Home

Burnham Independence IN10 User's Manual

1. SLI YO NMOHS SV 9351933 LSNW Q30vid3H 38 ISNW 30 HUM 314405 SV 3 3HL 30 AN AINO ZINI 3NWA Sv9 vA rR 1VISOWN3H MA Sv9 AN 5531 1 Ke dom ka I 4 4 M Ue CH lt Ne A TI wart z 9 x I 584 1 TNT 310N 335 ek pL L cx Le SN 195 sas J WVHDVIG MOTI3A 3HHM HM 038 dy MO N3349 M9 v 3078 AlddNS 83 3OvMLI SUHM HUM HM 8 XOV1B 3l euo 19 3000 882288 9 007 OMY 325 009 935 WIN3NIINOO QN OND 8 4 2 052 318 2 9 008 68 335 TI3MA3NOH NOSN3S 331IN9I 553 ONIMIM M3dWVO 1N3A ML ZINI 8 3ZIS 39vVL10A INN 12 143234 INIA HOLIMS 39335 OMY 1 3215 3 501 54 318 0 LINDYIO
2. uoniuB 9 Ep 9 1614 3359 OL ANVONOO3S N3ANOJSNVHI N3389 HOVIIV AINO 7 W3dWnr Q3Ovid3N SS3NNVH N3dAVO INIA AINO 1N3A 5531 33108 03 OLNI 303 TWNOWdO IN3A 6NI ST300W 304 03810038 Z INSTWAINDZ 5 NMOHS SV O30vid3N 38 ISNA 5 SV 3HL jO SALON r o 8 o eios M3dWva 1 AWO OIN 1N3A 5531 IVISONHSHL e lt Z INNA SV A N ANO 22 22 m i 25 ORS SD sa ee BING H Sud N SVO UNN 01 Wis1uagou 9 z vy L 04 Y 9 YOLVINDID 2 OGNHOTI AVHDVIG 1 09 02 AlddNS aNd Zi 1 A8 MOTI3A lvISOWN3HL HM vi8091 QN TISMA3NOH NO Bx 349 Ss ang 78 JOVAL JUHM HM 8 3 x
3. OL AMVONOO3S H3AHOJSNVML WONJ 3339 AINO VOVNVO ond M3dWnr O039v1d3M SS3NNVH LNJA ATNO 5531 83108 503 CANI OLNI 303 1VNOILdO 33dAVO 513009 303 93911093 N3dWVO SLI HO NMOHS SV G35V1d33 38 ISNW 38 LSNW JHL HUM 03114405 SV TWNISIYO JHL 30 31 SALON rn mes 4 INJA SS sa su Sv9 ry 1 7 b lt gt L RNC Re 1VISOWH3HL AMVONOO3S oo 4 AHS Neo 1 09 01 Aldd S M3MOd 21 I CRM fa O3NNOOSIQ HVNOLLdO 0839 1 HOLIMS 100 n0N 1 1 09 o21 INGHUROUSAO aoas 3w Adans 1 N3MOd bie 8 L INA T amine Sal n W3TMISNI AB 034405 SHIU jio lVISOWN3HL AZ 5 9 lx Y anaw sas SI B8 22284 TISW3NOH 1 43 1 p Ht I
4. EEEE x MTD ON BASE SIDE PANELS Manifold and 1 Main Burners 74 4 Manifold and Main Burners 1 Inch Main Burners Only Marn Burer Main Burner with Pilot Bracket Continuous Ignition 0350 Pilot 8236097 Main Burner with Pilot Bracket Continuous Ignition Q327 Pilot 9236039 Main Burner with Pilot Bracket Intermittent Ignition Q348 Pilot 2296098 1 82260033 1 canoes 117 ecco 82260063 _ eos 82260103 es pum 5 Main Burner Orifice 45 Pink 822711 3 Nata xg Main Burner Orifice 4447 White 822710 Main burner Orifice 55 Green 822708 3 Main Burner Orifice 1 25 mm Purple 822705 554 Main Burner 3 64 Blue 822704 Screw Machine Slotted Round Head 10 32 x 3 16 80860800 2 Screw Self Tapping Phillips Pan Head 1 4 20 x 1 2 80860700 4 4 Note Orifice Sizes shown for normal altitude 0 2000 feet For High Altitude consult factory 5 75 76 SEE AND GAS VALVE GROUP TAB ORIFICE BRACKET MTD ON BASE SIDE PANELS VENTURI 227 BEND TAB SLIP TAB BETWEEN OVER ORIFICE ORIFICE BRACKET amp BRACKET FLUSH FLARED END OF WITH SIDE VENTURI TUBE TYP BOTH SIDES TYP BOTH SIDES Manifold and 40mm Main Burners 4 Manifold and Main Burners 40MM MAIN BURNERS ONL
5. 335 1 E QNO 5 3 0 unn 9 vs n 1545 2278 TI3MA3NOH L 8 1 2 waj 310v1d393N N3dAVO IN3A deu cene seus derer 310N 335 10119 verco SS3NNVH N3dAVG TISMA3NOH 1N3A 1N3A 36 Steam Boiler with Intermittent Ignition and Float Low Water Cutoff See Figure 38 1 Normal Operation a Thermostat calls for heat Thermostat Isolation Relay is energized closing contacts Vent Damper if used opens as stated in Vent Damper Sequence of Operation Ignition Module is energized Pilot Valve opens and Igniter 15 energized to ignite Pilot Burner Sensor proves presence of pilot flame Main Valve s opens and ignites Main Burners After Thermostat is satisfied Ignition Module is de energized extinguishing pilot and main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when steam pressure exceeds set point Maximum allowable pressure is 15 psi Normal operation resumes when system pressure falls below set point Low Water Cutoff LWCO Automatically interrupts main burner operation when surface of boiler water falls to lowest permissible operating level Normal operation resumes when water returns t
6. 86 THIS PAGE LEFT BLANK INTENTIONALLY 87 12 Transformer Steam and Gravity Water Only 13 Flame Rollout Switch 14 Blocked Vent Switch 15 Ignition Module Intermittent Ignition Only HE E ELA 16 Vent Damper ee ee ee wc 0 2120212 12 227 2 2 2222 1385 20 21 Quantity Description Part No rer nro wre wee eee ree All components for use in both USA and Canada unless marked with for USA Only or for Canada Only 89 Low Water Cut Off 1 90 WARNING DO to cut factory wires to install an aftermarket Low Water Cut 1 Only use connections specifically identified for Low Water Cut Off In all cases follow the Low Water Cut Off manufacturer s instructions When A low water cutoff is required to protect a hot water boiler when any connected heat distributor radiation 18 installed below the top of the hot water boiler i e baseboard on the same floor level as the boiler In addition some jurisdictions require the use of a LWCO with a hot water boiler Where The universal location for a LWCO o
7. 2 81 3215 NOILO310Hd LINSYYNDYSAO 2 501 ANOS WMv M3L OMY 81 3215 2501 3MIM G30NVELS 1 OMV 81 325 1 09 01 Adds JINON NOLLINSI 01985 10114 TI3MA3NOH 48 Q Water Boiler with Intermittent Ignition EI and Tankless Heater See Figure 44 1 Normal Operation a Thermostat calls for heat or low limit senses water temperature below set point Vent Damper if used opens as stated in Vent Damper Sequence of Operation Ignition Module is energized Pilot Valve opens and Igniter 15 energized to ignite Pilot Burner Sensor proves presence of pilot flame Main Valve s opens and ignites Main Burners After Thermostat or low limit 1s satisfied Ignition Module is de energized extinguishing pilot and main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature is 250 F Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler
8. lt lt lt lt E 5 9 HL s bg e 9 ws 2 1 380 310V1d303M YIdNV XINO OLNI SS3NNVH M3dAVO IN3A 1N3A 42 N Water Boiler with Continuous Ignition Standing Pilot b Blocked Vent Switch Automatically interrupts and Gravity Circulation See Figure 41 main burner operation when excessive vent system blockage occurs Control is a multiple 1 Normal Operation use device If blocked vent switch is activated do a Thermostat calls for heat Thermostat Isolation not attempt to place boiler in operation Correct Relay is energized closing contacts source of blockage and reset blocked vent b Vent Damper if used opens as stated in Vent switch Damper Sequence of Operation c Flame Roll out Switch Automatically interrupts c Gas Valve s is energized allowing main gas flow boiler operation when flames or excessive heat and ignition of Main Burners are present in vestibule Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch d After Thermostat is satisfied Gas Valve s is de energized extinguishing main flame Vent Damper if used closes 2 Safely d Thermocouple senses pilot flame and causes gas
9. 1138 13M OINI SNIVA 30 SQN3 83108 INIOd 033 NMOG 38075 AlddnS 4 315 17 AlddNS 0109 838038 N31SAS S3NOZ OL lt 4391933 7041405 MOT 330 11 8 3NOZ OL 104 Buidid ainbi4 AIS LAYI M31O8 JO 1NONMJ Kl S3NOZ WONJ 1 1N3A 0014 40 9 VGISAS NIHLIM 3dld 340 112 JAWA M3IVM 3303 JYNSSIYd 7 H NOISNVdX3 3ATVA di 4 3AWA ONIONGSY Xidd Ns JAWA 3unSS3ud c 5 xod TINA TIVE 3ATVA SSVdA8 431108 t t a3sn 51 40005 1N3A NNOLN3ANOO 31 IAIA 53 1 M3lV3H M3lVM M3IV3H N31VM LOBYIONI OL 1O3MIONI 18 p uoz euoz 10 Buidid pepueuiuio2es VSZ 4 ACIS 1441 M31IO8 40 4 40073 30 9 NIHUM 3Jo 1no NIY 34155384 5 M3lVM 0100 W3lSAS 4 3 JAWA 440 10 5 3805538
10. GTI 221211 60410023 60410012 1 Right Side Panel 60410022 60410033 BEDE 6041004 60410053 60410063 60410073 60410083 Front Removable Panel 60410093 60410103 60410113 60410123 60410114 60410124 60410035 1 60410045 60410055 60410065 6041007 Rear Panel 60410085 60410095 60410105 60410115 60410125 60410034 1 60410044 60410054 60410064 60410074 4 Vestibule Panel 60410084 ES 60410094 60410104 81 Jacket Assembly Continued Refer to Figure on Page 80 Upper et Rear Panel torso ECL 2 6041003 6041004 6041005 6041006 6A Front Top Panel 6041008 6041009 6041010 6041011 6041012 Rear Top Panel No ws ws ine sr ine ine 529 ws Tz o 7041004 7041005 7041006 7041007 7041008 7041009 7041010 70410114 7041012 Lower Front Bar AIR oO o ojojoijioIijio joI joI jo e 5 9 7041003 7 82 Key Steam Trim Low Water Cut Hyerolevel CG4002060 Less Probe Se Key No 88 i 7A 7B s a
11. OL ANVONOO3S MN3AMBOJSNVHL QNnONO N33H9 HOVLLY AINO VOVNVO SS3NMVH ONIMIM INJA AINO M3dAVQ 1N3A 5531 31 08 303 OLNI 304 M3dAVG 6NI STAGON 303 Q3NInO3H N3dWVO LN3A LNATWAINDA SLI YO NMOHS SV 38 ISAW Q3ovid3N 38 15001 JHL SV JHL 40 ANY 3l I pode 6 310N 335 o pd An oon Amm 39NvITV OLNI Z SAWA SVO been eec s AVISOWN3HL 5 1 A lt lt lt lt 4 5 5 WwHS133801 310N 335 1 09 02 ul Y3MOd 21 n M aL Spr c Eie ELE TRECE O3NNOOSId TWNOLLdO NOILO3IONd HOLIMS HS L L og ozi 1 3933 10n0 T104 1 dans 11 n 4 sna HOLIMS ano ERSTE PME AINO OLNI A8 G3HddnS SAAN 335 5 a 5 57 7 IVISOWN3HL mnm 757 s H _ n Eh m HM 98 1 mE TI
