U.S. Boiler Company Burnham Hydronics Revolution RV3 Service manual

8140638R4-2/06
As an ENERGY STAR®Partner, Burnham Hydronics has determined that the Revolution Series meets the ENERGY
STAR®guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
Price - $5.00
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NOITULOVER
®
RELIOBDERIF-SAG

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.
REGNAD
ynarosihtfoytinicivehtnisdiuqilrosropavelbammalfrehtoroenilosagesuroerotsTONOD
.ecnailpparehto
lacirtceleynahcuotTONOD-ecnailppaynaetarepootyrtTONOD,sropavsagllemsuoyfI
yletomeramorfreilppussagehtllac,yletaidemmI.gnidliubehtnienohpynaesurohctiws
tcatnoc,elbaliavanusireilppusehtfirosnoitcurtsnis'reilppussagehtwolloF.enohpdetacol
.tnemtrapederifeht
REGNAD
noitautissuodrazahyltnenimminasetacidnI
,htaednitluserlliw,dediovatonfi,hcihw
ytreporplaitnatsbusroyruj
nisuoires
.egamad
GNINRAW
noitautissuodrazahyllaitnetopasetacidnI
,htaednitluserdluoc,dediovatonfi,hcihw
ytreporplaitnatsbusroyru
jnisuoires
.egamad
NOITUAC
noitautissuodrazahyllaitnetopasetacidnI
nitluseryam,dediovatonfi,hcihw
ytreporproyrujnironimroetaredom
.
egamad
ECITON
nosnoitcurtsnilaicepssetacidnI
ecnanetniamro,noitarepo,noitallatsni
otdetalertontubtnatropmierahcihw
.sd
razahyrujnilanosrep
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.
This Revolution®Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters:
Approval No. G1-0698-26.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas Fitter.

3
ECITON
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dellatsniyltcerroceraslortnocllatahteesotrotcartnocgnillatsniehtfoytilibisnopserehtsitI
.etelpmocsinoitallatsniehtnehwylreporpgnitarepoeradna
GNINRAW
ehtwolloF.ylefasetarepootecivresdnaecnanetniamralugerseriuqerreliobsihT
.launamsihtnideniatnocsnoitcurtsni
ytreporpesuacnacecnanetniamroecivres,noitaretla,tnemtsujda,noitallatsnireporpmI
erofeblaunameritne
ehtdnatsrednudnadaeR.efilfossolroyrujnilanosrep,egamad
ebtsumecivresdnanoitallatsnI.ecivresro,noitarepopu-trats,noitallatsnignitpmetta
.ycnegaecivresrorellatsnielbaegdelwonkdna,delliks,decneirepxenaybylnodemrofrep
.detnevylreporpebtsumreliobsihT
snoisivorperaerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenreliobsihT
.rianoitalitnevdnanoitsubmocetauqedarof
ehtfotratsehterofebdenaelcdnadetcepsniebtsummetsysgnitnevehtforoiretniehT
ynarofnosaesgnitaehehttuohguorhtyllacidoirepdetcepsniebdluohsdnanosaesgnitaeh
suoixonwollaotyrassecensimetsysgnitnevdetcurtsbonudnanaelcA.snoitcurtsbo
drawotetubirtnoclliwdnaylefastnevotefilfossolroyrujniesuacdluoctahtsemuf
.ycneiciffes'reliobehtgniniatniam
gnippatehtotnidellatsnisievlavfeilererusserpasselnuetelpmoctonsinoitallatsnI
roflaunamsihtfonoitceSmirTdnagnipiPretaWehteeS-.ecnailppafopotnodetacol
.sliated
tondnanwodtuhsotreliobehtesuacyamhcihwsecivedytefashtiwdeilppussireliobsihT
metsysgnitaeheht,ytilibissopasisepipnezorfoteudegamadfI.ecivrestuohtiwtrats-er
dluohssmraladnasdraugefasetairporpparo;rehtaewdlocnidednettanutfelebtondluohs
.evitareponisireliobehtfiegamadtneverpotmetsysgnitaehehtnodellatsnieb
sgnittifepipynawercsnutonoD.erusserphgihrednuretawtohyrevsniatnocreliobsihT
ehtgnirussaylevitisoptuohtiwreliobsihtfostnenopmocynatcennocsidottpmettaron
nehwtnempiuqednagnihtolcevitcetorpraewsyawlA.erusserponsahdnaloocsiretaw
ehtnoylertonoD.seirujnidlacstneverpotreliobsihtgnicivresropugnitrats,gnillatsni
.reliobehtfoerusserpdnaerutarepmetehtenimretedotseguagerutarepmetdnaerusserp
oD.gnitareposireliobehtnehwtohyrevemocebhcihwstnenopmocsniatnocreliobsihT
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reporpesusyawlA.mrahevitcudorperrehtodnastcefedhtrib,recnacesuacotainrofilaC
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slaunamsrerutcafunamtnenopmocnide
niatnocesohtllagnidulcni,snoitcurtsnilladaeR
rogniniatniam,gnitarepo,pugnitrats,gnillatsnierofebreliobehthtiwdedivorperahcihw
.gnicivres
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liobpeeK
.sdiuqilrosropav
.semitllataecalpniebtsumsdraugdnaserusolcne,setalprevocllA

