Burnham E4 User Manual

INSTALLATION, OPERATING AND  
SERVICE INSTRUCTIONS FOR  
CARE-FREE  
ELECTRIC BOILER  
MODEL E4  
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  
Boiler Serial Number  
Installation Date  
E4 _ _-_____  
6_ _ _ _ _ _ _  
Heating Contractor  
Phone Number  
Address  
8143606R7-2/06  
Price - $3.00  
SECTION I: INSTALLATION INSTRUCTIONS  
A. Inspect Shipment carefully for any signs of damage.  
passing through the holes provided in the wall  
mounting channels. Figure 1 shows bolt center  
dimensions. It is recommended that 1/2" plywood  
be used as a base for mounting the boiler so that the  
structure is adequate to carry the weight imposed upon  
it – see Figure 1 for weight of boiler when full of water.  
Boiler should be level for proper operation of BUILT-  
IN AIR SEPARATOR.  
1. All equipment is carefully manufactured, inspected  
and packed. Our responsibility ceases upon delivery  
of Boiler to the carrier in good condition.  
2. Any claims for damage or shortage in shipment  
must be led immediately against the carrier by  
the consignee. No claims for variances from,  
or shortage in orders, will be allowed by Boiler  
Manufacturer, unless presented within sixty (60)  
days after receipt of goods.  
E. Connect Supply and Return Piping to Heating  
System using standard recognized practices. See Figure  
2. Install an appropriate size expansion tank in system  
as per Figure 2. Do not connect into the 3/4" tee on top  
of the boiler; instead install an automatic oat type air  
vent at this point. Water content of the boiler is given  
in Figure 1.  
B. Read These Instructions Carefully before proceeding  
with installation and operation of the “CARE-FREE”  
Electric Boiler.  
1. The “CARE-FREE” is U.L. listed, constructed  
and tested in accordance with the requirements of  
the ASME Boiler and Pressure Vessel Code and  
designed for use in any conventional hydronic  
system except steam and gravity hot water.  
The relief valve outlet should be piped full size to a  
drain or near the oor.  
The heating elements are NOT compatible with  
ethylene glycol based antifreeze.  
If a low water cut-off is required, it must be mounted in  
the system piping above the boiler.  
The minimum safe water level of a hot water boiler is  
just above the highest water containing cavity of the  
boiler; that is, a hot water boiler must be full of water to  
operate safely.  
2. The “CARE-FREE” Electric Boilers are shipped  
completely assembled less circulator. All electrical  
controls are mounted and wired in a compartment  
immediately behind the Front Door of the Boiler  
Jacket, see Figure 1.  
C. Locate Boiler in or adjacent to the space to be heated  
with consideration given to the location of the electrical  
service. Although its compactness will allow the  
“CARE-FREE” Electric Boiler to be mounted almost  
anywhere – closet, alcove, or other small area, see  
CLEARANCE REQUIREMENTS on Page 2.  
If it is required to perform a long term pressure test of  
the hydronic system, the boiler should rst e isolated to  
avoid a pressure test including the boiler, ALL trapped  
air must rst be removed from the boiler.  
A loss of pressure during such a test, with no visible  
water leakage, is an indication that the boiler contained  
trapped air.  
D. Mount Boiler to wall using four 3/8" lag screws  
or anchor bolts (depending upon wall construction)  
Figure 2: Recommended Boiler Piping  
3
F. Install Electric Wiring in accordance with  
NATIONAL ELECTRICAL CODE and Local  
Regulations. The Burnham “CARE-FREE” Electric  
Boilers may be used with 208 and 240 volt, 60 cycle,  
single phase power and one 3 wire power supply. Since  
the heaters are rated at 240 volts, however, any input  
voltage less than this affects boiler capacity, see Figure  
3.  
G. A Prewired Low Voltage Control System is furnished  
with every “CARE-FREE” boiler.  
1. All controls are furnished in a compartment at the  
front of the boiler for easy accessibility. In addition  
to the Transformer used to power the system, are  
the following: Circulator Relay, Heating Element  
Sequencers (one per Heating Element), Dual High  
Limit Control, Circulator Operation Selector Switch,  
Circulator Fuse and Heating Element Relays.  
To remove Front Door for access to terminal blocks and  
controls:  
2. If the Circulator Fuse is blown, power is interrupted  
to the Transformer and hence, the control system  
de-energized. This action prevents the Heating  
Elements from coming on while the Circulator is  
inoperative.  
1. CAUTION – make sure Electrical Service to Boiler  
is disconnected.  
2. Remove retaining screw at top of door.  
3. Lower Door as far as possible, then push forward  
until Hinge Pins in lower corners slide out of the  
slots.  
