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Burnham BASE-RAY 81441001R8-3/06 User's Manual

1. limitations As shown in the adjacent diagram the diameter of the fittings cannot exceed 11 2 radiator union elbows and regular pipe unions usually measure more 34 copper sweat or screw fittings usually measure less When iron pipe and fit tings are used straight connections may be made with 74 right and left coupling and corner connections with 3 4 street elbow Because of these space limitations Burnham has available a No 90 S Compression Connector for use with the Projecting Corner Plate see illustration Because of the radius on the face of INVERTED CORNER PLATE fittings having a diameter greater than 1 2 may be used see illustration For easy and quick connections at inside corners however we recommend the Burnham No 90 S Compression Connector for use with the 4 5 8 Inverted Corner Plate Both are illustrated VALVE ENCLOSURES have been designed to accommodate almost all makes of shut off valves and steam traps See Il lustration for Enclosure dimensions 8 PROJECTING CORNER PLATES OR BASEBOARD EXTENSION END OF ASSEMBLY OF INVERTED CORNER PLATE TOP VIEW INSTALLATION INSTRUCTIONS Wall Preparation To prevent excessive heat loss through the walls in back of BASE RAY it is recommended that the stud space behind the Assemblies be insulated to a height of at least 12 above the floor with 4 mineral wool batts blanket or loose insulation may also be used or other app
2. off fraction of a turn to permit movement caused by expansion and contractions of sections Adjust Bottom Center Supports by turning Cap Screws down until they begin to contact floor Do not extend the Cap Screws any further Connect assemblies to piping Complete remainder of piping to boiler fill system with water and check for leaks CARE MUST BEEXERCISED TO SEE THAT 30 PSIGAUGE PRESSURE IS NOT EXCEEDED DO NOT PRESSURE TEST WITH AIR MOLDING BASEBOARD EXTENSION PLATE f LEFT HAND END CAP DROP PIPING UNDER DOORS FIREPLACES ETC 7 Installation of Valve enclosures furnished in right hand and left hand patterns Remove knockout in end of Valve Enclosure if piping to run through Valve Enclosure Bend tab on Valve Enclosure so that hole is on inside of Valve Enclosure facing wall Place Valve Enclosure next to BASE RAY and fasten to BASE RAY with 4 thumb screw furnished Insert screw furnished through tab on Valve Enclosure and fasten to wall Set Valve Enclosure Cover in place SENS lt s NN N A nee AVR NANA ND NN lt T gt r gt WI NA N k NN w N w oa PIPING INTO NEXT ROOM RIGHT HAND VALVE ENCLOSURE RIGHT HAND END CAP ALT FOR SPLICE PLATE 11 8 Installation of Corner Plates INVERTED CORNER PLATES for inside corners furnished in two types 4 5 8 standard plate is used when Assemblies on adjoining walls extend to within 4 3 8 of the corn
3. or more pieces or sub assemblies none of which exceeds 6 lineal ft ASSEMBLIES AND SUB ASSEMBLIES ARE MADE UP OF FOLLOWING SECTIONS 18 24 24 12 18 24 ASSEMBLIES Left Left 24 Int Right Right Panel Panel End End End End 1 Ft Assembly Ses ase 1 2 Ft Assembly ueu gn age 1 2 2 Ft Assembly 1 1 3 Ft Assembly 1 1 3 Ft Assembly 1 1 4 Ft Assembly 1 1 4 Ft Assembly 1 1 1 5 Ft Assembly 1 1 1 Se Ft Assembly 1 1 1 6 Ft Assembly 1 1 1 SUB ASSEMBLIES 51 2 Ft L H i Sub Assy 5N L 2 6 Ft Center 3 Sub Assy All R H _ __ Required ioti Sub Assy Number REAR VIEW Use of PTFE Teflon tape or paste containing PTFE is not recommended as overtightening is possible causing cracking of the Base Ray tappings Sub Assembly Chart RUN L H CENTER 6 Ft 51 2 Ft S s Ft 6 Ft 71 2 Ft 5 FL 8 Ft 6 Ft ss 81 2 Ft 5 2 Ft a 9 Ft 6 Ft 9 Ft 95 2 Ft _ 10 Ft 6 Ft 1012 Ft Se FL ass 11 Ft 6 Ft cs 1112 Ft 9 2 Ft a 12 Ft 6 Ft mie T2 FE 512 FL 6 Ft 13 Fi 6 Ft 6 Ft 13 Ft 9 Ft 6 Ft 14 Ft 6 Ft 6 Ft 14 Ft 512 Fi 6 Ft 19 Fi 6 Ft 6 Ft 15 Ft 51 2 Ft 6 Ft 16 Ft 6 Ft 6 Ft 16 Ft 9 FL 6 Ft 17 Ft 6 Ft 6 Ft 17 rk 9 FL 6 Ft 18 FE 6 Ft 6 Ft 1812 Ft 9a FL 2 6 Ft 19 Ft 6 Ft 2 6 Ft 191 Fi 9 2 FL 2 6 Ft 20 Ft 6 Ft 2 6 Ft 2012 Ft OY Ft 2 6 Ft 2
4. or swing joint such as illustrated 90 ELL WROUGHT MALE CU X CU ADAPTER 3 4 IPS X 344 CU IN UPPER TAPPING OF BASE RAY WROUGHT MALE ADAPTER 3 4 IPS X 3 4 CU IN LOWER TAPPING OF BASE RAY INSTALLATION WITH BURNHAM RADIANT OR SLENDERIZED RADIATORS Since a BASE RAY installation is made in much the same manner as any other radiator system BURNHAM RADIANT OR SLENDER IZED RADIATORS may be used in a BASE RAY Radiant Baseboard System TWO TIER INSTALLATION Where wall space is limited BASE RAY may be installed in tiers Both sections may be upright or lower section inverted as illustrated Legs on end sections are cut off to enhance appearance RATING CORRECTION FACTOR lt If BASE RAY is installed in tiers in accordance with the illustrations each tier will have a rating of 91 times the rating shown in the Tables on pages 2 and 3 e ZA y i yn Oo y _ SA TII DOL sS ELLE Lf Top Sections Upright Bottom Sectiens Inverted aC FDP oe ou ei OL d amp amp w w GT AU ke Pee wm A 2 mm KA YW WY i gu yd V Both Sections Upright POSSIBLE PIPING ARRANGEMENTS TWO TIER BASE RAY FORCED CIRCULATION HOT WATER SYSTEMS AIR VENT RADIATOR VALVE BALANCING ELL SUPPLY amp RETURN AT SAME END OF ASSEMBLY 14 AIR VENT PLUG TEE FOR DRAIN SUPPLY amp RETURN AT OPPOSITE ENDS OF AS