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
GNINRAW
snoitcurtsniesehtwolloftonoduoyfI
tluseryamnoisolpxeroerifa,yltcaxe
lanosreproegamadytreporpgnisuac
.yrujni
REGNAD
rehtoroenilosagerehwreliobllatsnitonoD
fosecruosro,sdiuqilrosropavelbammalf
,srenaelc,sehcaelb.e.i(snobracordyh
cirbaf,srevomertniap,syarps,slacimehc
.derotsrodesuera).cte,srenetfos
ECITON
,reliobehtfotnetnocretawwolehtoteuD
ehtotdragerhtiwreliobehtfognizis-sim
evissecxenitluserlliwdaolmetsysgnitaeh
tnenopmocdetareleccadnagnilcycreliob
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otreliobehtezisrevoTONOD.snoitacilppa
snoitallatsnireliobraludoM.metsyseht
reliobfodoohilekilehtecuderyltaerg
.gnizisrevo
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 CAN/
CGA B149 Installation Codes.
B. Appliance is design certified for installation on combus-
tible flooring. Do not install boiler on carpeting.
C. Provide clearance between boiler jacket and combus-
tible material in accordance with local fire 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 floor. For basement installation provide
solid base such as concrete, if floor is not level or if
water may be encountered on floor around boiler. Floor
must be able to support weight of boiler, water and all
additional system components.
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 unconfined
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a confined 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
floors, between wall-ceiling joints, between wall
panels, at plumbing and electrical penetrations,
and at other openings.
I. Pre-Installation
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:
USA - National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation;
Canada - Natural Gas Installation Code, CAN/CGA-
B149.1, or Propane Installation Code, CAN/CGA-
B149.2, Venting Systems and Air Supply for Appli-
ances.
GNINRAW
rianoitalitnevdnanoitsubmocetauqedA
reporperussaotdedivorpebtsum
.noitsubmoc

7
5. For boiler located in an unconfined space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air infiltration through cracks
around windows and doors.
ECITON
delaes(tnevtceridhtiwdetareposrelioB
gnideenmorftpmexeera)noitsubmoc
ehtmorfrianoitsubmocrofsnoisivorp
dellatsnisignipipekatniriadedivorp,moor
sihtnisnoitcurtsniehtdnaedocrep
.launam
6. For boiler located within unconfined space in
building of unusually tight construction or within
confined 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
confined space. Use indoor air if two permanent
openings communicate directly with additional
space(s) of sufficient volume such that combined
volume of all spaces meet criteria for unconfined
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 fixed 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
NOITUAC
reliobpmubtonoD.reliobpordtonoD
.roolftsniagatekcaj
.ylnoedisthgirmorfreliobtfiL
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.
GNINRAW
ebdluohsreliobsihtfonoitallatsnI
delliksdnadeniartybylnonekatrednu
.ycnegaecivresdeifilauqamorflennosrep
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.
NOITUAC
nanireliobsihtgnitarepodiova,).5noitpOtneVrewoP(noitsubmocrofriaroodnignisufI
sireliobfI.tneserpera.cte,tsudllawyrd,srebifnoitalusniesool,tsudwaserehwtnemnorivne
yliaddetcepsnidnadenaelcebtsumstropdnaroiretnirenrubeht,snoitidnocesehtrednudetarepo
.noitareporeporperusniot