12. SCREW b I s WIRING TERMINAI PILOT ADJUSTMENT UNDER CAP SCREW DUTLET PRESSURE T ONLY TAP TOP VIEW OF ROBERTSHAW GAS VALVE Figure 47 Gas Valve Pressure Tap Robertshaw Gas Valve 4 Connect manometer to gas valve pressure tapping for IN12 connect to gas valve with pilot control See Figure 46 or 47 5 For natural gas fired boiler temporarily turn off all other gas fired appliances E Follow Lighting or Operating Instructions 1 To place boiler in operation See Figure 48 49 50 or 51 Sequence of Operation is outlined with wiring diagrams in Section VIII Electrical 2 Electronic Ignition Modules with LED indicators Table 7 cross references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams The yellow LED indicates the status of the flame see Table 8 The green LED indicates the status of the system see Table 9 See Figure 52 for LED locations FOR YOUR SAFETY READ BEFORE LIGHTING WARNING A This appliance has a pilot which must be lighted by hand When lighting the pilot followthese instruc tions exactly C BEFORE LIGHTING smell all around the appliancefor gas Be sureto smell next to the floor because some gas is heavier than air and will settle on thefloor WHAT TO DO IF YOU SMELL GAS gt Do not try to light any appliance Do not touch any electric switch do not use any ph
13. e 5 011235 21 2 03 3310935 5 011935 9 403 1 14 15437108 15 NOILISNNOD 5 2 437108 5 MAIA ACIS LAAT 8072 73 Fog 55 19 1 39nv5 45 ZA 7081405 38055334 GI31V3H 5531 1 337108 331V ASIA AMIS 1481 ond 9 011840 3015 A ddns 30197105815 3015 1350 3SNVHL M 7081405 80197102412 NV NOLLVNISADO 83193H SSIDINGL ANOHLIA 337108 331V 5 ASIA 3GIS 1481 3NI 40073 3HSINSN4 NI NADHS 599 CWNDILdO 3415 144052 2019105515 341 1 7051405 80119112412 ANY 1INI1 NDILVNISWDO Dimensional Data Approx Dimensions in inches Recommended Water Volume Water Volume Gal Shipping Min Round Gas Weight Chimney Size Conn Steam Water Diameter x Height NPT Boiler Boiler Lbs 1 4 112 2 ran 10 1 2 1 7 9 12 2 6 1 1 8 9 3 14 4 7 2 40 1 4 15 3 8 3 4 12 1 18 8 9 4 37 3 4 exist 15 210 195 18 5 8 2 38 3 4 45 1 2 40 172 43 3 4 21 78 20 1 15 chimney height is from bottom of Draft Hood opening to top of Chimney 2 Gas connection size on IN10 IN11 Continuous Ignition Standing Pilot is 1 555 24 1 4 27 1 2 30 3 4 815 37 1 4 350 420
14. Q30v1d3M 38 LSNW I JAWA 5 9 Ya 1 ANO ZINI 5 9 INGON 222528 41 AINO JAVA Sv9 vna 335 HOLIMS 584 UMS gh A p 3ATVA 9 ax o1g AES 3wu d ae N3TIVISNI Ave WOL98S TI3MA3NOH JINON NOILINS 10114 V8r O TI3MA3NOH 58 Tq 000007 E AVI3H 1545 00088 TI3MA3NOH 58 lt 6NI 513009 304 93033 YAdNVG IN3A IN3TIVAIQO3 SLI HO NMOHS SV 3HIM G39V1d33 5 SV 30 3171 SALON 1 09 01 14405 33MOd 310854 HOLIMS 5 SY3H10 IVISOWH3HL XO8 310V1d303M IN3A wn 310N 335 2 310N 335 553 IN3A 1N3A 44 O Water Boiler with Intermittent Ignition EI and Gravity Circulation See Figure 42 1 Normal Operation a Thermostat calls for heat Thermostat Isolation Relay is energized closing contacts Vent Damper if used opens as stated in Vent Damper Sequence of Operation Ignition Module is energized Pilot Valve opens and Igniter 15 energiz
15. 2501 3MIM 5 WAV M3L OMV 3ZIS 39VL10A WVHDVIG 310N 335 1N3A D k 0 L E LN3A QN9 Arc 2 310N 335 SS3N3MVH IN3A 01985 TI3MA3NOH 1018 8 TI3MA3NOH SYSHLO IVISOWN3HLI AvZ M Water Boiler with Intermittent Ignition EI and Intermittent Circulation See Figure 40 1 Normal Operation a b Thermostat calls for heat Vent Damper if used opens as stated in Vent Damper Sequence of Operation Ignition Module is energized Pilot Valve opens and Igniter 15 energized to ignite Pilot Burner Sensor proves presence of pilot flame Main Valve s opens and ignites Main Burners After Thermostat is satisfied Ignition Module is de energized extinguishing pilot and main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature is 250 F Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boil
16. a Limit Automatically interrupts main burner valve to turn off main burner and pilot burner gas operation when water temperature exceeds set flow should pilot burner flame extinguish point Maximum allowable temperature is 250 F Normal operation resumes when water temperature falls below set point 43 uone n2415 13 uoniuB uayuu Zr SNIMIM ONSDWI 3llHM HM 038 04 39NVHO AD M9 NMONB8 3078 18 HM 8 400 WHIA 2 002 3MIM SMV 8 3215 009 5 WLNANILNOD 485 4 2 082 318 2 9 008v6t 35 31 9 0 9 WMV M3L XO ML OMY 81 3ZIS 39VL10A WMV M3L ML OMY vl 3ZIS 39VL10A 9 S01 SZ 318 2 LINDYID 33Mod 2 81 3215 2 901 3MIM 5 1 OMY 81 3215 5 3339 OL 35 M3AHOJSNVHL WONj N3339 HOVLLY AINO VOVNVO ond SS3NNVH YadNVG IN3A AINO 3N3dAVGO IN3A 5531 83108 303 OLNI 303 TWNOWdO 38 1SnW
17. 2 and the supplied is installed in Tapping P refer to amper motor 15 de energized Section V Piping and Trim e When the call for heat is satisfied the damper relay coil is de energized closing contacts which energize the damper motor This causes the damper to close When the damper blade reaches the fully closed position the damper motor is de energized F Wire control circuit as shown in the appropriate wiring diagram See Table 6 Table 6 Thermostat Heat Anticipator Settings Ignition System System Type Continuous Standing Pilot Intermittent El Figure 35 Page 30 Heat Anticipator Setting 1 Steam with Probe McDonnell amp Miller PS 802 or Hydrolevel CGB 400 Low Water Cutoff Steam with Float McDonnell amp Miller 67 Low Water Cutoff Water Intermittent Circulation Figure 39 Page 38 Figure 40 Page 40 Water Gravity Circulation Figure 41 Page 42 Figure 42 Page 44 Water with Tankless Heater Figure 43 Page 46 Figure 44 Page 48 Figure 36 Page 32 Figure 37 Page 34 Figure 38 Page 36 1 If system tends to overheat above thermostat s temperature setting reduce heat anticipator setting by 0 1 or 0 2 amps If system tends to shortcycle without reaching desired room temperature increase heat anticipator setting by 0 1 or 0 2 amps 27 Figure 33 Vent Damper Harness to Limit WIRING HARNESS WITH POLARIZED CONNECTOR S SUPPLIED WITH DAMPER 6 PIN VENT DAMPER RECEP
18. 485 2 18157 3 Steam boiler s steamable water volume water volume from NWL normal water level to low water cutoff level Heating Surface 4 35 sq ft per flueway steam 5 72 sq ft per flueway water Table of Contents I Pre Installation 7 VIE Venting 24 Knockdown Boiler Assembly 9 Electrical u 26 Semi Pak Boiler Assembly 13 IX System Start up 50 IV Packaged Boiler Assembly 15 X Service Instructions 62 V Piping and Trim 16 XI Repair Parts 69 Gas Piping a a sasana ss 22 Appendix Low Water Cut Off DWCO 90 LEFT END SECTION LEFT END SECTION RIGHT END SECTION STEAM DR WATER WATER STEAM WATER LESS HEATER OPTIONAL HEATER Figure 2 Section Tappings Table 1 Trim and Control Installation in Section Tappings i Steam Boiler with Steam Boiler with Water Boiler Water Boiler with Probe L W C O Float L W C O Tankless Heater Bush to 1 4 1 Nipple amp Union Plug Lower Tapping Bush Plug Lower Tapping Bush to Gauge Glass Gauge L W C O Street to 1 4 Upper Tapping 1 4 Upper Tapping Elbow Syphon amp Limit Press Temp Gauge Press Temp Gauge Bush to 175 3 Npl Elbow Bush to 175 3 Npl
19. ON position to OFF 5 Rotate gas control knob on BOTH gas valves clock wise from ON position to OFF 6 Replace front door DUAL VR8304 Figure 51 Operating Instructions Intermittent Ignition System El VR8304 IN12 only Gas Valves Table 7 Ignition Module Terminal Cross Reference SOSOM Continous Retry DAA PASA Mac Terminal Designation Terminal Number wey UI 22001 GND 24V GND 24V SPARK 0 FLAME LED STATUS LED Figure 52 LED Locations TABLE 8 Yellow LED Flame Codes Yellow LED Recommended Flash Code Service Action Weak Flame Signal System will operate reliably but flame signal is Perform routine less than desired maintenance to Note This indication may flash temporarily assure optimum during or shortly after lightoff on some flame signal applications Service call recommended sense wiring Note This indication may flash temporarily contamination of during or shortly after lightoff on some flame rod burner applications ground connection No Flame or Flame Signal below minimum threshold for system operation Flash Code Descriptions Marginal Flame Signal less than 1 1 Check gas supply System may not operate reliably over time pilot burner flame 1 Heartbeat Constant second bright 7 second dim cycles The flash code number signifies that the LED flashes X times at
20. b Install Vent Damper Harness into top of limit c Remove factory installed jumper plug from Vent Damper Receptacle Plug Vent Damper Harness into Vent Damper Receptacle See Figure 31 d Install cable clamp around flexible Vent Damper Harness Attach to jacket top panel See Figure 33 3 Note After vent damper is installed and operated through one 1 cycle the control circuit will operate only when vent damper is in control circuit C Install thermostat Locate on inside wall approximately 4 feet above floor Do not install on outside wall near fireplace or where influenced by drafts or restricted air flow hot or cold pipes lighting fixtures television or sunlight Allow free air movement by avoiding placement of furniture near thermostat Set heat anticipator to match system requirements See l Table 6 In general setting heat anticipator too low will cause boiler to short cycle without bringing heated space up to temperature Setting heat anticipator too high will allow boiler to operate longer than necessary and overheat space A separate electrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch 1s recommended and may be required by some local jurisdictions Boiler is rated for 120 VAC 60 hertz less than 12 amperes 2 For zone valve wiring provide separate 24V transformer rather than attempting to use boiler mounted contro