5. room using the procedure outlined in the IFB lt R Heat Loss Calculation Guide No H 21 or the ASHRAE Guide 2 Using 2109F as design water temperature and 500 lbs hr as flow rate select length of BASE RAY Assembly for each room to produce desired output Design water temperature other than 2109F may be used but should not exceed 2309F If system designed on 20 F drop this 2109F average water temperature means roughly that under maximum load conditions the water leaves the boiler at 220 F and returns at 2009F and returns at 2009F Since maximum load conditions occur only at rare intervals the system usually operates at considerably lower water temperatures 3 Locate BASE RAY Assemblies on Floor Plan drawn to scale 4 Layout Piping on Floor Plan as illustrated Since the temperature ofthe water decreases progressively from the first Heating Unit to the Last Heating Unit on a circuit the system should be laid out if possible so that the Heating Units with the hotter water are in areas such as the living room bath and dining room Heating Units in bedrooms kitchen and similar areas should be located on the end of the loop 5 Measure length of Circuit horizontal and vertical from boiler supply to boiler return include BASE RAY lengths In Series Loop Systems on rare instances a BASE RAY Assembly Radiant Radiator or Slenderized Radiator is connected to the main with branches Since a one pipe fitting is used add 12 addit
6. 1 Ft 6 Ft 2 6 Ft 21 2 Ft 02 FI 2 6 Ft 22 FI 6 Ft 2 6 Ft 221 2 Fi 9 2 Ft 2 6 Ft 23 Ft 6 Ft 2 6 Ft 23 Ft 9 Ft 2 6 Ft 24 Ft 6 Ft 2 6 Ft R H 1 Ft 1 Ft 2 Ft 2 Ft 3 Ft 3 Ft 4 Ft 4 Ft 5 Ft p F 6 Ft 6 Ft 1 Ft 1 Ft 2 Fi 2 Ft 3 Ft 3 Ft 4 Ft 4 Ft 5 Ft 5 Ft 6 Ft 6 Ft 1 Ft 1 Ft 2 Ft 2 Ft 3 Ft 3 Ft 4 Ft 4 Ft 5 Ft 5 Ft 6 Ft 6 Ft BASE RAY HYDRONICS Types of Systems Hydronic Heating Systems are classified according to the pip ing arrangement and heating medium employed BASE RAY Is very versatile in that it may be used in almost all types of systems as noted below 1 Series Loop Forced Circulation Hot Water 2 One Pipe Forced Circulation Hot Water 3 Two Pipe Reverse Return Gravity or Forced Circulation Hot Water 4 Two Pipe Steam or Vapor It is not recommended that BASE RAY be used in a One Pipe Steam System System Description 1 Series Loop isa forced circulation hot water heating system with the BASE RAY Assemblies connected so that all the water flowing through a circuit passes through each series connected Assembly in the circuit Thus the Assemblies serve as portions of the main 2 One Pipe is a forced circulation hot water heating system utilizing one continuous main from boiler supply to boiler return BASE RAY Assemblies are connected to this pipe or main by two smaller pipes known as branches When connecting these branches
7. 10 5 35 7 8610 9870 9240 8510 7880 7250 6510 5780 4305 3 21 11 0 37 4 9020 10340 9680 8910 8250 7590 6820 6050 4510 3 32 11 5 39 1 9430 10810 10120 9320 8630 7940 7130 6330 4715 3 42 12 0 40 8 9840 11280 10560 9720 9000 8280 7440 6600 4920 3 53 12 5 42 5 10250 11750 11000 10130 9380 8630 7750 6880 5125 3 64 13 0 44 2 10660 12220 11440 15030 9750 8970 8060 7150 5330 3 74 13 5 45 9 11070 12690 11880 10940 10130 9320 8370 7430 5535 3 85 14 0 47 6 11480 13160 12320 11340 10500 9660 8680 7 7 00 5740 3 96 14 5 49 3 11890 13630 12760 11750 10880 10010 8990 7960 5945 4 06 15 0 51 0 12300 14100 13200 12150 11250 10350 9300 8250 6150 4 17 15 5 52 12710 14570 13640 12560 11630 10700 9610 8530 6355 4 28 16 0 54 4 13120 15040 14080 12960 12000 11040 9920 8800 6560 4 38 10 5 56 1 13530 15510 14520 13370 12380 11390 10230 9080 6765 4 49 17 0 57 8 13940 15980 14960 13770 12750 11730 10540 9350 6970 4 60 17 5 59 5 14350 16450 15400 14180 13130 12080 10850 9630 7175 4 70 18 0 61 2 14760 16920 15840 14580 13500 12420 11160 9900 7380 4 91 18 5 62 9 15170 17390 16280 14990 13880 12770 11470 10180 7585 4 92 19 0 64 6 15580 17860 16720 15990 14250 13110 11780 10450 7790 5 03 19 5 66 3 15990 18330 17160 15800 14630 13460 12090 10730 7995 5 13 20 0 68 0 16400 18800 17600 16200 15000 13800 12400 11000 8200 5 24 20 5 69 7 16810 19270 18040 16610 15380 14150 12710 11280 8405 5 35 21 0 71 4 17220 19740 18480 17010 15750 14490 13020 11550 8610 5 45 21 5 73 1 17630 20210 18920