A Circulator Operation Selector Switch provides for  
either Continuous or Intermittent Circulator operation.  
With the switch in the “CONT.” position the Circulator  
Delay Control will be bypassed and the Circulator will  
operate continuously. The room Thermostat regulates  
only the operation of the Heating Elements in the boiler.  
4. Raise one side of Door until Door will clear opening  
– pull forward for removal.  
Repeat above in reverse for replacing Door.  
Provisions are provided in the right side of the boiler  
jacket for power input, circulator, and thermostat  
wiring, see Figure 1.  
With the Circulator Switch in the “INT.” position, the  
Thermostat will operate both the Circulator and the  
Heating Elements. Timing and wiring of the bimetal  
heaters in the Circulator Relay and Sequencers assures  
Circulator operation before and after Heating Elements  
are energized and de-energized, respectively. The  
Sequencers permit only one Heating Element at a time  
(from bottom to top) to be energized thus preventing  
a sudden inrush of electrical current. More detailed  
operation is described in subsequent pages.  
The power input legs are connected to the L1 and  
L2 terminals on the terminal board on the control  
compartment of the boiler. The neutral leg is connected  
to the terminal marked N. Minimum recommended  
wire sizes are shown in Figure 1. A separate grounding  
conductor of at least #6AWG copper must be run to the  
eld grounding lug on the control panel.  
The Circulator is to be connected from its housing to  
the terminals marked N and M on the Main Terminal  
Block using Flexible Conduit, see Figures 2 and 4.  
If the “QUICK CONNECT CIRCULATOR-PAK”  
is ordered as Optional Equipment from the Boiler  
Manufacturer, the Flexible Conduit for connecting the  
circulator will be furnished.  
Wiring of a one zone system is shown in Figure 4.  
Figures 5 and 6 show wiring for zoned systems, the  
former when Zone Valves are used and the latter when  
multiple Circulators are used.  
Figure 3: Boiler Capacity at Various Voltages  
4
SECTION II: OPERATING AND SERVICE INSTRUCTIONS  
7. ROOM THERMOSTAT OPENS  
A. Intermittent Circulator Operation  
8. HEATING ELEMENTS DE-ENERGIZED  
1. ROOM THERMOSTAT CLOSES  
When the thermostat is satised and opens its  
contacts, the low voltage circuits to the Heating  
Element Relay and the Heating Element Sequencers  
are broken. The Heating Element Relays “drop-out”  
immediately and totally de-energize the Heating  
Elements and pilot lights. After a time delay of 45  
seconds, the main contacts of all the Sequencers  
“break” thus resetting the Heating Element Relays.  
2. CIRCULATOR MOTOR ENERGIZED  
a. As the thermostat closes its contacts, a low  
voltage circuit (24V.) is completed to the bimetal  
heater in the circulator relay (24A51). After  
a time delay of 15 seconds, the main contacts  
(120V.) of the circulator relay close to start the  
circulator.  
3. HEATING ELEMENT #1 ENERGIZED  
9. CIRCULATOR MOTOR DE-ENERGIZED  
a. Simultaneous with the completing of the circuit  
for the circulator relay, two additional circuits  
are completed.  
Simultaneous with the breaking of the low voltage  
circuit to the Heating Element Sequencers is the  
breaking of the low voltage circuit to the Circulator  
Relay by the opening of the thermostat contact.  
After a time delay of 90 seconds after all Heating  
Elements are “off” the bimetal heater opens the  
main contacts in the Circulator Relay thus stopping  
the circulator. When the boiler is zoned with  
circulator and switching relays as illustrated in  
Figure 6 on Page 8 the circulator switch must be in  
the “constant” position; therefore the circulator will  
not have any delay when the thermostat(s) closes or  
opens its contacts.  
b. The rst circuit is for the Heating Element  
Relays which pull in immediately and the  
second is for the bimetal heater in the #1 Heating  
Element Sequencer (24A54).  
c. These two circuits will be energized only if the  
boiler is not “OFF” on limit.  
d. After a time delay of 45 seconds (30 seconds  
after the circulator has started) the main and  
auxiliary contacts of the #1 Sequencer close;  
the main contacts (240V.) energizing heating  
element #1 and its pilot light (located at the  
bottom of the side panel), the auxiliary contacts  
(24V.) energizing the bimetal heater in the #2  
Heating Element Sequencer.  
B. Continuous Circulator Operation  
If the Circulator Switch (located in the control portion  
of the Boiler Jacket) is placed in the “CONT.” position,  
the Circulator will run continuously and the Heating  
Elements will sequence as in steps 3-6 and 8 above.  