21. 92 HM JAWA SY9 aay QM Z x 3931 Id 2 NO AINO AVHO AD N33H9 49 i AINO ZINI OLNI NMOS JAVA SV9 5 584 5531 ania 18 HOLIMS HOLIMS 3AWA 1 HA 318 rotas 1N3A 110 7103 L Xovi8 8 587587 ao 314 p 3009 33IM NE SAWA SYO Z Vi e lt N AYHS1838O8 2 s V JAVA SYS 7 am AVHS123802 2 _ ae ak c LV 4 NOII231ONd HOLIMS 1 F c 310N 336 1 09 02 lN3NM ON3AO 39lAN3S Av138 1 1 3ONVITIV W3Mod poe sed hee HL SAG 33 z z s LVLSOWYSHL 1 09 051 14405 YIMOd QN9 71 21 Su3HlO I1VISOWN3Hl AvZ m AVI34 1545 20088 TI3MA3NOH 38084 SNISN3S 319V1d393M N3dWVO IN3A 335 SS3NMVH 335 1N3A 30 H Steam Boiler with Continuous Ignition Standing Pilot b Low Water Cutoff LWCO Automatically and Probe Low Water Cutoff See Figure 35 interrupts main burner operation when sur
22. 9296109 5 2 5 2 2 2 2 Pilot Tubing 1 4 OD x 30 8236122 Pilot Tubing 1 4 OD x 40 8236123 Gas Valve Honeywell VR8204C3007 81660145 Gas Valve Honeywell VR8304P4306 81660161 Igniter Sensor Cable 36 Honeywell 394800 36 8236084 Ground Wire Assembly 6136054 Key EH 9 5A 5B U O O 5G ES 2 Pilot Burner Honeywell Q348A1010 8236081 Included with 5A B U ilot Orifice Honeywell 388146KP Compression Nut Fitting 1 4 OD x 1 4 C C Included with 5A and 5E Pilot Tubing 1 4 OD x 40 8236123 Gas Valve Honeywell VR8204C3015 81660146 Gas Valve Honeywell VR8304P4314 81660160 Igniter Sensor Cable 36 Honeywell 394800 36 8236084 Ground Wire Assembly 5G Note Gas Valve specifications shown for normal altitude 0 2000 feet For High Altitude consult factory 2 3Nvd MV8 JIL 3015 1441 INOY4 N3MO1 7T38V1 73877 NOLLONYLSNI LNOYS 5 13 31 3I8ISSINN3d 153 01 AINO 33il08 WV3lS 138 1 NOLLIOOV M3IVM 1N300334 73891 9NLIVH 0901 TANVd 3 NOLLONYLSNI M3dWVO 3NVd JINEILSSA 73891 vliva 5 TANVd TANVd TANVd uk 401 LNOYS 401 9 69 80 Quantity Key Jacket Assembly
23. Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature is 250 F Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch 15 activated do not attempt to place boiler in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch 1s activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch Thermocouple senses pilot flame and causes gas valve to turn off main burner and pilot burner gas flow should pilot burner flame extinguish 47 13 pp 9 11 614 M3N09S N3349 OL AMVONOO3S M3AHOJSNVHI 3349 HOVllV AINO VQVNVO SS3NBVH H3dAVO INJA AINO 33dWVG 5531 83108 303 OLNI TVNOlldO 1N3A 6NI NYHL 513000 04
24. Elbow Return Return 2 Npl Circ Flange 2 Npl Circ Flange Gasket Circulator Return Gasket Circulator Return 3 Nipple amp Street Elbow 3 Nipple amp Street Elbow 3 Nipple amp Street Elbow 3 Nipple amp Street Elbow Safety Relief Valve Safety Relief Valve Safety Relief Valve Safety Relief Valve Ae 3 2 2 Bush to 34 Drain Valve Bush to Drain Valve Bush to Drain Valve and or Bush to Drain Valve and or and or Optional Return and or Optional Return Optional Gravity Return Optional Gravity Return Optional Supply IN3 6 Optional Supply IN3 6 Plug IN3 12 Plug IN3 12 Required Supply IN7 12 Required Supply IN7 12 Optional Gravity Supply Optional Gravity Supply Bush to 74 amp Bush to 74 Well Well Syphon Limit Pressure Gauge Limit Limit Not Applicable Not Applicable Not Applicable Tankless Heater Low Water Cutoff ssn AN 3 1 E EMI EM n 1 1 Pre Installation WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage or personal injury DANGER Do not install boiler where gasoline or other flammable vapors or liquids or sources of hydrocarbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used or stored NOTICE Due to the low water content of the boiler mis sizing of the boiler with regard to the heating system load will result
25. JAVA 5 9 2 310N 335 WVHDVIG 3 MVHSIN3803 2 SS3N3VH ONIMIM 310V1d393N 3 AINO dci qq INJA IN3A ZINI OLNI Su3HlO 5 L Water Boiler with Continuous Ignition Standing Pilot and Intermittent Circulation See Figure 39 1 Normal Operation a b Thermostat calls for heat Vent Damper if used opens as stated in Vent Damper Sequence of Operation Gas Valve s 15 energized allowing main gas flow and ignition of Main Burners After Thermostat 15 satisfied Gas Valve s is de energized extinguishing main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature is 250 F Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch is activated do not attempt to place boi
26. LEVEL PLATE STEAM BOILER ONLY LEFT SIDE PANEL OPERATING RUCTION LABEL FRONT REMOVABLE DOOR WIRING LABEL LOWER FRONT TIE BAR Figure 9 Jacket Assembly 10 9 Install front removable door by engaging upper side edges of panel with side receiving flanges sliding up and under top panel flange seating front door fully then sliding down to engage bottom flange behind lower front tie bar G Install Pilot Burner Assembly shipped in Gas Controls Carton See Figure 10 r MANIFOLD BRACKET MAIN BURNER GAS 7 I MANIFOLD SLOT BURNER V TRAY FOR MAIN PIN BURNER INSERTIUN l l Cum HITCH PIN CLIP X WHERE USED N PIECE ORIFICE Pd INSULATIDN Figure 10 Combustion Chamber 1 Remove jacket front removable door a Remove burner access panel located above burners b Install Pilot Burner Assembly where noted on gas manifold i Insert rear of burner in burner tray slot ii Position burner over the orifice NOTE The burner to the right may need to be lifted from the orifice to install pilot burner assembly Reinstall lifted burner over the orifice c Reinstall burner access panel H Install Gas Valve on main gas burner assembly if not factory assembled See Figure 11 12 13 or 14 1 Connect gas valve to manifold 2 Connect pilot tubing from pilot burner to gas valve pilot tapping 3 Con
27. 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 PROCEDURE FOR OBTAINING WARRANTY SERVICE 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 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 THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MA
28. burner to right is removed 1 burners only 9 Check burners to be sure they do not contain foreign matter or restrictions Clean burners with a soft bristle brush blow any dirt out with compressed air or use a vacuum cleaner See Figure 58 G Remove Pilot Assembly for Servicing Remove machine screw s holding pilot burner to pilot bracket after first removing burner with pilot assembly as described in Step F number 8 above To adjust or check spark gap between electrode and hood on Honeywell 0348 intermittent EI pilot see Figure 59 1 Use a round wire gauge to check spark gap 2 Spark gap should be 0 125 for optimum performance IGNITION ELECTRODE A pii FLAME SENSOR STRAP Figure 59 Honeywell Q348 Spark Gap 64 H Install Burners by reversing procedures used to remove burner Main burners must be in slots in rear of burner tray and seated on main burner orifices Reconnect pilot gas supply and thermocouple lead continuous ignition or igniter sensor ground See Table 11 for Pilot Burner location Table 11 Pilot Burner Location Burners numbered left to right as viewed from front of boiler Boiler Size IN3 INA INS 6 IN8 IN9 Lubrication Manufacturers Instruction should be followed on all parts installed on boiler requiring lubrication This includes 1 Type of lubricant to be used 2 Frequency of lubrication 3 Points to lubricate J Check operation Follow S
29. emos Canopy Assembly emo emo emo 61110043 61110053 61110063 2B Rear Draft Hood Carton Assembly Lemon C Canopy Draft Hood Carton Assembly complete Lomo Carriage Bolt 74 20 x 1 Flat Washer 74 eun Wingnut 1 4 20 All Components for use in both USA or Canada unless marked with for USA Only or for Canada Only No os ine se ine sr Tine ine 590 S Tz 3 Base Assembly 220201 8 71860059 71860069 Base Tray 71860089 71860099 71860109 71860119 71860129 71860031 71860041 71860051 71860061 71860071 71860081 71860091 71860101 71860111 71860121 Base End Insulation 720601 3B Wrapper A No os ine ws ine sr Tine ine 50 159 3 Base Assembly Continued OI IE RES EE Exec cr 25125125 8 961081 12060055 151 1 1 1 1 1 7206006 1 1 1 1 1 1 1 7206007 1 151 1 1 1 7206008 1 1 1 1 1 7206009 7206010 7206011 72060126 1 3B2 Base Rear Insulation 1 1 1 gt 3C Front Panel Assembly 1 Ea EJ Ea IER Burner Tray 1 Inch Main Burners 71806037 71806047 7180605 Burner Tray 40mm Main Burn