8. 1380 10330 9100 6825 35 18 0 61 2 14760 16020 14940 13860 12780 11700 10620 9360 7020 36 18 5 62 9 15170 16470 15360 14250 13140 12030 10920 9620 7215 37 19 0 64 6 15580 16910 15770 14630 13490 12350 11210 9880 7410 38 19 5 66 3 15990 17360 16190 15020 13850 12680 11510 10140 7605 38 20 0 68 0 16400 17800 16600 15400 14200 13000 11800 10400 7800 39 20 5 69 7 16810 18250 17020 15790 14560 13330 12100 10660 7995 AO 21 0 71 4 17220 18690 17430 16170 14910 13650 12390 10920 8190 41 21 5 73 1 17630 19140 17850 16560 15270 13980 12690 11180 8385 42 22 0 74 8 18040 19580 18260 16940 15620 14300 12980 11440 8580 42 I B R Ratings are determined from tests made in accordance with the I B R Testing and Rating Code for Baseboard Type of Radiation including an allowance of 15 for heating effect permitted by the Code Ratings based on active length Active length same as total length 2 The Hot Water Ratings at 500 Ib Flow Rate are based on a standard water flow rate of 500 Ibs per hour one gallon per minute through the Base Ray These ratings should be used for all installations except as noted under 2000 Lb Flow Rate Add 2 to length for each bushing Add 5 to length for each valve enclosure Based on 54 pipe connections For Ratings at the following temperatures multiply the 150 rating by the multiplier of the desired temperature Temperature Multiplier 150 1 0 120 54 130 68 110 42 140 82 No 9A
9. 17420 16130 14840 13330 11830 8815 5 56 22 0 74 8 18040 20680 19360 17820 16500 15180 13640 12100 9020 5 67 I B R Ratings are determined from tests made in accordance with the I B R Testing and Rating Code for Baseboard Type of Radiation including an allowance of 15 for heating effect permitted by the Code Ratings based on active length Active length same as total length The Hot Water Ratings at 2000 Ib Flow Rate are limited to installations where the water flow rate through the Base Ray is greater than 2000 Ibs per hour four gallons per minute Where the water flow rate through the Base Ray is not known the rating at the standard flow rate of 500 Ibs per hour must be used Add 2 to length for each bushing Add 5 to length for each valve enclosure Based on 34 pipe connections 9A Base Ray Water Content 2 5 Ibs or 3 gal per linear ft Dimensions and Specifications Ja 1 FRONT VIEW BASE RAY TAPPINGS Tapped 3 4 top and bot tom of end sections A 3 4 x 1 8 vent bushing is furnished with each Base Ray Assembly Only one air vent location need be used Copper tubing is not recommended for steam appli cations due to high heat loss through the tubing and thermal expansion noise Maximum recommended length for steam applications is 10 lineal feet Base Ray Assembly Chart BASE RAY Assemblies up to and including 6 lineal ft are shipped in one piece Longer Assemblies are shipped in two
10. 8 7 4510 4900 4570 4240 3910 3580 3250 2860 2145 16 6 0 20 4 4920 5340 4980 4620 4260 3900 3540 3120 2340 Az 6 5 22 1 5330 5790 5400 5010 4620 4230 3840 3380 2535 18 7 0 23 8 5740 6230 5810 5390 4970 4550 4130 3640 2730 18 7 5 25 5 6150 6680 6230 5780 5330 4880 4430 3900 2925 19 8 0 27 2 6560 7120 6640 6160 5680 5200 4720 4160 3120 20 8 5 28 9 6970 7570 7060 6550 6040 5530 5020 4420 3315 21 9 0 30 6 7380 8010 7470 6930 6390 5850 5310 4680 3510 22 9 5 32 3 7790 8460 7890 7320 6750 6180 5610 4940 3705 22 10 0 34 0 8200 8900 8300 7700 7100 6500 5900 5200 3900 23 10 5 35 7 8610 9350 8715 8090 7460 6830 6200 5460 4095 24 11 0 37 4 9020 9790 9130 8470 7810 7150 6490 5720 4290 25 11 5 39 1 9430 10240 9550 8860 8170 7480 6790 5980 4485 26 12 0 40 8 9840 10680 9960 9240 8520 7800 7080 6240 4680 26 12 5 42 5 10250 11130 10380 9630 8880 8130 7380 6500 4785 27 13 0 44 2 10660 11570 10790 10010 9230 8450 7670 6760 5070 28 13 5 45 9 11070 12020 11210 10400 9590 8780 7970 7020 5265 29 14 0 47 6 11480 12460 11620 10780 9940 9100 8260 7280 5460 30 14 5 49 3 11890 12910 12040 11170 10300 9430 8550 7540 5655 30 15 0 51 0 12300 13350 12450 11550 10650 9750 8850 7800 5850 31 15 5 52 7 12710 13800 12870 11940 11010 10080 9150 8060 6045 32 16 0 54 4 13120 14240 13280 12320 11360 10400 9440 8320 6240 33 16 5 56 1 13530 14690 13700 12710 11720 10730 9470 8580 6435 34 17 0 57 8 13940 15130 14110 13090 12070 11050 10030 8840 6630 34 17 5 59 5 14350 15580 14530 13480 12430 1
11. Base Ray I B R Ratings Steam and Hot Water 2000 LBS HR Flow Rate Sies Steam HOT WATER RATINGS IN BTU PER HOUR AT Pressure Length in Rating Rating 2000 LBS HR FOUR G P M FLOW RATE Drop in Lineal Feet Square Feet B T U Per AT AVERAGE WAER TEMPERATURE OF Inches of Hr At215 F 230 F 220 F 210 F 200 F 190 F 180 F 170 F 1509F Water Per Lin Ft 3 40 820 940 880 810 750 690 620 550 410 1 5 5 1 1230 1410 1320 1220 1130 1040 930 830 615 1 29 2 0 6 8 1640 1880 1760 1620 1500 1380 1240 1100 820 1 39 25 8 5 2050 2350 2200 2030 1880 1730 1550 1380 1025 1 50 3 0 10 2 2460 2820 2640 2430 2250 2070 1860 1650 1230 1 61 3 5 11 9 2870 32990 3080 2840 2630 2420 2170 1930 1435 1 71 4 0 13 6 3280 3760 3520 3240 3000 2760 2480 2200 1640 1 82 4 5 15 3 3690 4230 3960 3650 3380 3110 2790 2480 1845 1 93 5 0 17 0 4100 4700 4400 4050 3750 3450 3100 2 50 2050 2 03 55 18 7 4510 5170 4840 4460 4130 3800 3410 3030 2255 2 14 6 0 20 4 4920 5640 5280 4860 4500 4140 3720 3300 2460 2 25 6 5 22 1 5330 6110 5720 5270 4880 4490 4030 3580 2665 2 35 7 0 23 8 5740 6580 6160 5670 5250 4830 4340 3850 2870 2 46 15 25 5 6150 7050 6600 6080 5630 5180 4650 4130 3075 2 57 8 0 27 2 6560 7520 7040 6480 6000 5520 4960 4400 3280 2 68 8 5 28 9 6970 7990 7480 6890 6380 5870 5270 4680 3485 246 9 0 30 6 7380 8460 7920 7290 6750 6210 5580 4950 3690 2 89 9 5 32 3 7790 8930 8360 7700 7130 6560 5890 5230 3895 3 00 10 0 34 0 8200 9400 8800 8100 7500 6900 6200 5500 4100 3 10