8
III. Venting / Air Intake Piping
Figure A: Burnham Vent
GNINRAW
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C4-92LAnonrehtoyna
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.).cte,detniap,delaes(riaperdoogniebdluohssecafrus
eraerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenecnailppasihT
.riano
italitnevdnanoitsubmocetauqedarofsnoisivorp
.epipekatniriafoezisecudertonoD
-erPehtnideniatnocsnoitcirt
sernoitcurtsnirianoitsubmocwollofdnadnatsrednu,daeR
.launamsihtfosnoitcurtsninoitallatsnI
fosecruosro,sdiuqilrosropavelbammalfrehtoroenilosagerehwecnailppaetarepotonoD
,srenetfoscirbaf,srevomertniap,syarps,slacimehc,srenaelc,sehcaelb.e.i(snobracordyh
.riaehtnitneserpro/dnaderots,desuera).cte
ehtotnidetnevebnacecnailpparehtoon,yenmihchguorhtepiptnevgnillatsninehW
.yenmihc
.4elbaTotrefeR.shtgnelekatniria/tnevmumixamdeecxetonoD
ECITON
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gnitnevssel-teksagdeilppusylsuoiverpehthtiwelbaegnahcretnisitnenopmoctnev
odyehtsa,niojotreisaednarekciuqyllarenegerastnenopmoctnevrewenehT.stnenopmoc
.dehcattaerasdnabpmalcriehtdnanoitacilppatnalaesehteriuqerton
adnatnenopmoctnev
deteksagatneveehtnI
-nocretniebtsumtnenopmoctnevssel-teksag
htiwdetaicossasnoitcurtsniehtwollof,detcen
foselpicnirpgnidiugowtehT.D3roC3erugiF
:swollofsaerasnoitcurtsnieseht
stnenopmoctnevfogniniojynA)1
enotsaeltasevlovnitaht
tnenopmoctnevssel-teksag
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ssel-teksagafodneelamefehT)2
seriuqersyawlatnenopmoctnev
ehtfosseldrager,dnabpmalca
tnevelamgnitamehtfongised
.tnenopmoc
.tnalaesdnadnabpmalcahtiwdeilppussitnenopmoctnevssel-teksaghcaE
3enodnadnabpmalcenosniatnoctahtelbaliavasi,2036116rebmuntrap,tiKnoitisnarTtneVA
.tnalaesfoebutecnuo

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
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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
deficiencies 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
fireplace 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
five (5) minutes of main burner operation. Use the
flame 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, fireplace 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 fire officials 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 configuration all of the air for combus-
tion is supplied directly to the burner enclosure from
outdoors and flue gases are vented directly outdoors
(through wall or roof). In the Power Vent configura-
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 configuration of
venting system. See Table 1.
4. This appliance requires a Special Gas Vent. The
product is designed to use Burnham supplied
AL 29-4C® Stainless Steel vent system components.
The following manufacturers offer similar
AL 29-4C®components and are approved for use
with this product: Heat-Fab Inc. - Saf-T-Vent, Flex-
L International Inc. - Star-34, Z-Flex U. S., Inc. -
Z-Vent, and Protech Systems , Inc.- FasNSeal™.
The use of these alternate manufacturer’s venting
systems will require adapters to connect to the
Burnham 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 Burnham Vent System Components.
ledoM
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epiPekatnIriA"4
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4VR&3VR0125----------
805
7VR&6VR,5VR----------0125