30. in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch Igniter Sensor senses pilot flame and causes ignition module to turn off main burner and pilot burner gas flow should pilot burner flame extinguish Five to six minutes after shutdown Ignition Module restarts ignition sequence For Electronic Ignition Trouble Shooting Guide see Page 65 For LED Status Codes see Tables 8 and 9 on pages 55 and 56 49 IX System Start up WARNING Completely read understand and follow all instructions in this manual before attempting start up Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas Fired Low Pressure Steam and Hot Water Boilers ANSI Z21 13 B Check Main Burners Main burners must be in slots in rear of burner tray and seated on main burner orifices C Fill boiler with water 1 Steam fill to normal water line See Figure 1 2 Water fill heating system to approximately 12 PSI Vent air from system D Prepare to check operation 1 Obtain gas h
31. inches w c can not be attained check gas valve inlet pressure If less than 11 0 inches w c contact gas supplier for assistance M Clean Heating System Steam A local qualified water treatment chemical specialist is a suggested source for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations 1 Oil from new piping connections and sediment in existing piping must be removed from system to prevent unsteady water line and carry over of entrained water into supply main a Fill boiler to normal waterline b Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 c Operate boiler with steam in entire system for several days to bring system oil and dirt back to boiler d Drain condensate from drain valve in wet return Operate boiler until condensate runs clean Boil out boiler a Follow instructions TO TURN OFF GAS TO APPLIANCE See Figure 48 49 50 or 51 b Fill boiler to normal waterline e Remove safety valve d Pour recommended boil out compound into boiler through safety valve opening e Reinstall safety valve in Tapping E with spindle in vertical position See Figures 1 and 2 f Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Check controls operation per Paragraphs F to J Boil water for at least 5 hours g Fol
32. manner a Remove Safety Relief Valve using extreme care to avoid damaging it b Partially fill boiler Pour recommended compound into boiler through safety relief valve opening Replace Safety Relief Valve Fill entire system with water Start firing equipment Circulate the water through the entire system Vent the system including the radiation Allow boiler water to reach operating temperature if possible Continue to Circulate the water for a few hours Stop the firing equipment c k Drain the system in a manner and to a location that hot water can be discharged with safety 1 Remove plugs from all available returns and wash the water side of the boiler as thoroughly as possible using a high pressure water stream m Refill the system with fresh water n Add recommended boiler water treatment 2 Make pH or Alkalinity Test a After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with Hydrion paper which is used in the same manner as litmus paper except it gives specific readings A color chart on the side of the small Hydrion dispenser gives the reading in pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add re
33. of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of 10 years from the date of original boiler installation In the event that such cast iron section assembly is found to be defective in material or workmanship during this period U S Boiler Company Inc will repair or replace at its option the defective cast iron section assembly FIRST THROUGH 5 YEAR LIMITED WARRANTY AGAINST WATERSIDE CORROSION IN THE MEGASTEAM SERIES U S Boiler Company Inc warrants the cast iron sections of the MegaSteam boiler to resist TEMPERATURE INDUCED CHLORIDE ACTIVATED GRAPHITIC CORROSION for a period of five years from the date of original installation In the event that any cast iron section of a MegaSteam boiler fails due to this corrosion mechanism during this period U S Boiler Company Inc will repair or replace at its option the failed cast iron section assembly LIFETIME NIPPLE LEAKAGE WARRANTY U S Boiler Company Inc warrants the cast iron and steel nipples that join the sections to be free from defects in material and workmanship for the lifetime of the original owner at the time of installation In the event that such nipples are found to be defective in material or workmanship during this period U S Boiler Company Inc will repair or replace at its option the cast iron section assembly ADDITIONAL TERMS AND CONDITIONS This warranty does not cover expenses for remo
34. repeat procedure starting at step b Remove surface blow off piping Install 1 NPT plug in Tapping L See Figure 2 4 Add Boiler Water Treatment a Remove safety valve b Pour recommended compound into boiler through safety valve opening Reinstall safety valve in Tapping E with spindle in vertical position See Figures 1 and 2 Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Boil water or heat water to 180 F Measure boiler water alkalinity pH should be between 7 and 11 Add recommended water treatment chemicals if necessary to bring the pH within the specified range 5 If unsteady water line foaming or priming persist a Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Install gate valve shut off valve in Hartford Loop Install drain valves in return main and at boiler See Figure 23 Connect hoses from drain valves to floor drain Close gate valve in Hartford Loop Open drain valve in return main Fill boiler to normal water line Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Operate boiler for at least 30 minutes after condensate begins to run hot Follow instructions TO TURN OFF GAS TO APPLIANCE See Figure 48 49 50 or 51 Close all radiator valves Remove all supply main air valves Plug openings in supply ma
35. 0N 3AWA svo MOTI3A TIMA3NOH 000000422222 JLIHM HM 22 RA 8 li aay 9NINIM Id 9NMIM 39NYNO NO QN3931 39 i HA 1 8 5 9 mhoid IN3A 1N3A 5537 0330018 ev Xovi8 E HAB 2 N 8668 A 3009 3NIM b 1 H QM 2 1 1 E Ln us EE 22 J 3j nn rs 3X zu 2 a 3 lt AINO 1014 v8reo JINON NOILINSI 1 S 310N 33s svo c SYD 1 193NNOOSId i1n0 mos rh 3ONVIT haan Coe 1N38N12N3AO 39lAN3S EL NOILIND 1 T f 1347 Aans nO 9 YINYOISNVYL T t 9 Eg d TET DD 1 PP MX gt 7 mer yosnas uaunor sow sa s 4 AVIS LVLSOWY3HL v 3108 335 ANVQNOO3S s DE E
36. 2000 to 5000 ft elevation USA VII Venting WARNING This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air Read understand and follow combustion air instruction restrictions contained in the Pre Installation instructions of this manual Do not operate appliance where gasoline or other flammable vapors or liquids or sources of hydrocarbons i e bleaches cleaners chemicals sprays paint removers fabric softeners etc are used stored and or present in the air A Install vent system in accordance with local building codes or local authority having jurisdiction or National Fuel Gas Code ANSI Z223 1 NFPA 54 Part CAUTION 7 Venting of Equipment and or CAN CSA B149 1 Installation Codes Install any of the following for this Independence Series Category I draft hood equipped appliance Provide adequate clearance for servicing 6 minimum clearance between damper and combustible construction Do not use one vent damper to control two heating appliances 1 Type B or Type L gas vent Install in accordance with listing and manufacturer s instructions 2 Masonry or metal chimney Build and install in accordance with local building codes or local authority having jurisdiction or Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances 211 and or National Building Code of Canad
37. 2Hz remains off for two seconds and then repeats sequence 55 Table 9 Green LED Status Codes Green LED Flash Code Indicates X OFF No Call for Heat Flash Fast Startup Flame sense calibration Heartbeat Normal operation Next System Action Recommended Service Action 5 minute Retry Delay Pilot flame not detected during trial for ignition Recycle Flame failed during run Flame sensed out of sequence Low secondary voltage supply below 15 5 Vac 5 minute Retry Delay On every third retry on same Call for Heat On every 6th flame failure during run on the same Call for Heat Flame sensed out of sequence longer than 10 seconds Soft lockout due to error detected during self check sequences 7 Flame sense leakage to ground Flash Code Descriptions Flash Fast rapid blinking Initiate new trial for ignition after retry delay completed Initiate new trial for ignition Flash code will remain through the ignition trial until flame is proved If situation self corrects within 10 seconds control returns to normal sequence If flame out of sequence re mains longer than 10 seconds control goes to Flash code 6 4 see below Control remains in wait mode When the fault corrects control resumes nor mal operation after a one minute delay Control remains in wait mode When the fault corrects control resumes nor mal operation after one minute delay Initiate new trial for i