12. INSTALLATION MANUAL FOR BURNHAM BASE RA Y TABLE OF CONTENTS I B R RATINGS 8 INSTALLATION DETAILS ASSEMBLY CHART 9 INSTALLATION INSTRUCTIONS SYSTEM TYPES ASSEMBLY INSTRUCTIONS SERIES LOOP SYSTEMS SPECIAL APPLICATIONS SERIES LOOP DESIGN WARRANTY Heating Contractor Installation Date ry Burnham Hydronics U S Boiler Co Inc 81441001R8 3 06 Price 2 00 For Ratings at the following temperatures multiply the 150 rating by the multiplier of the desired temperature Temperature Multiplier 150 1 0 110 42 100 32 130 68 120 54 140 82 No 9A Base Ray I B R Ratings Steam and Hot Water 500 LBS HR Flow Rate Steam HOT WATER RATINGS IN BTU PER HOUR AT Pressure Length in ath Rating 500 LBS HR ONE G P M FLOW RATE Drop in Lineal Feet Sauare Feel B T U Per AT AVERAGE WAER TEMPERATURE OF Inches of Hr At215 F 230 F 220 F 210 F 200 F 190 F 180 F 170 F 150 F Water Per Lin Ft 3 40 820 890 830 770 710 60 590 520 390 1 5 5 1 1230 1340 1250 1160 1070 980 890 780 585 10 2 0 6 8 1640 1780 1660 1540 1420 1300 1180 1040 780 10 2 5 8 5 2050 2230 2080 1930 1780 1630 1480 1300 975 11 3 0 10 2 2460 2670 2490 2310 2130 1950 1770 1560 1170 2 3 5 11 9 2870 3120 2910 2700 2490 2280 2070 1820 1365 13 4 0 13 6 3280 3560 3320 3080 2840 2600 2360 2080 1560 14 4 5 15 3 3690 4010 3740 3470 3200 2930 2660 2340 1755 14 5 0 17 0 4100 4450 4150 3850 3550 3250 2950 2600 1950 15 5 5 1
13. SEMBLY All Base Ray repair parts may be obtained through your local Burnham Wholesale Distributor Should you require assistance in locating a Burnham Distributor in your area or have guestions regarding the availability of Burnham products or repair parts please contact Burnham Customer Service at 717 481 8400 or Fax 717 481 8408 15 Limited Warranty DUO RAD DUO RAD II AND CAST IRON RADIATION Limited Warranty Except as provided below with respect to products or parts not manufactured by U S Boiler Co Inc U S Boiler Co Inc warrants to the original owner at the original installation site that products manufactured by U S Boiler Co Inc comply at the time of manufacture with recognized Hydronics industry regulatory agency standards and reguirements then in effect and will be free from defects in materials and workmanship for a period of one year after the date of installation The remedy for breach of this warranty is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use and does not extend to liability for incidental special or conseguential damages or losses such as loss of the use of the products inconvenience loss of time or labor expense involved in repairing or replacing alleged defective product U S Boiler Co Inc shall have no responsibility for the performance of any product sold by it under conditions varying materially from those under which such
14. d and when contracted for by the Buyer to be installed or handled is not covered by this warranty U S Boiler Co Inc does not assume any responsibility in connection with such eguipment operation warranty performance or any other liability connected thereto Then foregoing provisions of this WARRANTY shall be effective to the maximum extent permitted by applicable law and to the extent that any such provision would otherwise have an unconscionable result or would otherwise be inconsistent with applicable law such provision shall be limited in effect to the minimum extent necessary to avoid such unconscionable result or inconsistency with applicable law Any implied warranties including implied warranties of merchantability and fitness for a particular purpose shall to the extent permitted by applicable law be limited in duration to a period of one year after the date of installation To the extent permitted by applicable law the remedies for breach of any such implied warranty shall be limited to the remedies set forth above with respect to a breach of the express limited warranty provided With respect to the limitations on implied warranties set forth above U S Boiler Co Inc hereby notifies each person to whom such warranty is made as follows Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or conseguential damages so the above limitations or exclusions may not ap