11
5. Horizontal vent pipe must maintain a minimum ¼
inch per foot slope down towards boiler.
6. Use noncombustible ¾ inch pipe strap to support
horizontal runs and maintain vent location and slope
while preventing sags in pipe. Do not restrict
thermal expansion or movement of vent system.
Maximum support spacing is five (5) feet. Do not
penetrate any part of the vent system with fasteners.
7. Vent length restrictions are based on equivalent
length of vent/air pipe (total length of straight pipe
plus equivalent length of fittings). Maximum vent/
air lengths are listed in Table 4. Do not exceed
maximum vent/air intake lengths. Table 3 lists
equivalent lengths for fittings. Do not include vent/
air terminals in equivalent feet calculations.
8. Provide and maintain vent pipe minimum clearances
to combustible materials. Vent pipe minimum
clearance to combustible material is four (4) inches
when vent is installed in a fully enclosed (chase)
application or three (3) inches when vent is installed
with at least one side open, similar to a joist bay
application. Use double wall thimble (Burnham Part
No. 8116115) when penetrating a combustible wall.
Other wall thimble manufactures are American
Metal Products, Hart & Cooley, and Metal Fab.
9. Do not install venting system components on the
exterior of the building except as specifically
required by these instructions. The vent termination
location is restricted as follows:
a. Minimum twelve (12) inches above grade plus
normally expected snow accumulation level, or
seven (7) feet above grade if located adjacent to
public walkway. Do not install over public
walkway where local experience indicates
appliance flue gas vapor or condensate creates a
nuisance or hazard.
b. Minimum three (3) feet above any forced air
inlet located within ten (10) feet.
c. Direct Vent - Minimum one (1) foot below, one
(1) foot horizontally from, or one (1) foot above
any door, window, or gravity air inlet.
Power Vent - Minimum four (4) feet below, four
(4) feet horizontally from, or four (4) feet above
any door, window, or gravity air inlet.
d. Minimum four (4) feet horizontally from electric
meters, gas meters, regulators, and relief valves.
This distance may be reduced if equipment is
protected from damage due to condensation or
vapor by enclosure, overhangs, etc.
e. Minimum twelve (12) inches from overhang or
corner of building.
10. Enclose vent passing through occupied or unoccu-
pied spaces above the boiler with material having a
fire resistance rating of at least equal to the rating of
the adjoining floor or ceiling. Maintain minimum
clearances to combustible materials. See Figure 1.
Note: For one or two family dwellings, fire resis-
tance rating requirement may not need to be met, but
is recommended.
11. Plan venting system to avoid possible contact with
plumbing or electrical wires. Start at vent connector
on top of boiler and work towards vent terminal.
12. Once a vent pipe manufacturer and system is chosen
never mix and match vent systems.
13. If a non-standard length pipe is required:
Gasketed Vent System: The use of the adjustable
length pipe (P/N 8116319U) is recommended to
complete a non-standard pipe length. This pipe
requires a minimum installed length of 12¾ inch and
can adjust across a 7 inch gap up to a maximum of
19¾ inch long. (Note for the adjustable pipe the
installed length should be measured from the
centerline of the bead on the male end of the first
pipe to the end of the female pipe excluding the
locking band of the second pipe with a single
gasket.) Only in the event the adjustable length pipe
is not sufficient a standard length pipe may be cut
using the procedure outlined below for the Gasket-
Less Vent System.
GNINRAW
fohtgneldellatsnimumixamdeecxereveN
.epiphtgnelelbatsujdarofsehcni¾91
.elbissopsiegakaelsageulffoksiR
Gasket-Less Vent System: Carefully cut pipe to
length using a hacksaw with minimum 32 teeth per
inch or circular saw with metal abrasive wheel.
Remove male (bead) end only – female (bell) end
accepts next fitting or pipe.
ECITON
rodelifdnaepiphtiwerauqsebtsumtuC
ylluferaC.gniniojerofebhtoomsdednas
htiwdnahybepiptucfossendnuorerusn
e
VTRhtiwtniojlaeS.gnillatsnierofebsevolg
.launamsihtnideificeps
14. Seal all Burnham Gasket-Less vent, Burnham
mixed vent (Gasket-Less and Gasketed) and field
cut joints using Dow Corning Silastic 732 RTV,
Dow Corning Silastic 736 RTV, GE RTV106,
Polybac #500 RTV, Sil-bond RTV 4500 (Acetoxy)
and Sil-bond RTV 6500. Do not use other adhesives
or sealants.