38. 3A LNATWAINDS SLI NMOHS SV HUM Q30V 1833 38 LSAW 030v1d33 38 LSNW JHL 03114405 Sv JHL 30 3l L SALON 2 7 310N 335 at 30NviTI SNIMIM TWNYSLNI 021 TWNYSLNI TVNH31IX3 SIVA SVP TVNH31X3 TI3MA3NOH asas wv JAWA 599 NINHSI38087 OLNI 30111955 1 09 021 M al AlddnS Y3MOd 033 QM 21 3349 X9 Leo mee ere s O3NNOOSIQ 00 AYIM NOLLO3103d HOLIMS NONI ino Tow 1 09 021 Alddns YIMOd s 8 HOLIMS 1N3A ML 0340018 OMY 81 325 INN iR 310N 335 YO ML Z 335 OMY 3ZIS 39VL10A 25501 67 318 2 G3LINN 9 2 81 3215 lt lt was 1 1 9 50 5 WMV M3L 81 3ZIS 5 9 TI3MA3NOH
39. 3MA3NOH i ILLI 1 3AWA 5 9 TI3MA3NOH lk ETE V a i SYD AINO 80 7 310V1d303M M3dAVO IN3A 33 SS3NNVH ONIBIM IN3A 1N3 N 840 34 J Steam Boiler with Continuous Ignition Standing Pilot b Low Water Cutoff LWCO Automatically and Float Low Water Cutoff See Figure 37 interrupts main burner operation when surface of boiler water falls to lowest permissible operating level Normal operation resumes when water returns to normal level 1 Normal Operation a Thermostat calls for heat Thermostat Isolation Relay is energized closing contacts Vent Damper if used opens as stated in Vent Damper Sequence of Operation Gas Valve s is energized allowing main gas flow and ignition of Main Burners After Thermostat is satisfied Gas Valve s is de energized extinguishing main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when steam pressure exceeds set point Maximum allowable pressure is 15 psi Normal operation resumes when system pressure falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler in operation Correct s
40. 4 W31SAS TINA S3NOZ JAWA Y SSVdAB 831108 01 t W31SAS JAWA 3NOZ 40005 quon 5 dooog 38 INIA TVNOLN3ANOO 3 IATA 393und 3A1VA 81 3NOZ M3lV3H OL OL M3IV3H 330 1 5 Pd 3NOZ Pd S3NOZ NONJ IN3A 19 SHUT OFF F SHUT OFF 7 VALVES ___ VALVES GAH HHS S Ht AIR 01 CH CIRCULATOR 1 SUPPLY MAIN TO RETURN MAIN FROM COMBINED Ht amp COOLING SYSTE Figure 26 Recommended Piping for Combination Heating and Cooling Refrigeration Systems NG COMBINED HEATI COOLING SYSTEM der TAPPING N i WATER TEMPERATURE LIMIT IN TAPPING P TAPPING E d 41 14 PIPING TO CIRCULATOR 1 p ae HSR 1 BOILER e Le RETURN INDEPENDENCE STEAM BOILER ALLIANCE Figure 27 Recommended Piping for Indirect Water Heater TM 5 Use boiler bypass 1f boiler 1s operated in system which has a large volume or excessive radiation where low boiler water temperatures may be encountered 1 e converted gravity circulation system etc a Bypass should be same size as supply and return lines with valves located in bypass and supply outlet as illustrated in Figures 25 and 25A in order to regulat
41. 4 5531 9 1 I o EP 275 0 44 r F 2 Se su ud ud 1 PR AMVONOO3S 3LON 335 MOTI3A is H 2 Qu SONOS 1 08 06 3ONVITIV 36 ul N3389 M9 21 n JOVAL 3LIHM HUM vg 3AWA nc FCR ois pin nam ns ae Gis ee ig 3 4009 51 05 LL LL EE LE Ln REI aa OM 1 9 021 gomas 14 HONS Adans 159 110 1031 0 002 OMV 81 325 SC SW 009 9 5 8 4 2 052 318VO 9 008v6 TI3MA3NOH NOSN3S N3lIN9 _ N3TIVISNI 03114405 WMY N L 310N 335 81 3715 WMV M3L 3215 9 901 SZ 318VO Q3LIATI M3MOd 2 81 375 39VL10A
42. AT ALL MANUAL GAS VALVES ARE OPEN SUPPLY TUBING AND PRESSURES ARE GOOD AND PILOT BURNER ORIFICE IS NOT BLOCKED I CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE ANO PILOT OPERATOR ON GAS CONTROL CHECK 24 ACROSS TERMINALS ON MODULE IF VOLTAGE IS OKAY GAS CONTROL IF LE NOTE MAY BE NECESSARY TO RECYCLE THE CALL FOR HEAT TO CLEAR THE PILOT SUPPLY TUBES OF AIR YES NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE CLEAN FLAME ROD CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE CHECK FOR CRACKED CERAMIC FLAME ROO INSULATOR CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF PROBLEM PERSISTS REPLACE MODULE ur YES MAIN BURNER V p CHECK FOR 24 VAC ACROSS PV MV PV TERMINALS ON MODULE IF NO VOLTAGE REPLACE MODULE LIGHTS CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL IF OKAY REPLACE GAS CONTROL YES SPARK STOPS WHEN N PILOTIS NOTE CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE NOTE IF GROUND IS POOR OR ERRATIC SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL AT THE TIME OF CHECKOUT CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE ADJUST PILOT FLAME IF CHECKS ARE OK
43. AY REPLACE MODULE YES CHECK FOR PROPER THERMOSTAT CONTROLLER OPERATION REMOVE MV LEAD AT MODULE VALVE CLOSES RECHECK TEMPERATURE CONTROLLER AND WIRING IF NOT REPLACE GAS CONTROL Honeywell Hot Surface to Pilot Trouble Shooting Guide START TURN GAS SUPPLY OFF SET THERMOSTAT TO CALL FOR HEAT GAS VALVE IS POWERED 24 VAC NOMINAL IGNITER WARMS UP AND GLOWS RED i PILOT VALVE OPENS YES TURN GAS ON PILOT BURNER LIGHTS YES MAIN VALVE OPENS YES SYSTEM OK NO NO NO NO CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROL THERMOSTAT WIRING DAMPER IF USED IS OPEN AND END SWITCH MADE UNPLUG PILOT BURNER CABLE MEASURE VOLTAGE AT GAS VALVE HSI TERMINALS 24 NOMINAL SEE INSET YES eREPLACE IGNITER FLAME ROD ASSEMBLY eMEASURE VOLTAGE AS VALVE G VOLTAGE MUST BE AT LEAST 19 5 VAC YES eREPLACE IGNITER FLAME ROD ASSEMBLY REPLACE IGNITER FLAME ROD ASSEMBLY AND RETAIN RESTART TROUBLESHOOTING SEQUENCE DOES MAIN VALVE OPEN YES eDISCARD OLD IGNITER FLAME ROD ASSEMBLY NO 5 VALVE NO eCHECK TRANS FORMER AND LINE VOLTAGE SUPPLY NO SERVICE 67 68 Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repair Parts list designates parts that contain refractory ceram
44. ESET BUTTON44 Rotate gas control knob clockwise ON position to OFF position 15 Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step NOTE Vent damper must be open during this five 5 minute wait period 16 11 18 Remove the burner access panel located above the burners Find the pilot by following the aluminum tube from the gas control valveto the pilot located between the steel tube burners PILOT BURNER THERMOCOUPLE Turn gas control knob counterclockwise PILOT position Push in red reset button and hold in Immediately light the pilot with a match Continue to hold the red res et button for about one 1 minute after the pilot is lit Releas e button and it will pop back up Pilot should remain lit If it goes out repeat Steps 8 13 gt f button does pop up when released stop and immediately call your service technician or gas supplier gt If the pilot will not stay lit after several tries turn gas control knob clockwise y to OFF and call your service technician or gas supplier Replace burner access panel ed reset Turn gas control knob nad 10 rod ifr position Knob can be turned to ON on button is up Replace front door Turn on all electric power to the app
45. IDENTIAL 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 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 wil
46. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR INDEPENDENCE GAS FIRED BOILER W For service 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 IN Heating Contractor Phone Number Address T Burnham Hydronics U S E Company Inc 8141049R26 10 08 Price 5 00 The New York City Department of Buildings has approved the Independence Series boiler Approval No MEA 154 93 E Vol III The City of New York requires a Licensed Master Plumber supervise the installation of this product The Massachusetts Board of Plumbers and Gas Fitters has approved the Independence Series boiler See the Massachusetts Board of Plumbers and Gas Fitters website http license reg state ma us pubLic pb pre form asp for the latest Approval Code or ask your local Sales Representative The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning product life DANGER CAUTION Indicates an imminently hazardous situation Indicates a potentially hazardous situation which which if not avoided will result in death serious if n
47. IV Packaged Boiler Assembly iv Install Junction Box to jacket from inside Paragraph E vestibule area with two 2 blunt sheet metal screws provided b Mount transformer on Junction Box For Canadian boiler provide strain relief by loosely securing Transformer to Junction Box with wire tie inserted through Transformer plate and a Junction Box mounting hole See Figure 19 Fork connector on yellow wire of gas valve harness must be removed and wire stripped before making wire connections Refer to Section VIII for wiring d Steam Boilers only Secure the R8222 Thermostat Isolation Relay to upper left corner of jacket vestibule panel with sheet metal screws provided See Figure 20 e Water with tankless heater only EZWT and WCT Secure R8225D relay to Junction Box See Figure 1 4 Water Boiler Figure 19B Junction Box and Transformer Assembly a Install Temperature Pressure Gauge into upper Tapping C bushed to 1 4 NPT See Figure 1 and 2 Tighten by wrench applied to square shank on back of gauge DO NOT APPLY PRESSURE ON GAUGE CASE since this may destroy calibration of gauge Figure 20 Thermostat Isolation Relay Attachment Figure 19A Junction Box and Mounting Bracket Assembly 14 IV Packaged Boiler Assembly E Install Jacket Front Panel WARNING F Install Draft Hood Models IN3 through IN9 Installation of this boiler should be undertaken only by trained and skilled