15. d using 1 wide tape for this purpose preferably with a thermal setting adhesive available from Burnham at nominal charge With theadhesive side down pressone halfoftapeagainst the top of BASE RAY and the other half against the wall as illustrated on page 9 WOOD MOULDING lt For finished installation 3 4 guarter round or other wood moulding should be nailed to wall on top of BASE RAY over Air Seal and Trim and down side of Valve Enclosures When Projecting Corner Plates are used install wood moulding at base of Corner Plate to hold in place An illustration showing the application of the moulding can be found on page 9 PAINTING BASE RAY and Trim are primed with a latex water based paint and must be top coated with a high grade oil or solvent based enamel to prevent rusting of the metals immediately after installation Primer coated products should not be allowed to sweat as a result of high room humidity or cold water in system The use of flat wall paint is not recommended since it may chip or crack when applied to surfaces that are heated Consult reputable paint dealer 13 SPECIAL APPLICATIONS BASE RAY INSTALLED ON THREE WALLS OFROOM When BASE RAY is installed on three walls expansion noises are sometimes created by the middle assembly when rigid piping is used to connect all three assemblies together Flexibility can be gained by connecting two of the adjoining assemblies with a flexible connector
16. er If this distance is greater than 4 3 8 but less than 10 3 8 the 10 5 8 plate is used Extended Plate may be cut to desired length with hacksaw Set Inverted Corner Plate in place overlapping the end of the adjoining BASE RAY Assemblies Secure to floor with wood screws furnished If installation is on tile with wood sub flooring drill 1 2 holes in tile in line with holes in Corner Plate Holes should not penetrate sub flooring Substitute screws of same size as furnished but longer and secure Corner Plate to sub flooring Ifinstallation is on masonry floor drill 1 2 holes approximately 1 deep in floor in line with holes in Corner Plate Drive slightly oversized wood plugs into holes and secure Corner Plate to plugs with wood screws furnished PROJECTING CORNER PLATE for concealing pipe and fittings at outside corners See section on MAXIMUM DI MENSION OF FITTINGS page 8 Assemblies on adjoining walls must extend to within 3 of corner Set Projecting Corner Plate in place overlapping the ends of the adjoining BASE RAY Assemblies Secure with moulding not furnished at top and bottom 12 Installation of Baseboard Extension Splice Plates End Caps and Filler Pieces BASEBOARD EXTENSION Extension panels are furnished in six foot lengths but may be cut to desired lengths with hacksaw Extensions are supported by hang ers which are attached to studs stud locations determined in Step 1 with
17. hould be thoroughly cleaned with kerosene or gasoline and wiped dry with a clean cloth Place a thin coating of nipple lubricant on nipples and insert into the nipple ports of one assembly without cocking Engage nipples in nipple ports of second assembly and push sections together by hand as far as possible keeping ends of sections parallel In order to secure necessary leverage with BASE RAY Clamp cut two pieces of 1 4 steel pipe 15 long and place them on the two cam handles Insert BASE RAY Clamp nose in the recesses in the BASE RAY castings being certain that the nose of the clamp is resting on the bottom of the recess THIS IS IMPORTANT If the clamp nose will not reach the bottom of the recess exert light pressure downward on the cam handles until the two castings are PARTIALLY drawn together Release the pressure on the handles and the clamp nose will then drop to the bottom of the recess INVERTED CORNER PLATE FILLER PIECE OR SPLICE PLATE BASE RAY LEFT HAND VALVE ENCLOSURE 10 FIXED RIGHT HAND BASEBOARD oN CORNER PLATE END CAP EXT 8 yf PA K A lt L Z X Press down on both cam handles simultaneously until castings are drawn together Be sure clamp is not tilted since this may break casting If nipples do not draw up evenly during final tightening strike end of assembly with wood block and hammer or mallet to bring the sections back in line Do not strike BASE RAY sections wi
18. iced as tests have proven the ability ofa Series Loop System to produce comfort conditions equal to those produced by other hydronic heating systems Series Loop Systems are ideal for homes without basements especially those built on concrete slabs as it eliminates the necessity for running the mains in the attic or in the concrete slab With proper design the Series Loop System can be used to advantage in apartment construction As indicated in the adjacent piping diagrams the supply runs from the boiler to the first BASE RAY Assembly in the circuit and then from Assembly to Assembly dropping below the floor only when necessary to avoid obstructions such as doors fireplaces etc BASE RAY Baseboard Extensions are used to conceal the piping run above the floor It is sound practice to run a loop around an ordinary 5 or 6 room house In the case of very small two story homes the loop may take in both first floor and second floor rooms Larger ranch style two story and split level homes may use two separate loops running from the same supply line and coming back into the common return line An example of this is shown lower right where the rooms on each floor are on a separate loop In some two story homes it might be desirable to put part of each floor on one loop and the other portions of each floor on a second loop Do not include three stories on one loop In multiple loop systems a valve should be placed at the return end of each loo
