Burnham Revolution Service manual

8140638R5-9/09
As an ENERGY STAR®Partner, Burnham Hydronics has determined that the Revolution Series meets the ENERGY
STAR® guidelines for energy efciency established by the United States Environmental Protection Agency (EPA).
Price - $5.00
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2
IMPORTANT INFORMATION - READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.
All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.
The New York City Department of Buildings has approved the Independence® PV boiler: Approval No. MEA 100-98-E.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Independence® PV boiler. See the Massachusetts Board
of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest
Approval Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
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
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other
appliance.
If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas
supplier’s instructions or if the supplier is unavailable, contact the re department.

3
WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efciency.
Installation is not complete unless a pressure relief valve is installed into the tapping located on top of
appliance. - See the Water Piping and Trim Section of this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc-
tions, including all those contained in component manufacturers manuals which are provided with the
boiler before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.
All cover plates, enclosures and guards must be in place at all times.
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility
of the installing contractor to see that all controls are correctly installed and are operating properly when the
installation is complete.

4
Table of Contents
I. Pre-Installation............................... 6
II. Unpack Boiler ................................ 7
III. Venting/Air Intake Piping ..............8
IV. Condensate Drains ....................... 43
V. Water Piping and Trim ................. 44
VI. Gas Piping.................................... 48
Figure 1: Minimum Clearances to Combustibles
VII. Electrical....................................... 51
VIII. Modular Installation .................... 66
IX. System Start-up ............................ 70
X. Service .......................................... 75
XI. Repair Parts .................................. 82
XII. Appendix
Low Water Cut Off ....................... 99

5
Figure 2: Dimensions

6
WARNING
If you do not follow these instructions exactly,
a re or explosion may result causing property
damage or personal injury.
DANGER
Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
NOTICE
Due to the low water content of the boiler, mis-
sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler to
the system. Modular boiler installations greatly
reduce the likelihood of boiler oversizing.
A.Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to the National
Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or
Natural Gas and Propane Installation Code CAN/CSA
B149.1 Installation Codes.
B. Applianceisdesigncertiedforinstallationoncombus-
tibleooring.Donotinstallboileroncarpeting.
C. Provide clearance between boiler jacket and combus-
tiblematerialinaccordancewithlocalreordinance.
Refer to Figure 1 for minimum listed clearance from
combustible material. Recommended service clearance
is 24 inches from left side, right side and front. Service
clearances may be reduced to minimum clearances to
combustible materials.
D. Installonleveloor.Forbasementinstallationprovide
solidbasesuchasconcrete,ifoorisnotlevelorif
watermaybeencounteredonooraroundboiler.Floor
must be able to support weight of boiler, water and all
additional system components.
E. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
F. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes, or:
I. Pre-Installation
USA - National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation;
Canada - Natural Gas and Propane Installation Code,
CAN/CSA-B149.1.
WARNING
Adequate combustion and ventilation air must
be provided to assure proper combustion.
The following guideline is based on the National Fuel Gas
Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and;
b. Weather-stripping has been added on openable
windows and doors, and;
c. Caulking or sealants applied in joints around
window and door frames, between sill plates and
oors,betweenwall-ceilingjoints,betweenwall
panels, at plumbing and electrical penetrations,
and at other openings.
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
providedbyfreshairinltrationthroughcracks
around windows and doors.
NOTICE
Boilers operated with direct vent (sealed
combustion) are exempt from needing provisions
for combustion air from the room, provided
air intake piping is installed per Code and the
instructions in the manual.