48. JONVITIV S M3HOS OL AMVONOO3S MN3WHOJSNVHI GNNOYS 3389 HOVIIV AINO VOVNVO 7 s3adAnr Q30v1d3N SS3NBSVH LN3A AINO 33dAVO 5531 83108 303 OLNI 303 TWNOWdO 6NI ENI ST300A 304 934033 N3dAVO 72 4N3TVAInO3 SLI NO NMOHS SV Q30v1d33 5 ll 38 1SnW JHL 08314405 SV 3 TWNIDINO 30 3l SALON moan EMIR a AWA SV9 M3dAVO IN3A 5531 4 gt NAON lt gt F n 1 TN ERES S 310N 335 6 bag 1 2 sud Ms L 7081409 Av13M SONVITIV 2777271 2 9 1 6 gt gt gt o koe 335 1 09 02 AlddnS 21 AWARD UTE EA TA Yr MON E ra ZLNI C 3AWA Sv9 Hs E 273 O3NNOOSIG 1 09 021 5 9 19310849 HOLIMS TI3MA3NOH 100 1108 Adans 3993 MOT INTON 8 M3MOd 0198 21 TI3MA3NOH s 8 HOLIMS 1N3A r 4 A8 Q3liddns
49. LDT TUBING og MANIFOLD a 227 IGNITER SENSUR CABLE IGNITION MODULE Figure 14 Pilot and Gas Piping Intermittent Ignition El IN12 Only 11 I 12 Install Blocked Vent Switch with sheet metal screws 1 Models IN3 IN9 Install on rear flange of canopy See Figure 15 Figure 15 Blocked Vent Switch Installation IN3 through IN9 2 Models IN10 IN12 Install on right side of draft hood See Figure 16 Reset switch must face away from draft hood relief opening 3 Attach black 18 2 harness to Blocked Vent Switch terminals Use end with two fully insulated disconnects 4 Secure harness to right side jacket panel with clamp BLOCKET VENT SWITCH Figure 16 Blocked Vent Switch Installation IN10 through IN12 5 Insert harness through 74 inch hole in right side jacket panel Secure with strain relief bushing Intermittent Ignition Install Ignition Module 1 Mount ignition module mounting bracket to inside of right side panel using 2 6 x 3 4 sheet metal screws provided 2 Mount ignition module to bracket using 2 8 12 sheet metal screws provided 3 Install 3 wire harness from ignition module to gas valve as shown in wiring diagrams K Continue to Section III Semi Pak Boiler Assembly Step C Ill Semi Pak Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a
50. R SAFETY READ BEFORE OPERATING WARNING A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Besureto smell next to the floor becaus e some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS gt Do not try to light any appliance gt Do not touch any electric switch do not use phone in your building gt Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions If you do not follow thes e instructions exactly afire or explosion may result causing property damage personal injury or loss of life gt f you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to ins pect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to the
51. RE SER SLOPE 41 32 Steam Boiler with Intermittent Ignition and Probe Low Water Cutoff See Figure 36 1 Normal Operation a Thermostat calls for heat Thermostat Isolation Relay is energized closing contacts Vent Damper if used opens as stated in Vent Damper Sequence of Operation Ignition Module is energized Pilot Valve opens and Igniter 15 energized to ignite Pilot Burner Sensor proves presence of pilot flame Main Valve s opens and ignites Main Burners After Thermostat is satisfied Ignition Module is de energized extinguishing pilot and main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when steam pressure exceeds set point Maximum allowable pressure is 15 psi Normal operation resumes when system pressure falls below set point Low Water Cutoff LWCO Automatically interrupts main burner operation when surface of boiler water falls to lowest permissible operating level Normal operation resumes when water returns to normal level Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler opera
52. SA B149 1 Installation Codes or size system using standard engineering methods acceptable to authority having jurisdiction WARNING Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas WARNING Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping B Connect boiler gas valve to gas supply system Use methods and materials in accordance with local plumbing codes and requirements of gas supplier In absence of such requirements follow the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CSA B149 1 Installation Codes 2 Use thread joint compounds pipe dope resistant to action of liquefied petroleum gas 3 Install sediment trap ground joint union and manual shut off valve upstream of boiler gas valve and outside Jacket See Figure 29 SHUT OFF VALVE 1 GROUND JOINT UNION Figure 29 Recommended Gas Piping 4 All above ground gas piping upstream from manual psig or less isolate boiler from gas supply piping gas valve must be electrically continuous and by closing boiler s individual manual shut off valve bonded to a grounding electrode Do not use gas 2 piping as a grounding electrode Refer to the National Electrical Code ANSI NFPA 70 and or C22 1 Electrical Code Using soap solution or similar non combustible solution electronic leak detect
53. SOFT BRISTLE BRUSH REMOVABLE STEEL TUBE BURNER FLAME ROLL QUT SWITCH FLUE BRUSH Figure 58 Boiler Flueway Cleaning i Inspect connecting lines to boiler for accumulation of mud and scale Clean as necessary ii Examine wiring for brittle or worn insulation and clean electrical contact iii Inspect solder joints on bellows and float Check float for evidence of collapse Check mercury bulb where applicable for mercury separation or discoloration Do not attempt to repair mechanisms in field Complete replacement mechanisms including gaskets and instructions are available from low water cutoff manufacturer c Five 5 Years or 100 000 switch cycles Replace switch and float mechanisms C Water Feeder and Additional Low Water Cutoff Refer to manufacturer s instructions D Vent System Check annually for 1 2 3 obstructions accumulations of soot deterioration of vent pipe or vent accessories due to condensation or other reasons proper support no sags particularly in horizontal runs 5 tightness of joints Remove all accumulations of soot with wire brush and vacuum Remove all obstructions Replace all deteriorated parts and support properly Seal all joints Clean Boiler Flueways 1 Shut down gas boiler in accordance with lighting operating instructions attached to inside of Front Removable Door See Figure 45 2 Remove Burner Access Panel and Burners See Paragraph F Clean Burner
54. Screw Cap Hex Head 3 8 16 x 7 8 Limit Honeywell L8148E1299 Intermittent Circulation Only Limit Honeywell L6081A1010 Tankless Heater Only Limit Honeywell L4006A2015 Gravity Circulation Only Well Honeywell 123871A Tankless Heater Only Well Honeywell 123870A Intermittent or Gravity Circulation Only 8B 2 8C 4 9C 80160607 10A 80160469 80160400U 80160452 80160426 UJ Temperature Pressure Gauge ENFM 41042 5210 Drain Valve Conbraco 31 612 02 Bushing 2 NPT x 3 4 NPT Transformer 50VA Honeywell AT150D1019 Tankless Heater or Gravity Circulation Only Relay DPST Honeywell R8225D1029 Tankless Heater Only Relay SPST Honeywell R8222K1000 Gravity Circulation Only 8056169U 1B 80660301 80660051 80160186 80160265 80160127 8056044 8056007 _ 806602020 806602016 806602006 806602014 80861301 80860406 6031201 6036007 6091202 6031203 7036001 8036020 80860600 80861337 85 Description Part No Quantity No Transformer J Box Adapter Plate 2 meras Sheet Metal Screw 8 x 1 2 Type B Bushing Heyeo 06 75 8196066 1 t
55. TACLE IN LIMIT OR JUNCTION BOX INTERMITTENT 24V TO DAMPER FROM THERMOSTAT UMIT GROUND INTERMITTENT 24V FROM DAMPER TO GAS VALVE IGNITION MODULE CONSTANT 24V POWER TO DAMPER WIRE COLORS OF VENT DAMPER RECEPTACLE Figure 34 Vent Damper Schematic Wiring Diagram 28 THIS PAGE LEFT INTENTIONALLY BLANK 29 6 941614 H3TIVISNI A8 03114405 51081 4 331VA S M3N2S 9 N33N9 OL ANVONOO3S W3ANOJSNVNI WONJ 3389 AINO VOVNVO 77 9014 SS3N3VH 8 1N3A AINO 3N3dMYG INJA 5531 831108 NYHL OLNI 303 W3dWVO LN3A 6NI 513008 303 93811033 72 IN3IVAInO3 SLI NMOHS SV 38 LSNW 030v1d3N 38 15 JHL 03114405 SV TVNI9IHO JHL 40 31 WAV M3L YO ML 3215 WAV M3L YO ML IZIS 39V110A INN 2 501 5 318 2 LINDYID Q31IATl 2 8 3215 39V110A S310N 2 60 5 WAV M3l 81 3215 JOVLIOA MOT QN3931 OILVN3HOS AINO MOTI3A bie ONIIM
56. Tv wo ino Two wer vez 5 Pilot Burner and Gas Valve Continuous Ignition Standing Pilot Natural Gas sme 1 T ST p ie SIUE MM Pilot Tubing 1 4 OD x 30 8236122 4 ow o3 Pilot Tubing 1 4 OD 40 E esie 5A B 5 5C 5E Gas Valve Honeywell VR8300C4266 100334 01 1 mf Gas Valve Robertshaw 7000ERHC S7C 21909139 Gas Valve ITT K3A451 81660080 ESE 5F Thermocouple Honeywell Q309A 8236024 1 2236023 Kosa kuma ses Compression Nut Fitting 1 4 OD x 1 4 C C Included with 5A and 5E 8236109 Pilot Tubing 1 4 OD x 30 8236122 Pilot Tubing 1 4 OD x 40 8236123 B 5 Gas Valve Honeywell VR8200C3013 81660144 Gas Valve Honeywell VR8300C4035 81660163 Thermocouple Honeywell Q309A 8236024 Note Gas Valve specifications shown for normal altitude 0 2000 feet For High Altitude consult factory 40mm Burners Only 78 5 5 D E 5F Quantity __________ Description Part No 5 Pilot Burner and Gas Valve Intermittent Ignition El Natural Gas Pilot Burner Honeywell 034841002 8236072 Included ompression Nut Fitting 1 4 OD x 1 4 C C Included with 5A and 5E