19. ional feet to the measured length to obtain total length of Circuit 6 Knowing the load length of the loop from Steps 2 and 5 above Table A will indicate whether or not a standard 74 or 1 circulator is adequate TABLE A TABLE B Btu Hr Output of Btu Hr Output of BASE RAY BASE RAY Assemblies Each Assemblies All Loop Loops NOTE Table based on head developed by Standard 34 or 1 circulator 20 F Drop through system Total Length of Loop Ft Length of Longest Loop Ft NOTE Table based on 20 F Drop through Circuit 34 piping If for a given output the total length of the loop exceeds the values shown in Table A the loop may be split into two circuits see Illustration Check load length of each circuit Determine from Table B if 1 trunk is adeguate 41 NO SA BASE RAY 44 NO 9A BASE RAY ABOVE FLOOR PIPING BASEMENT PIPING BASE RAY SERIES LOOP INSTALLATION SINGLE CIRCUIT BASE RAY SERIES LOOP INSTALLATION TWO CIRCUITS For Piping Arrangements and Design conditions other than those given above follow procedure outlined in I B R Instal lation Guide No 200 Installation Details ABASE RAY heating system is extremely easy to install no other heating system requires less labor The same installa tion practices that are used in an ordinary radiator system are followed Use conventional methods in selecting boiler and pipe sizes including mains rise
20. n in this direction Slide over end of Extension Panel END CAP SPLICE PLATES ADJUSTABLE END CAPS amp FILLER PIECES Adjustable End Caps arc available in both left hand and right hand patterns and are used in the same loca tions as the standard end caps except the 9 length of the adjustable end caps makes it possible to fill in spaces of up to 7 1 2 A knockout is also available in the ends for piping Filler pieces are used where a 9 space or less exists between two sections of baseboard or between a section of baseboard and baseboard extension To install adjustable end cap or filler piece accessory insert bolt thru hole in accessory and engage toggle as shown below Place accessory against BASE RAY at same time pushing toggle thru air outlet of BASE RAY With accessory in final location tighten bolt until accessory is secure Use finger to keep toggle in vertical position as shown below ADJUSTABLE ENO CAP LH SHOWN FIG INSTALLATION OF ADJUSTABLE END CAP PROPER LOCATION OF TOGGLE WHEN SECURING ACCESSORY TO BASE RAY AIR OUTLET BASE R FILLER PIECE INSTALLATION OF BASE RAY ADJUSTABLE END CAP amp FILLER PIECE 10 Completing Installation Important AIR SEAL It is necessary to prevent leakage of air between the walls and BASE RAY since this will cause dirt streaks on the wall above the heating unit This can be avoided by installing an Air Seal We recommende
21. p for balancing EXPANSION BASE RAY Assemblies and connecting pip ing will vary in length with water temperature changes in the system To prevent distortion or noise as this expansion takes place adequate measures must be provided in the system design and by the installer Proper location of breaks in a run when the piping must drop through the floor to clear obstructions such as doors and fireplaces expansion fittings use of flexible tubing at the end ofa run offsetting the vertical risers in adequate size holes 1 4 holes for 24 copper tubing 11 x 1 2 elongated holes for 74 steel pipe all provide for expansion and make for a guality installation In systems where high boiler water temperature must be maintained for domestic hot water length of BASE RAY Assemblies between two inside adjacent cor ners when BASE RAY is on three walls should not exceed 25 feet unless there is an expansion break between or swing Joint provided at end See SPECIAL APPLICATIONS page 14 It is also desirable on these types of systems to provide a by pass and mixing valve between boiler supply and return so that in mild weather temperature changes in the system will be gradual instead of rapid BALANCING SYSTEM lt System should be balanced on days when average winter temperatures prevail outdoors Jeres Loop System NR RL R for sach Fionr To Design Series Loop Base Ray Installation 1 Calculate the Heat Loss of each
22. ply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Burnham Hydronics 03 03