12
C. Install Vent Pipe, Burnham Gasket-Less Vent System.
1. Procedure for Joining Burnham Gasket-Less Vent Pipe and Fittings. See Figure 3A.
Figure 3A: Burnham Gasket-Less Vent Joint Detail
Figure 3B: Burnham Gasketed Vent Joint Detail
a. Clean joints of pipe or fittings using an alcohol pad to remove any dirt and grease.
b. Slip a locking band over female (bell) end of pipe/fitting.
c. Apply a continuous ¼ inch bead of sealant around male end of joint no more than 1/8 inch from end.
d. Align weld seams and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure bead in
male end rest against the end of the female pipe.
e. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary.
f. Slip the locking band over joint and align closest bead in locking band with bead in male end of pipe.
g. Tighten locking band by HAND with a 5/16” nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH
SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
h. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid
condensate will not escape.
D. Install Vent Pipe, Burnham Gasketed Vent System.
1. Procedure for Joining Burnham Gasketed Vent Pipe and Fittings. See Figure 3B.
a. Wipe the male end of each joint using an alcohol pad to remove any dirt and grease.
b. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure
bead in male end of pipe is below locking band and rest against the end of the female pipe. Verify the factory-installed
gasket is not dislodged or cut.

13
c. Tighten locking band by HAND with a 5/16” nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH
SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
d. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid conden-
sate will not escape.
E. Install Vent Pipe, Burnham Gasket-Less & Gasketed Vent System.
1. Procedure for joining the male end of Burnham Gasket-Less Vent with the female end of Burnham Gasketed Vent. See
Figure 3C.
Figure 3C: Burnham Gasket-Less Male and Gasketed Female Vent Joint Detail
Figure 3D: Burnham Gasket-Less Female and Gasketed Male Vent Joint Detail
a. Clean the male end of each joint using an alcohol pad to remove any dirt and grease.
b. Apply a continuous ¼ inch bead of sealant around male end of joint no more than 1/8 inch from end.
c. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure
bead in male end of pipe is below locking band and rest against the end of the female pipe. Verify the factory-installed
gasket is not dislodged or cut.
d. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary.
e. Tighten locking band by HAND with a 5/16” nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH
SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM!
f. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid
condensate will not escape.
2. Procedure for joining the female end of Burnham Gasket-Less Vent with the male end of Burnham Gasketed Vent. See
Figure 3D.

