. Adjust thermostat to highest setting.
i.
15
16
17
18
19
VIII. Service
A. General. Inspection and service should be conducted
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify proper
operation after servicing.
WARNING
20
203PV
1&2
204PV
2&3
205PV
3&4
206PV
4&5
21
203PV
204PV
205PV
206PV
22
Ne bra ska
Oreg on
Ala ska
N eva da
P enns yl van ia
Arizo na
Rh ode Isla nd
Arkan sas
Ne w Jersey
S outh Caroli na
Cal iforn ia
S outh Dakota
Col ora do
Tennes s ee
Conn ecticut
Te xas
Del aware
Utah
Fl ori da
Co unties
Ve rm ont
Ge org ia
A ll other Co unties
Hawa ii
New Mexico
Ida ho
Ne w York
Ill inois
India na
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
Kan sas
K entuc ky
Loui sia na
Mai ne
A ll other Co unties
N orth Caroli na
West Virgin ia
Wisc onsin
M aryla nd
Oh io
Wyomi ng
Michig an
M issis sip pi
Co unties
M iss ouri
A ll other Co unties
Monta na
Cana da
Okl ahom a
A
A
23
1.
2.
3.
4.
5.
6.
Jacket .................................................. 29
7.
8.
SERVICE SCHEDULE
DATE
SERVICE PERFORMED
24
Key
No.
1. Section Assembly
203PV
204PV
205PV
206PV
617 170321
617 170421
617 170521
617 170621
2. Canopy/Blower Assembly
2A
Cano py
[1] 61117034
2B
2C
Wash er, , SA E
2D
2E
[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
2K
2L
2M
Flue B affle
[1] 71117035
25
Key
No.
204PV
205PV
206PV
3A
3B
Ba se Wrapp er
3B1
3B2
3C
[2] 720601
[1] 72 060035
[1] 72 060045
[1] 72 060055
[1] 72 060065
3D
Burner Tray
3E
3E1
B ase Leg
3E2
Nylo n Glide
[4] 6 186001
[4] 71 860021
8 186006
3F
3G
3H
[1] 70 460012
3J
3K
3L
3M
Washer, 5/16, US S
3N
Washer, Loc k, US S
3P
3R
[1] 6 206002
[20] 80 860700
[4] 80 860717
[4] 80 860403
[2] Common Hardwa re
26
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
4C
M anifold
[1] 8 236098
[1] 82 260033 [1] 82 260043 [1] 82 260053 [1] 82 260063
4D (Natural
Ga s Only )
4D
(LP/Propane
Only )
4E
[2] 80 860800
4F
[4] 80 860700
27
[3] 822712
-----
-----
-----
-----
[5] 8 22711
[7] 8 22711
[9] 8 22711
[3] 822708
-----
-----
-----
-----
[5] 822705
[7] 822705
[9] 822705
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
[1] 8 236107
5A
P ilo t Or ifi ce , N atural Ga s Ho neywe ll 38 814 6NE
5B
5C
5D
[1] 81 660176
[1] 81 660180
5E
5F
[1] 8 236084
5G
[1] 6 136054
28
Key
No.
204PV
205PV
206PV
6. Jacket
6A
6B
6C
6D
6E
6F
6G
6H
[2] 8 136257
6J
[1] 8 136266
6K
[1] 8 136048
6L
[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
204PV
205PV
206PV
7B
7B1
7B2
Im mersion Well,
(Dual Limit Only)
7B3
7C
[1] 80 160155U
7C1
[1] 80 160096U
7C2
[1] 8 136259
7D
[1] 80 160044
7D1
[1] 7 186018
7E
NPT,
[1] 81 660319
[1] 80 160156
Included with 7B
[1] 80 160426
[1] 80 160474
[1] 80 160180
[1] 80 160181
7F
[1] 80 160108
7G
[1] 8 056164U
[1] 8 056174
[1] 8 056173
[1] 8 056170
[1] 8 056176
7H
7J
Flange, 1 NPT
7 J1
7 J2
7K
Drain Valve,
7H1
NP T, Conbraco 31-606-02
Description
203PV
204PV
205PV
611170322
611170522
[1] 8116102
[1] 8116103
8A
Vent Connector
8B
Vent Terminal
[1] 8116063
8C
Locking Band
[1] 8116101
8D
[1] 8 056052
31
206PV
32