23. product is usually tested under existing industry standards nor for any damage to the product from abrasion erosion corrosion deterioration or the like due to abnormal temperatures or the influence of foreign matter or energy nor for the design or operation of any system of which any such product may be made a part or for the suitability of any such product for any particular application For products or parts not manufactured by U S Boiler Co Inc the warranty obligation of U S Boiler Co Inc shall in all respects conform and be limited to the warranty actually extended to U S Boiler Co Inc by its vendors Warranty service can be obtained by contacting the original installer of the product and providing him with a detailed description of any apparent defect If this procedure fails to result in satisfactory warranty service the owner should notify U S Boiler Co Inc P O Box 3079 Lancaster PA 17604 Transportation to a factory or other designated facility for repairs of any products or items alleged defective shall in all events be the responsibility and at the cost of the owner Notwithstanding any of the above provision 1 failures resulting from misuse 1mproper installation or lack of maintenance are not covered by this warranty and 2 U S Boiler Co Inc s liability under this warranty shall not exceed the selling price of the product found to be defective Eguipment furnished by the Buyer either mounted or unmounte
24. roved insulating materials This is particularly essential if the BASE RAY is recessed Mark Stud locations Allowance for Finished Flooring to Wall to Wall Carpeting If BASE RAY is to be installed prior to the finished floor a wooden strip 2 2 in width and equal in height to the finished floor should be installed along the base of all walls where baseboard assemblies and trim are to be placed If allowance is not made for wall to wall carpeting or for carpeting that is to be laid with edges flush to the room side surface of BASE RAY the air inlet of the BASE RAY will be restricted resulting in a reduction in output To compensate for the wall to wall carpeting baseboard assemblies and trim should be raised by laying under them a strip of wood 2 2 wide and the same thickness as the carpet and pad Recessing of BASE RAY Assemblies and Trim If BASE RAY to be installed free standing proceed to Step 4 BASE RAY and Trim may be partially recessed or installed free standing against the finished wall surface Although procedure for preparing recess may vary slightly with type of finished wall in general steps outlined below for lath and plaster construction may be followed a Nail 1 2 plaster ground to studs with the bottom of the plaster ground located 10 above finished floor Additional height must be allowed if recess prepared before finished floor is laid or if wall to wall carpeting is to be installed
25. rs and branches Supply and return connections to BASE RAY are made in the same way as with conventional radiators I B R Installation Guide No 200 for Hydronic Heating Systems shows installation details for both the conventional piping system and the Series Loop System LOCATION OF BASE RAY BASE RAY should be placed along exposed walls in place of the regular wood baseboard Ifthe outside walls do not provide sufficient space place additional assemblies on inside wall RECESSED BASE RAY may be recessed the depth of the lath and plaster and will extend into the room approximately one and a quarter inches EXPANSION BASE RAY will expand about 1 8 in 10 lineal feet with a temperature rise of 180 F To provide for this holes cut through the floors should be larger than the pipe and swing connections should be located in branches between the Main and Risers VENTING When two or more BASE RAY assemblies are connected in series on a hot water Job it is necessary to vent each assembly unless the assemblies are connected at the top tapping When connected in series on a two pipe steam Job the assemblies should be connected at the bottom and only one steam air vent need be used MAXIMUM DIMENSIONS OF FITTINGS Inasmuch as the BASEBOARD EXTENSION PANELS and PROJECTING CORNER PLATES are installed flush with the face of BASE RAY there are a few types of fittings that cannot be used in back of these parts because of the space
26. see Step 2 of Installation Instructions b Line back of recess with paper backed aluminum foil This can be accomplished quickly and neatly by stapling foil to studs with staple gun Foil surface should be on room side 4 Wi on di exe fir er A 4 227722 A oye wt BASE RAY INSTALLATION WALL TO WALL CARPETING Locate Holes for Piping see Illustrations FINISHED WALL OR BACK OF RECESS ALLOWANCE FOR VAVE ENCLOSURE IF USED NEXT TO WALL N rr THIS DMENSION __ TO BE DETERMINED ON THE JOB NEPE 5 N H xi ELONGATED HOLE FOR T IRON PIPE RISER I HOLE FOR 3 COPPER RISER PIPING THRU FLOOR i y FINISHED WALL OR BACK OF RECESS ALLOWANCE FOR SU I HOLE O FINISHED FLOOR OR WOOD STRIP W W CARPETING PIPING THRU WALL 5 Assembling BASE RAY BASE RAY is shipped assembled in lengths up to six 6 lineal feet longer assemblies are shipped in two or more sub assemblies for assembly on the job see BASE RAY Assembly chart page 4 One man can join tow sub assemblies together in a matter of minutes providing he has a BASE RAY Assembly Clamp available ata nominal charge and follows the recommended procedure In assembling BASE RAY sub assemblies on the job the sections should be lined up face down on the floor or other flat surface near the wall on which they are to be installed Ends of section nipple ports and nipples s