7
6. For boiler located within unconned space in
building of unusually tight construction or within
conned space, provide outdoor air through two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within twelve (12) inches of top of space.
Locate remaining opening within twelve (12) inches
of bottom of space. Minimum dimension of air
opening is three (3) inches. Size each opening per
following:
a. Direct communication with outdoors. Minimum
free area of one (1) square inch per 4,000 Btu per
hour input of all equipment in space.
b. Vertical ducts. Minimum free area of one (1)
square inch per 4,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
c. Horizontal ducts. Minimum free area of one (1)
square inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
Alternate method for boiler located within
connedspace.Useindoorairiftwopermanent
openings communicate directly with additional
space(s)ofsufcientvolumesuchthatcombined
volumeofallspacesmeetcriteriaforunconned
space. Size each opening for minimum free area
of one (1) square inch per 1,000 Btu per hour
input of all equipment in spaces, but not less than
100 square inches.
7. Combustion Air/Ventilation Duct Louvers and
Grilles. Equip outside openings with louvers to
prevent entrance of rain and snow, and screens to
prevent entrance of insects and rodents. Louvers and
grillesmustbexedinopenpositionorinterlocked
with equipment to open automatically before burner
operation. Screens must not be smaller than ¼ inch
mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
Lift boiler from right side only.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift and remove outside container. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
D. Remove all boiler hold-down fasteners.
WARNING
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualied service agency.
E. Tilt the boiler to it’s front side or back side and slide a
wooden slat under the three raised feet.
F. Tilt the boiler in the opposite direction and slide another
wooden slat under the three raised feet.
G. Slide the boiler left or right off the skid using the two
wooden slats as runners.
H. Move boiler to its permanent location.
CAUTION
If using indoor air for combustion (Power Vent Option 5.), avoid operating this boiler in an environment where
saw dust, loose insulation bers, dry wall dust, etc. are present. If boiler is operated under these conditions,
the burner interior and ports must be cleaned and inspected daily to insure proper operation.

8
III. Venting / Air Intake Piping
NOTICE
The gasketed vent system components pictured below in Figure A are being phased in and each vent
component is interchangeable with the previously supplied gasket-less venting components. The newer
vent components are generally quicker and easier to join, as they do not require the sealant application and
their clamp bands are attached.
In the event a gasketed vent component and a
gasket-less vent component must be intercon-
nected, follow the instructions associated with
Figure 3C or 3D. The two guiding principles of
these instructions are as follows:
1) Any joining of vent components
that involves at least one
gasket-less vent component
always requires the sealant
application.
2) The female end of a gasket-less
vent component always requires
a clamp band, regardless of the
design of the mating male vent
component.
Each gasket-less vent component is supplied with a clamp band and sealant.
A Vent Transition Kit, part number 6116302, is available that contains one clamp band and one 3 ounce tube
of sealant.
Figure A: Burnham Vent
WARNING
Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other
non AL29-4C®based vent systems.
Do not use a barometric damper or drafthood with this appliance.
Do not use vent dampers with this boiler.
Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should
be in good repair (sealed, painted, etc.).
This appliance needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
Do not reduce size of air intake pipe.
Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation
instructions of this manual.
Do not operate appliance where gasoline or other ammable vapors or liquids, or sources of hydro-
carbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used,
stored and/or present in the air.
When installing vent pipe through chimney, no other appliance can be vented into the chimney.
Do not exceed maximum vent/air intake lengths. Refer to Table 4.

9
Table 1: Air Intake / Vent System Options
Table 3: Burnham Vent System and Air Intake System Components
Table 2: Vent System Components Included with Boiler
Option Description Additional Vent Kit
Required
Part
Number
Installation
Drawing and
Specication
(Section)
1. Separate
Horizontal
Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating horizontally (through a sidewall)
with individual penetrations for the vent and air intake piping
and terminals.
No See Table 2 F.
2. Separate
Vertical
Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating vertically (through the roof) with
individual penetrations for the vent and air intake piping and
terminals.
Yes 6116062
(RV3-RV7) G.
3. Combination
Horizontal
Direct Vent (sealed combustion) with the vent pipe and air
intake pipe joining at a common terminal and terminating
horizontally (through a sidewall up to 15” thick) with only
one penetration.
Yes 61106012
(RV3-RV7) H
4. Combination
Vertical
Direct Vent (sealed combustion) with the vent pipe and air
intake pipe joining at a common terminal and terminating
vertically (through the roof) with only one penetration.
Yes 61106014
(RV3-RV7) I.
5. Indoor Air Power Vent - Air used for combustion is provided from within
the building. Yes
61106008
(RV3-RV4) J.
61106009
(RV5-RV7)
6. PVC Air
Intake Allows use of PVC pipe (4” Dia. S & D [thin wall] PVC) in lieu of single wall metal pipe for air intake piping. Yes 6116054 (RV3-RV7) K.
Vent System Components Part
Number
Gasketed Vent Terminal Horizontal (RV3 - RV7) 8116234
Disc Air Intake - 3” (RV3 - RV4) 6116045
Disc Air Intake - 4” (RV5 - RV7) 6116044
Vent System Component Part Number Equivalent
Feet of Pipe
3” Dia. Pipe x 1 Ft 8116296U 1
3” Dia. Pipe x 3 Ft 8116298U 3
3” Dia. Pipe x 5 Ft 8116300U 5
3” Dia. Pipe x Adjustable 8116319U
Equal to
Installed Length
(1.06 TO 1.64)
3” Dia. 90° Elbow 8116294U 5
3” Dia. 45° Elbow 8116292U 5
3” Dia. Horizontal Drain Tee 8116302U 2
3” Dia. Vertical Drain Tee 8116304U 7½
3” Single Wall Thimble 8116116 ---
3” Double Wall Thimble 8116115 ---
Intake System
Components
(Parts by Others)
Equivalent
Feet of Pipe *
4” ID Pipe x 1 Ft 1
4” ID Pipe x 2 Ft 2
4” ID Pipe x 4 Ft 4
4” ID Pipe x 5 Ft 5
4” 90° Elbow 5
4” 45° Elbow 5
* Equivalent Feet of Pipe Based on
Standard 4” Smoke Pipe Design