57. UTLET 9 9 N CDLD RELIEF 7 VAL VE Figure 28 Tankless Heater Piping 2 Water without tankless heater Install in same manner as space heating zone F Tankless Heater if used See Figure 28 1 Install automatic tempering or mixing valve to prevent delivery of scalding hot water to fixtures Higher temperature water for dishwashers and automatic washers is possible by piping hot water from heater prior to entering mixing valve Install per manufacturer s instructions WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures 2 Install flow regulator Match regulator rating to tankless heater rating Install in cold water inlet below and minimum 3 feet downstream of tankless heater inlet 3 Install water softener in areas of hard water this will reduce mineral deposits which could hinder heat transfer and delivery of hot water Ifa long term pressure test of the hydronic system is required the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler To perform long term pressure test including the boiler ALL trapped air must first 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 21 VI Gas Piping WARNING Failure to properly pipe gas suppl
58. Y eque Intermittent Ignition Only 24 Volt Continuous Ignition Standing Pilot Natural Gas ventes riveree Man 1 1 1 14 3 24 Volt Continuous Ignition Standing Pilot LP Gas Main Burner with 41 Pilot Bracket 823136 1 4B 1 1 1 1 1 Regem pn Manifold 4 Manifold and Main Burners 40MM MAIN BURNERS ONLY Continued Key Natural Gas High Altitude 2000 5000 Ft USA Only Man Burner a Burner Once 5 ST T T Toz LP Gas High Altitude 2000 5000 Ft USA Only eeeeeowem wm 121351515151715 Natural Gas High Altitude 5000 9000 Ft USA Only Bumer Orc EN ES ESTE Bumer Ori 42 LP Gas High Altitude 5000 9000 Ft USA Only Main Burner Orifice 54 2 Main Burner Orifice 53 Natural Gas High Altitude 2000 4500 Ft Canada Only Main Burner Orifice 37 2 Main Burner 36 3 4 5 7 LP Gas High Altitude 2000 4500 Ft Canada Only 4D Main Burner Orifice 52 Screw Machine Slotted Round Head 10 32 x 3 16 Screw Self Tapping Phillips Pan Head 1 4 20 x 1 2 Injection Shield Assembly 77 Description Part No No ns Tine ins
59. Y ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Y Burnham Hydronics 03 03 Limited Warranty FOR RESIDENTIAL CAST IRON STEAM BOILERS By this Warranty Statement the U S Boiler Company Inc of Lancaster Pennsylvania issues limited warranties subject to the terms and conditions stated below These limited warranties apply to residential cast iron boilers labeled Independence Independence PV V8H and MegaSteam Series these warranties are issued only to the original homeowner at the original place of installation FIRST YEAR LIMITED WARRANTY FOR RESIDENTIAL CAST IRON STEAM BOILERS U S Boiler Company Inc warrants its residential cast iron steam boilers labeled Independence Independence PV V8H and MegaSteam Series to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of one year from the date of original installation In the event that any part of such a steam boiler is found to be defective in material or workmanship during the one year period then U S Boiler Company Inc will repair or replace at its option the defective part SECOND THROUGH 10 YEAR LIMITED WARRANTY FOR THE CAST IRON SECTION ASSEMBLY OF RESIDENTIAL CAST IRON STEAM BOILERS U S Boiler Company Inc warrants the cast iron section assembly of its residential cast iron steam boilers labeled Independence Independence PV V8H and MegaSteam Series to be free
60. a Masonry chimney must be lined with approved clay flue lining or listed chimney lining system except as provided in ANSI Z223 1 NFPA 54 Paragraph 7 5 4 Exception Where permitted by the authority having jurisdiction existing chimneys shall be permitted to have their use continued when an appliance is replaced by an appliance of similar type input rating and efficiency 2 Vent damper should be same size as draft hood outlet See Figure 1 Unpack vent damper carefully 3 Single wall metal vent Allowed by ANSI Z223 1 NFPA 54 under very restrictive conditions PONOT TORTE CLOSET damper may damage gear train and void warranty DO NOT force the vent damper over the rolled bead on the draft hood collar The vent damper should rest on the rolled bead Please refer to the specifications installation instructions and trouble shooting guide packed in the vent damper carton for complete detailed installation instructions B Inspect chimney and remove any obstructions or Vent damper assembly includes pre wired restrictions Clean chimney if previously used for solid connection harness with polarized plug for use on or liquid fuel burning appliances or fireplaces all 24V standing pilot or intermittent ignition EI control systems DANGER 3 Mount vent damper assembly on draft hood without modification to either Refer to instructions packed with vent damper for specific instructions Vent damper position ind
61. al clearance may be required on left side if optional tankless heater is installed Service clearances may be reduced to minimum clearances to combustible materials E Install boiler on level floor as close to chimney as possible For basementinstallation provide a solid base such as concrete steel or masonry if floor is not level or if water may be encountered on floor around boiler K Protect gas ignition system components from water dripping spraying rain etc during boiler operation and service circulator replacement control replacement etc Provide combustion and ventilation air in accordance with applicable provisions of local building codes or the National Fuel Gas Code NFPA 54 ANSI Z223 1 Section 5 3 Air for Combustion and Ventilation or CAN CSA 149 1 Installation Code WARNING Adequate combustion and ventilation air must be provided to assure proper combustion The following guideline is based on the National Fuel Gas Code NFPA 54 ANSI Z223 1 1 Determine volume of space boiler room Rooms communicating directly with space through openings not furnished with doors are considered part of space Volume 82 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 ft per 1 000 Btuh space is consid
62. an fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention Xl Repair Parts Independence Repair Parts may be obtained through your local Burnham Wholesale distributor Should you require assis tance in locating a Burnham Distributor in your area or have questions regarding the availability of Burnham products or repair parts please contact Burnham Customer Service at 717 481 8400 or Fax 717 481 8408 SERVICE RECORD DATE SERVICE PERFORMED Description Part No ns re ss v wo Te Two wn vez 1 Section Assembly Left End Section less tankless heater 717100022 717100022 Left End Section with tankless heater 717100042 Center Section Right End Section Tie Rod 3 8 16 x 10 Tie Rod 3 8 16 x 12 1 2 Tie Rod 3 8 16 x 17 Tie Rod 3 8 16 x 20 3 4 Tie Rod 3 8 16 x 23 Tie Rod 3 8 16 x 27 1 2 Tie Rod 3 8 16 x 29 Tie Rod 3 8 16 x 32 3 4 Tie Rod 3 8 16 x 36 1 2 Tie Rod 3 8 16 x 39 Washer 3 8 Nut 3 8 16 mes r B C F G H gt gt m gt 0 0 515 2 2 gt 5 99 N UJ 70 i Tre Tre Te ne mo wr Tz 2 Canopy and Draft Hood Canopy Draft Hood Parts Lem s
63. appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Remove front door GAS CONTROL VALVES MANUAL SHUT OFF VALVE valve and both gas control Locate manual shut ofi valves at the end of the gas supply pipe going into the boiler Rotate handle on manual shut off valve clockwise from ON position to OFF Rotate gas control knob on BOTH gas valves clock wise from ON position to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step Rotate gas control knob on BOTH gas valves counterclockwise Y from OFF position to ON Do not force Rotate handle on manual shut off valve counter clockwise Y from OFF position to ON Do not force Replace front door Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate followthe instruc tions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting Turn off all electric powerto the appliance if service is to be performed Remove front door 4 Rotate handle on manual shut off valve clockwise oy from
64. ch become very hot when the boiler is operating Do not touch any components unless they are cool Boiler materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance Failure to follow all instructions in the proper order can cause personal injury or death Read instructions including all those contained in component manufacturers manuals which are provided with the boiler before installing starting up operating maintaining or servicing Keep boiler area clear and free from combustible materials gasoline and other flammable vapors or liquids cover plates enclosures and guards must be in place at all times ASIA 1 66 2 6NI END H31IAS 1N3A j 03325078 C2INI OIND H21IAS 1N3A 335018 331738 13395 eu Lal 5837104 779 NOTLO3NNOD Adds n 31108 19014 WW3LS gt ACIS LAATTI 11 Fog kaJ ZA TFA 19013 jeuoisuewig 911614 INO 926 1 Mi 2 4