27. th metal hammer Remove the clamp place the tie bolts in the bolt slots and tighten securely Sections being drawn together ready for tie bolt 6 Installation of BASE RAY Assemblies Install all fittings in end of sections and all necessary vents while assemblies are still laying flat on floor Install bottom center supports prior to raising assemblies to upright position Refer to table for number of supports required They should be spaced evenly Number of Top and Bottom Length Assembly Center Supports Required 1 to 14 Lineal Feet 1 15 to 21 Lineal Feet 2 22 to 2812 Lineal Feet 3 Install the spring clip Bottom Center support by pushing it all the way up against the bottom of two fins and next to the waterway of the section as illustrated below Run the 1 2 cap screw into the clip until head is not more than 74 from the clip ADJUSTABLE END CAP OR PROJECTING 5 amp WEY lt BASEBOARD BASE RAY EXTENSION MOLDING Spring Clip Bottom Center Support TOP CENTER SUPPORT Stand Assemblies upright place in position and fasten to the walls with Top Center Supports using the number shown in the table above Insert Top Center Supports in Air Outlet opening of Sections opposite studs stud locations determined in step 1 Use wood screw furnished with Top Center Support and screw into stud until tight the longer dimension of the top center support is in a vertical position when installed Back
28. to the main one of the standard tees is replaced by a special tee frequently called a one pipe fitting These one pipe fittings cause a portion of the water flowing through the main to pass through the BASE RAY Assemblies and back to the main again Two Pipe Reverse Return is a gravity or forced circulation hot water heating system utilizing one main to carry heated water from the boiler to the BASE RAY Assemblies and a second main to carry the cooled water from the Assemblies back to the boiler The Assemblies are connected to the return main in the reverse order from that in which they are connected to the supply main Very few designers use this type of system for residential applications since there 1s no difference between the heating qualities of this system and the other two hot water systems Two Pipe Steam or Vapor Systems are steam systems in which each BASE RAY Assembly is provided with two piping connections and where steam and condensate flow in separate mains and branches The Vapor system differs from the low pressure system only in the type of air valve used SERIES LOOP SYSTEMS Installation Data This type of installation in which the BASE RAY Assem blies serve as part of the main is the most economical way BASE RAY can be installed Substantial savings in labor and material are realized in that one pipe fittings shut off valves balancing cocks and additional piping are eliminated Quality is not sacrif
29. two No 10 x 1 1 2 wood screws Screw hangers to studs so that there is a hanger located at the extreme ends of the Baseboard Extension and at two foot intervals along its length If construction members are not suitably located use Moly Screw anchors to secure Hangers to wall Bottom of Hangers should rest on finished floor unless BASE RAY has been raised for wall to wall carpeting see page 9 If such is the case Hangers must be raised an equal amount Install END CAPS on Extension see succeeding para graph insert lip on top rear of Extension into slot at top of Hangers and snap channel on bottom of Extension under spacer arm on lower part of Hanger SPLICE PLATES used to make neat covering for joint where two Extension Panels butt together or where Ex tension Panel terminates at BASE RAY Plate hooks on bottom of Splice Plate over lip on bottom of Extension Panel and push top of Splice Plate toward wall until hooks on top of the Splice Plate snap into posi tion behind the Extension or the BASE RAY When the Splice Plate is used to join an Extension Panel to BASE RAY bottom hook which overlaps BASE RAY must be cut off END CAPS lt available in both left hand and right hand patterns for finishing off ends of Baseboard Extensions that terminate at doorways or at Valve Enclosures They can be used where Extensions butt against BASE RAY in preference to Splice Plate Remove Knockout in end of End Cap if piping is to ru

Burnham BASE-RAY 81441001R8-3/06 User's Manual

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