10
A. Vent Guidelines Due to Removal of an
Existing Boiler
For installations not involving the replacement of an
existing boiler, proceed to Step B.
When an existing boiler is removed from a common
venting system, the common venting system is likely to
be too large for proper venting of the remaining
appliances. At the time of removal of an existing boiler,
the following steps shall be followed with each appli-
ance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation:
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no block-
age or restriction, leakage, corrosion, and other
deciencieswhichcouldcauseanunsafecondition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
replacedampers.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate continu-
ously.
5. Test for spillage at the draft hood relief opening after
ve(5)minutesofmainburneroperation.Usethe
ameofamatchorcandle,orsmokefroma
cigarette, cigar or pipe.
6. 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,replacedampersand
any other gas burning appliance to their previous
conditions of use.
Table 4: Vent/Air Intake Length
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part II in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.
B. General Guidelines
1. Vent system installation must be in accordance with
National Fuel Gas Code, NFPA 54/ANSI Z221.3 or
applicable provisions of local building codes.
Contactlocalbuildingorreofcialsaboutrestric-
tions and installation inspection in your area.
2. The Revolution is designed to be installed as either a
Direct Vent boiler or Power Vent boiler. In the
DirectVentcongurationalloftheairforcombus-
tion is supplied directly to the burner enclosure from
outdoorsanduegasesareventeddirectlyoutdoors
(throughwallorroof).InthePowerVentcongura-
tion, room air provides air for combustion and
ventilation. Flue gases are still vented directly
outdoors (through wall or roof).
Note: Venting requirements change if indoor air is
used.
3. Refer to the appropriate drawings in this section of
thismanualtodeterminethepropercongurationof
venting system. See Table 1.
4. This appliance requires a Special Gas Vent. The
product is designed to use supplied AL 29-4C®
Stainless Steel vent system components. The
following manufacturers offer similarAL 29-4C®
components and are approved for use with this
product. Heat-Fab Inc. - Saf-T-Vent (800-772-0739);
Flex-L International Inc. - Star-34 (800-561-1980);
Z-Flex U. S., Inc. - Z-Vent (800-654-5600); and
Protech Systems, Inc.- FasNSeal™ (800-766-3473)
or equivalent. The use of these alternate manufac-
turer’s venting systems will require adapters to
connect to the supplied vent connector and vent
terminal. These adapters are not supplied with this
unit and should be obtained from the supplier of the
alternate manufacturer’s venting system. See Table
3 for complete list of U.S. Boiler Vent System
Components.
Model 3” Air Intake Pipe (Equiv. Ft.) 4” Air Intake Pipe (Equiv. Ft.) 3” Vent Pipe (Equiv. Ft.)
Min. Max. Min. Max. Min. Max.
RV3 & RV4 10 52 --- --- 850
RV5, RV6 & RV7 --- --- 10 52 850