4. HEATING ELEMENT #2 ENERGIZED  
a. 45 seconds after bimetal heater in #2 Heating  
Element Sequencer is energized, its main  
C. Dual Limit Operation  
contacts (240V.) and auxiliary contacts close;  
the main contacts energizing heating element #2  
and its pilot light (3rd lowest in the boiler), the  
auxiliary contacts (24V.) energizing the bimetal  
heater in the #3 Heating Element Sequencer.  
The Dual Limit Control consists of two independently  
adjustable temperature limits. The left hand adjustment  
is for the safety limit and should be set initially for  
220°F. The lower right hand adjustment is for the  
operating limit and should be set for 210°F with a  
differential setting (upper right hand adjustment) of 10º.  
These adjustments may be varied to suit the individual  
installation, with minimum of 10° difference between  
the limit settings. If the setting of the operating Limit  
or the safety limit is reached, the Heating Elements only  
will be de-energized; the Circulator will continue to  
run. If the Circulator Switch is in the “INT.” position,  
the Circulator runs until the thermostat is satised and  
the main contacts on the Circulator Relay open.  
5. HEATING ELEMENT #3 ENERGIZED  
a. 45 seconds after bimetal heater in the #3 Heating  
Element Sequencer is energized, its main  
contacts and auxiliary contacts close; the main  
contacts (240V.) energizing heating element #3  
and its pilot light (2nd lowest in the boiler), the  
auxiliary contacts (24V.) energizing the bimetal  
heater in the #4 Heating Element Sequencer.  
6. HEATING ELEMENT #4 ENERGIZED  
WARNING  
a. 45 seconds after bimetal heater in #4 Heating  
Element Sequencer is energized, its main  
contacts and auxiliary contacts close, the main  
contacts (240V.) energizing heating element #4  
and its pilot light (highest in the boiler) – nothing  
is connected to the auxiliary contacts.  
Before installation of the boiler is  
considered complete, the operation of the  
boiler controls should be checked,  
particularly the Operating & Safety Limit  
Controls.  
5
6
D. Indicator Lights  
E. Built-In Air Eliminator  
There is an indicator light for each heating element.  
If an indicator light is “on” it indicates its respective  
heating element is energized. If the light is “off” it  
indicates:  
An air eliminator has been built into the top of the  
electric boiler and a 3/4" tapping is provided with  
nipple and tee for connection of Relief Valve and a oat  
type Air Vent. See Figure 1.  
1. The heating element has not been energized.  
2. The heating element sequencer is malfunctioning.  
Figure 5: Wiring Diagram - 3 Zone System  
White-Rodgers 2 Wire Zone Valves  
Figure 6: Wiring Diagram - 2 Zone System  
Multiple Circulators  
7
Limited Warranty  
FOR RESIDENTIAL CAST IRON WATER BOILERS  
Subject to the terms and conditions set forth below, U.S. Boiler™  
accordance with U. S. Boiler Co., Inc. recommendations and hydronics  
industry standards. These warranties will be inapplicable if the residential  
grade water boiler is used or operated over its rated capacity, is  
subjected to unauthorized modification, or is damaged as a result of  
being otherwise improperly operated or serviced including, but not limited  
to, damage from any of the following: operation with insufficient water,  
allowing the boiler to freeze, subjecting the boiler to flood conditions, and  
operation with unapproved water or fuel additives which cause deposits  
or corrosion.  
Co., Inc. Lancaster, Pennsylvania hereby extends the following limited  
warranties to the original owner of a residential grade water boiler  
manufactured and shipped on or after July 1,1991:  
ONEYEAR LIMITED WARRANTY  
ON RESIDENTIAL GRADE WATER BOILERS  
U.S. Boiler Co., Inc. warrants to the original owner that its residential  
grade water boilers comply at the time of manufacture with recognized  
hydronic industry standards and requirements then in effect and will be  
free of defects in material and workmanship under normal usage for a  
period of one year from the date of original installation. If any part of a  
water boiler is found to be defective in material or workmanship during  
this one year period, U.S. Boiler Co., Inc. will, at its option, repair or  
replace the defective part.  
5. Removal and Installation: These warranties do not cover expenses  
of removal or reinstallation. The owner is responsible for the cost of  
removing and reinstalling any defective part and its replacements and all  
labor and material connected therewith.  
6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach of  
these warranties is limited to the repair or replacement of its parts in  
accordance with the terms and conditions of these warranties.  
LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER  
U.S. Boiler Co., Inc. warrants to the original owner that the heat  
exchanger of its residential grade water boilers will remain free from  
defects in material and workmanship under normal usage for the  
lifetime of the original owner at the original place of installation. If a  
claim is made under this warranty during the first ten years from the  
date of original installation, U.S. Boiler Co., Inc. will, at its option, repair  
or replace the heat exchanger. If a claim is made under this warranty  
after the expiration of ten years from the date of original installation,  
U.S. Boiler Co., Inc. will, at its option and upon payment of the pro-rated  
service charge set forth below, repair or replace the heat exchanger.  
The service charge applicable to a heat exchanger warranty claim is  
based upon the number of years the heat exchanger has been in service  
and will be determined as a percentage of the retail price of the heat  
exchanger model involved at the time the warranty claim is made as  
follows:  
7. Limitation of Damages: Under no circumstances shall U.S. Boiler Co.,  
Inc. be liable for incidental, indirect, special or consequential damages  
of any kind whatsoever under these warranties, including, but not limited  
to, injury or damage to persons or property and damages for loss of use,  
inconvenience or loss of time. U.S. Boiler Co., Inc. liability under these  
warranties shall under no circumstances exceed the purchase price paid  
by the owner for the residential grade water boiler involved. Some states  
do not allow the exclusion or limitation of incidental or consequential  
damages, so the above limitation or exclusion may not apply to you.  
8. Limitation of Warranties: These warranties set forth the entire  
obligation of U.S. Boiler Co., Inc. with respect to any defect in a  
residential grade water boiler and U.S. Boiler Co., Inc. shall have no  
express obligations, responsibilities or liabilities of any kind whatsoever  
other than those set forth herein. These warranties are given in lieu of all  
other express warranties.  
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING  
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A  
PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO  
A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF  
ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL  
GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER  
FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL  
PLACE OF INSTALLATION. SOME STATES DO NO ALLOW LIMITATION  
ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE  
LIMITATION MAY NOT APPLY TO YOU.  
Years  
In Service  
1-10  
11  
5
12  
10  
13  
15  
14  
20  
15  
25  
16  
30  
17  
35  
Service Charge  
as % of  
Retail Price  
No  
Charge  
Years  
In Service  
25 and  
above  
18  
40  
19  
45  
20  
50  
21  
55  
22  
60  
23  
65  
24  
70  
Service Charge  
as % of  
75  
Retail Price  
PROCEDURE FOR OBTAINING WARRANTY SERVICE  
NOTE: If the heat exchanger model involved is no longer available due to  
product obsolescence or redesign, the value used to establish the retail  
price will be the published price as shown in the Burnham Hydronics  
Repair Parts Price Sheet where the heat exchanger last appeared or the  
current retail price of the then nearest equivalent heat exchanger.  
In order to assure prompt warranty service, the owner is requested to  
complete and mail the attached Warranty Card within ten days after the  
installation of the boiler, although failure to comply with this request will  
not void the owner’s rights under these warranties.  
Upon discovery of a condition believed to be related to a defect in  
material or workmanship covered by these warranties, the owner should  
notify the installer, who will in turn notify the distributor. If this action is  
not possible or does not produce a prompt response, the owner should  
write to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079,  
Lancaster, PA 17604, giving full particulars in support of the claim.  
ADDITIONAL TERMS AND CONDITIONS  
1. Applicability: The limited warranties set forth above are extended  
only to the original owner at the original place of installation within the  
United States and Canada. These warranties are applicable only to  
water boilers designated as residential grade by U.S. Boiler Co., Inc. and  
installed in a single or two-family residence and do not apply to steam  
boilers of any kind or to commercial grade boilers.  
The owner is required to make available for inspection by U.S.  
Boiler Co., Inc. or its representative the parts claimed to be defective  
and, if requested by U.S. Boiler Co., Inc. to ship these parts prepaid to  
U.S. Boiler Co., Inc. at the above address for inspection or repair. In  
addition, the owner agrees to make all reasonable efforts to settle any  
disagreement arising in connection with a claim before resorting to legal  
remedies in the courts.  
2. Components Manufactured by Others: Upon expiration of the  
one year limited warranty on residential grade water boilers, all boiler  
components manufactured by others but furnished by U.S. Boiler Co.,  
Inc. (such as oil burner, circulator and controls) will be subject only to the  
manufacturer’s warranty, if any.  
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU  
MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO  
STATE.  
3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc.  
are conditioned upon the installation of the residential grade water boiler  
in strict compliance with U.S. Boiler Co., Inc. installation instructions. U.  
S. Boiler Co., Inc. specifically disclaims liability of any kind caused by or  
relating to improper installation.  
4. Proper Use and Maintenance: The warranties extended by U.S. Boiler  
Co., Inc. conditioned upon the use of the residential grade water boiler for  
its intended purposes and its maintenance  
03/03  

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