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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
CHG™ SERIES
CONDENSING HIGH EFFICIENCY
GAS - FIRED HOT WATER BOILER
Models: • CHG150 • CHG225
WarninG : Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
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Table of Contents I. Product Description .................................................................. 3 II. Specifications ........................................................................... 3 III. Before Installing ........................................................................ 4 IV. Locating The Boiler ................................................................... 4 V. Air For Ventilation ..................................................................... 6
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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. This boiler is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen. II Specifications Figure 2.1: General Configuration Table 2.2: Specifications D.O.E. V
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III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1. • Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and Safety Devices
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Figure 4.1: Clearances To Combustible Or non-combustible Material Table 4.2: Clearances From Vent Piping To Combustible Construction MINIMUM CLEARANCE TO COMBUSTIBLE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MATERIAL AT LEAST ONE SIDE OPEN, BURNHAM AL29-4C VERTICAL OR 1” COMBUSTIBLE MATERIAL ON A AL TERNA TE: HORIZONTAL MAXIMUM OF THREE SIDES HEAT FAB SAF-T VENT PROTECH FASNSEAL HORIZONTAL OR VERTICAL Z-FLEX Z-VENT III 2-1/2” WITH OFFSETS ENCLOSED ON ALL FOUR SIDES FLEX-L STAR-34 VERTICA
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ar w NINg OUTDOOR COMBUSTION AIR MUST BE PIPED TO THE AIR INTAKE. NEVER PIPE COMBUSTION AIR FROM AREAS CONTAINING CONTAMINATES SUCH AS SWIMMING POOLS AND LAUNDRY ROOM EXHAUST VENTS. CONTAMINATED COMBUSTION AIR WILL DAMAGE THE BOILER AND MA Y CAUSE PROPER TY DAMAGE, PERSONAL INJUR Y OR LOSS OF LIFE AND WILL VOID THE MANUF ACTURER’S W ARRANTY . V Air for Ventilation Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must s
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Figure 5.1: Boiler Installed In A 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.
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VI Venting ar w NINg Failure to vent this boiler in accordance with these instructions could result in unreliable boiler operation, severe damage to the boiler or property, or unsafe operation: • Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 4. • Do not attempt to mix components from different approved vent systems. • Do not obtain combustion air from within the building. • Do not install a barometric damper or drafthood on this boi
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The V ent Option #1 column in T able 6.2a describes a horizontal direct vent system using 3” vent pipe. From this column, we see that a CHG150 may have a vent length of up to 55ft. The first 90 elbow and the termination elbow are not considered. From T able 6.6, the equivalent length of the 3” 45 elbow is 4ft and the equivalent length of the 3” 90 degree elbow is 5.5ft. The maximum allowable run of straight pipe on this system is therefore: 55ft – 4 ft – 5.5ft = 40ft
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• The bottom of the vent and air intake terminals must be at least 12” above the normal snow line. In no case should they be less than 12” above grade level. • The bottom of the vent 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 t
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Table 6.2b: Summary of Vertical Venting Options VENT OPTION # 6 7 CLASSIFICATION USED IN THIS VERTICAL VERTICAL MANUAL DIRECT VENT DIRECT VENT ILLUSTRATED IN FIGURE 6.4 6.4 VENT PIPE STRUCTURE ROOF ROOF PENETRATION AIR INTAKE PIPE STRUCTURE ROOF ROOF PENETRATION VENT PIPE SIZE 3” 4” AIR INTAKE PIPE SIZE 4” 4” CHG150 49.5 FT N.R. CHG225 N.R. 47 FT CHG150 52 FT N.R. CHG225 N.R. 52 FT RODENT SCREEN BY VENT SYSTEM EXHAUST TERMINAL MANUFACTURER. SAME DIAMETER AS VENT SYSTEM. SEE TAB
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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 12
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• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See Section IV for more information on possible contaminates. 6) Permitted T erminals for V ertical V enting (V ent Options 6, 7) - A rodent screen is installed in the end of the vent pipe. V ent manufacturer part numbers for these screens are shown in T able 4. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rode
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Table 6.5: Burnham Vent/air intake System Components EquIV ENT al Par T VENT sysTEm COPONENT m NumbEr fEET O P f IPE 3” DIA. PIPE X 1 FT. 81 16296U 1 4” DIA. PIPE X 1 FT. 100176-01 3” DIA. PIPE X 3 FT. 81 16298U 3 4” DIA. PIPE X 3 FT. 100177-01 3” DIA. PIPE X 5 FT. 81 16300U 5 4” DIA. PIPE X 5 FT. 100178-01 3” DIA. PIPE x ADJUST ABLE 81 16319U **EqUAL TO Table 6.6: Vent/air intake Fitting INSTALLED LENGTH 4” DIA. PIPE x ADJUST ABLE 100179-01 Equivalent Length (1.06 to 1.64) VENT fITTINg EquI
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B. Removing an Existing Boiler From a Common Chimney Read this only if the CHG boiler is replacing an existing boiler that is being removed from a common chimney . This section does not apply to the installation of a CHG boiler . In some cases, when an existing boiler is removed from a common chimney , the common venting system may be too lar ge for the remaining appliances. At the time of removal of an existing boiler , the following steps shall be followed with each appliance r
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® 2) This appliance requires a Special Gas V ent. The product is designed to use Burnham supplied AL 29-4C Stainless Steel vent system components when utilizing the supplied vent adaptor . The following manufacturers of fer similar ® AL 29-4C components and are approved for use with this product. The use of these alternate manufacturer ’ s venting systems can be utilized by connecting directly to the installed vent pipe (supplied adaptor is not required). See T able 6.5 for com
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Figure 6.7a: Star-34 Connection to Vent Collar Figure 6.7b: Star-34 Connections l) Cut the excess joiner band so that it lays flat in the beaded ch annel (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 the female end and the stop bead of the male end (Fig 6.7b). n) Repeat Steps (h) – (m) for the remaining Star -34 components . p) Allow the silicone to cure per the silicone manufactur
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i) Align the second piece of pipe with the first and push them to gether as far as they will go, but not less than 1-3/4”. j) T ighten gear clamp to a minimum torque of 40 in-lbs and a m aximum of 50 in-lbs. k) Repeat Steps (h) – (j) for the remaining Z-V ent III componen ts. l) In horizontal vent systems, a locking band or gear clamp must be used at either side of the wall penetration to prevent shifting of the vent system in and out of the wall. This applies to both com
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Figure 6.: SaF-T Vent Ezseal Connection to Vent Collar 7) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the p iping labels are in the direction of flue gas flow . • Support horizontal piping sections at intervals of 6 feet or les s. • V ertical venting systems must be supported by at least one Fa sNSeal support. An additio
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Figure 6.10: FasnSeal Connection to Vent Collar VII Condensate Drain Line 1) All condensate which forms in the boiler or vent system collects in the sump under the heat exchanger and leaves the boiler through the condensate trap. This trap allows condensate to drain from the sump while retaining flue gases in the boiler . A length of drain hose is supplied with the boiler and is connected to the trap as shown in Figure 6.1 1. This hose may be routed through the back of the boiler or t