14
a. Clean joints of pipe or fittings using an alcohol
pad to remove any dirt and grease.
b. Slip a locking band over female (bell) end of
pipe/fitting.
c. Apply a continuous ¼ inch bead of sealant
around male end of joint no more than 1/8 inch
from end.
d. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint.
e. Smooth sealant around joint for a continuous
seal. Reapply sealant if necessary.
f. Slip the locking band over joint and align closest
bead in locking band with bead in male end of
pipe.
g. Tighten locking band by HAND with a 5/16” nut
driver until snug plus ¼ turn. DO NOT SE-
CURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT PUNC-
TURE THE VENT SYSTEM!
h. Once the installation is complete, operate
appliance and inspect all joints to ensure that flue
gases and/or liquid condensate will not escape.
F. Separate Horizontal Venting System. See
Figures 4 and 5.
Vent Piping –
1. This boiler is supplied with components as standard
equipment for installation of the separate horizontal
venting system.
2. Do not exceed maximum vent/air intake lengths.
Refer to Table 4.
3. Recommended horizontal installation consists of
vent being sloped down ¼ inch per foot toward
boiler. See Figure 4.
4. Use appropriate designed thimbles when passing
through combustible walls (thimble use optional for
noncombustible walls). Insert thimble through wall
from outside. Secure outside flange to wall with
nails or screws, and seal ID, OD and vent holes with
sealant material. Install inside flange to inside wall,
secure with nails or screws, and seal with sealant
material.
5. For noncombustible wall application when thimble
is not used, size opening such that bell with locking
band attached cannot pass through.
6. Join vent terminal to vent pipe. Locate vent pipe
such that vent terminal is between six (6) inches and
twenty-four (24) inches from wall when joined to
inside vent piping. See Figure 5.
7. Insert vent pipe through thimble/opening from
outside and join to vent system. Apply sealant
between vent pipe and opening/thimble to provide
weathertight seal.
Air Intake piping - See Figures 4 and 5.
8. Locate air intake termination on the same wall as the
vent termination if possible, to prevent nuisance
boiler shutdowns. However, boiler may be installed
with vertical venting and sidewall combustion air
inlet or visa versa, if installation conditions do not
allow alternate arrangement.
9. Do not exceed air intake length. See Table 4.
10. Use single wall metal pipe and fittings available at
most heating distributors, unless using PVC air
intake kit (part number 6116054). See Section III.
K. This kit will allow S & D (thin wall) PVC to be
used for air intake piping.
a. Air intake pipe diameter is based on boiler size.
RV3 - RV4 – uses 3 inch diameter piping*
RV5 - RV7 – uses 4 inch diameter piping
* The PVC air intake kit (P/N 6116054), if used, will
increase air intake pipe diameter to 4 inch.
11. Air intake termination must be located:
Horizontal - At least twelve (12) inches above
grade plus the expected snow accumulation.
12. Start at collar on burner enclosure (inside boiler
jacket) and work towards the air intake terminal.
13. Maintain minimum of ¼ inch per foot slope on
horizontal runs. Slope towards air inlet terminal
when possible. If not, slope towards boiler.
14. The air intake pipe must be adequately supported
with straps or supports no less than five (5) feet
apart on horizontal runs. The complete air intake
piping system must be rigid and able to withstand
minor impacts without collapse.
15. Inlet air pipe penetration:
Horizontal - Size wall penetration to allow easy
insertion of air inlet piping. Seal around pipe with
sealant to form weathertight exterior joint.
16. Seal all joints airtight, using silicone caulk or self-
adhesive aluminum tape.
17. Install Air Intake Terminal:
Horizontal - Remove four (4) screws from cover
plate and remove cover plate from terminal. Insert
intake piping into intake terminal collar. Secure
terminal to intake piping and seal joint with silicone
caulk or self-adhesive aluminum tape. Apply
continuous bead of silicone caulk around the back of
the intake terminal, approximately ¼ inch from its
edge. Push inlet terminal inward until terminal’s
back flange is against the wall surface. Secure the
terminal with noncorrosive fasteners (stainless steel,
brass or aluminum) to the wall. Reinstall the cover
plate with four (4) screws. Apply a bead of silicone
caulk to perimeter of intake terminal’s back flange
to provide a weathertight seal.

15
Figure 4: Recommended Separate Horizontal – Vent/Air Intake Installation

16
Figure 5: Separate Horizontal – Vent/Air Intake Terminal Configuration

17
Vertical Venting –
1. Do not exceed maximum vent lengths. Refer to
Table 4.
2. Slope horizontal runs minimum ¼ inch per foot
down towards boiler.
3. Install fire stops where vent passes through floors,
ceilings or framed walls. The fire stop must close
the opening between the vent pipe and the structure.
Fire stop manufacturers are Air-Jet,American Metal
Products, Metal-Fab, and Simpson Dura-Vent.
4. Whenever possible, install vent straight through the
roof. Refer to Figure 7 if offset is necessary.
Maintain minimum clearance to combustible
materials.
5. Install Vent Terminal.
a. Size roof opening to maintain minimum clear-
ance from combustible materials.
b. Extend vent pipe to maintain minimum vertical
and horizontal distance of twelve (12) inches
from roof surface. Allow additional vertical
distance for expected snow accumulation.
Provide brace as required. Refer to Figure 8.
c. Vertical venting requires use of the roof flashing
and storm collar to prevent moisture from
entering the structure.
d. Install storm collar on vent pipe immediately
above flashing. Apply Dow Corning Silastic 732
RTV Sealant between vent pipe and storm collar
to provide weathertight seal.
e. Attach vent terminal.
Vertical Air Intake Piping –
6. Do not exceed maximum air intake length. Refer to
Table 4.
G. Separate Vertical Venting System - See Figures 6, 7, 8 and 9.
ECITON
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tnenopmoC
rebmuNtraP
seirosseccAtneVlacitreV
)wolebsmetisedulcni( )7VR-3VR(2606116-------
lacitreV,lanimreTtneV-------1606116
"3,gnihsalFfooR-------0526118
S"3,ralloCmrot-------1526118
STNENOPMOCMETSYSGNITNEVLACITREVETARAPES

18
7. Locate air intake termination on the same roof
location as the vent termination if possible, to
prevent nuisance boiler shutdowns. However, boiler
may be installed with vertical venting and sidewall
combustion air inlet or visa versa, if installation
conditions do not allow alternate arrangement.
8. Use single wall metal pipe and fittings available at
most heating distributors, unless using PVC air
intake kit (P/N 6116054). See Section III. K. This
kit will allow S & D (thin wall) PVC to be used for
air intake piping.
a. Air intake pipe diameter is based on boiler size.
RV3 - RV4 – uses 3 inch diameter piping*
RV5 - RV7 – uses 4 inch diameter piping
* The PVC air intake kit (P/N 6116054), if used, will
increase air intake pipe diameter to 4 inch.
9. Air intake termination must be located:
Vertical - At least twelve (12) inches above the roof
surface plus the expected snow accumulation.
10. Start at collar on burner enclosure (inside boiler
jacket) and work towards the air intake terminal.
11. Maintain minimum of ¼ inch per foot slope on
horizontal runs. Slope down towards boiler.
12. The air intake pipe must be adequately supported
with straps or supports no less than five (5) feet
apart on horizontal runs. The complete air intake
piping system must be rigid and able to withstand
minor impacts without collapse.
13. Inlet air pipe penetration:
Vertical - Size roof opening to allow easy insertion
of inlet piping and allow proper installation of
flashing and storm collar.
a. Use appropriately designed vent flashing when
passing through roofs. Follow flashing manufac-
turers’instructions for installation procedures.
Flashing manufacturers are Air-Jet,American
Metal Products, Metal Fab, and Simpson Dura-
Vent.
b. Extend air intake pipe to maintain minimum
vertical and horizontal distance of twelve (12)
inches from roof surface. Allow additional
vertical distance for expected snow accumula-
tion. Provide brace as required. Refer to Figure
8.
c. Vertical air intake requires flashing and a storm
collar to prevent moisture from entering the
structure.
d. Install storm collar on air intake pipe immedi-
ately above flashing. Apply Dow Corning
Silastic 732 RTV Sealant between air intake pipe
and storm collar to provide weathertight seal.
e. All exposed air intake piping must be construct-
ed of corrosion resistant material such as
aluminum, stainless steel or PVC.
14. Seal all joints airtight, using silicone caulk or self-
adhesive aluminum tape.
15. Install Air Intake Terminal:
Vertical - Insert intake piping into intake terminal
collar. Secure terminal to intake piping and seal
joint with silicone caulk.

19
Figure 7: Attic OffsetFigure 6: Vertical Vent Installation

20
Figure 8: Vertical Vent/Air Termination
Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.