65. 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 continuously 5 Test for spillage at the draft hood relief opening after 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 condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code NFPA 54 51 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 11 in the National Fuel Gas Code NFPA 54 ANSI Z223 1 Figure 30 Typical Vent Installation 25 VIII Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or c
66. commended water treatment chemicals if necessary to bring the pH within the specified range With this lower level of protection care must be exercised to eliminate all of the free oxygen in the system b Boiler is now ready to be put into service CONDENSATION Following a cold start condensation sweating may occur in a gas fired boiler to such an extent that it appears that the boiler 15 leaking This condensation can be expected to stop after the boiler is hot Check Damper Operation If boiler is equipped with vent damper vent damper must be in open position when boiler main burners are operating Start boiler refer to instructions on damper to determine 1f damper 15 in full open position Review User s Information Manual and system operation with owner or operator Post instructions near boiler for reference by owner and service personnel Maintain instructions in legible condition 61 X Service Instructions DANGER This boiler uses flammable gas high voltage electricity moving parts and very hot water under high pressure Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service Do not attempt any service work if gas is present in the air in the vicinity of the boiler Never modify remove or tamper with any
67. control device WARNING This boiler must only be serviced and repaired by skilled and experienced service technicians If any controls are replaced they must be replaced with identical models Read understand and follow all the instructions and warnings contained in all the sections of this manual If any electrical wires are disconnected during service clearly label the wires and assure that the wires are reconnected properly Never jump out or bypass any safety or operating control or component of this boiler Read understand and follow all the instructions and warnings contained in ALL of the component instruction manuals Assure that all safety and operating controls and components are operating properly before placing the boiler back in service A General Inspection and service should be conducted annually except as noted Turn off electrical power and gas supply while conducting service or maintenance Follow instructions TO TURN OFF GAS TO APPLIANCE See Figures 48 49 50 or 51 B Maintenance of Low Water Cutoff 1 McDonnell amp Miller PS 802 or Hydrolevel CycleGard CG400 Probe Style Only a Drain boiler to point below Tapping K See Figure 2 b Disconnect wire s connecting control and probe c Remove control from probe DANGER Assure that the boiler is at zero pressure before removing the LWCO probe Do not rely on the pressure gauge to indicate that the boiler is at zero pressure Ope
68. device which automatically lights the pilot Do not try to light the pilot by hand Remove front door GAS CONTROL KNOB Locate the gas control valve at the end of the gas supply pipe going into the boiler The GAG gas control knob is the NLET brown or blue plastic knob located on top of the gas control valve Setthe thermostat to lowest setting Turn off all electric power to the appliance if service is to be performed 3 Remove front door 7 4 5 Rotate gas control knob clockwise CY from position to OFF Make sure knob rests against stop Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step Rotate gas control knob counterclockwise Y from OFF to ON Make sure knob rest against stop Do not force Replace front door Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier Rotate gas control knob clockwise CY from ON position to OFF Make sure knob rests against stop Replace front door Figure 50 Operating Instruction Intermittent Ignition System VR8204 and VR8304 except IN12 Gas Valves 53 54 FOR YOU
69. e sense wiring contamination of flame rod burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Reset by cycling Call for Heat If error repeats replace the control Y flash codes signify that the LED flashes X times at 2Hz remains off for two seconds flashes Y times at 2 Hz remains off for three seconds and then repeats the sequence 56 PILOT BURNER 3 8 9 5 mm THERMOCOUPLE Figure 53 Pilot Burner Flame Honeywell Q350 PILOT BURNER CENTER FLAME THERMOCOUPLE Figure 54 Pilot Burner Flame Honeywell Q327 COMBINATION IGNITION ELECTRODE SENSING PROBE Figure 55 Pilot Burner Flame Honeywell Q348 _ INCANDESCENT OUTER MANTLE BLUE WITH DC SIONAL DRANGE FLASHING 2 OUTER CONE 7 DARKER TRANSPARENT BLUE N 4 ____ INNER CONE k SHARPLY OUTLINED WITH N W T BRIGHT LIGHT BLUE 4 FLAME RETENTION INNER Y PARTIALLY LIFTED FROM BURNER 4 J Figure 56 40mm Main Burner Flame INCANDESCENT OUTER MANTLE BLUE WITH OCCASIONAL DRANGE FLASHING OUTER CONE DARKER TRANSPARENT BLUE INNER CONE SHARPLY DUTLINED WITH BRIGHT LIGHT BLUE FLAME RETENTION INNER CONE PARTIALLY LIFTED FROM BURNER Figure 57 1 Main Burner Flame F Check pilot burner flame and
70. e above address for inspection or repair In addition the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with his claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Burnham Hydronics
71. e operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency Installation is not complete unless a safety relief valve is installed See the Piping and Trim Section of this manual for details This boiler is supplied with safety devices which may cause the boiler to shut down and not re start without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative This boiler contains very hot water or steam under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the pressure and temperature of the boiler This boiler contains components whi
72. e water flow to maintain higher boiler water temperatures b Set bypass and boiler supply valves to a half throttle position to start c After installation is complete operate boiler according to Section IX System Start up 6 A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of installation The low water cut off 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 see XII Appendix for further details 7 Ifa tankless heater coil is used connect water lines to NPT tappings in coil plate 20 WATE SUPPLY E Alliance Indirect Water Heater if used Refer to Alliance Installation Operating and Service Instructions for additional information 1 Steam See Figure 27 for piping recommendations a Supply and Return Piping Connect supply piping to Tapping N 1 NPT and return piping to Tapping M 174 NPT Install zone circulator and strainer in supply piping Install check valve to prevent gravity circulation of boiler water b Limit See Figure 23 Install temperature limit control Honeywell L4006A or equal in Tapping P 24 NPT See Figure 2 Set at 180 F to prevent steam production during non space heating periods TANKLESS HEATER 25 N N INLET O
73. eating value in Btu per cubic foot from gas supplier 2 Adjust limit a Steam With 40441354 set cut out pressure MAIN scale on the pressure limit for 2 PSI and differential pressure DIFF scale below 2 PSI With L404A1651 or 4042 1367 set cut out pressure MAIN scale on the pressure limit for 1 PSI and differential pressure DIFF for 5 PSI These pressures may be varied to suit individual requirements of the system See Figure 18 b Water without tankless heater set at 200 F c Water with tankless heater set limit at 220 F and operating control to 200 F 3 Remove front removable panel See Figure 45 PANELS A step I 1 UP N LIGHTING DR OPERATING _____ INSTRUCTIONS REAR REMOVABLE PANEL N PANEL N STEP 2 FORWARD 1 STEP 3 1 LOWER FRONT TIE BAR dec SIDE VIEW Figure 45 Front Door Removal 50 PRESSURE REGULATOR GAS CONTROL ADJUSTMENT N KNOB UNDER CAP SCREW N N INLET PRESSURE Lox N 9 5 R OUTLET PRESSURE 47 _ 0 b OUTLET THERMOCOUPLE CONNECTION OL STANDING PILOT ONLY N PILOT OUTLET RED RESET BUTTON STANDING PILOT ONLY WIRING TERMINAL PILOT ADJUSTMENT UNDER CAP SCREW Figure 46 Gas Valve Pressure Tap Honeywell Gas Valves PRESSURE REGULATOR ADJUSTMENT UNDER
74. ed to ignite Pilot Burner Sensor proves presence of pilot flame Main Valve s opens and ignites Main Burners After Thermostat is satisfied Ignition Module is de energized extinguishing pilot and main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when water temperature exceeds set point Maximum allowable temperature is 250 F Normal operation resumes when water temperature falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch Igniter Sensor senses pilot flame and causes ignition module to turn off main burner and pilot burner gas flow should pilot burner flame extinguish Five to six minutes after shutdown Ignition Module restarts ignition sequence For Electronic Ignition Trouble Shooting Guide see Page 65 For LED Status Codes see Tables 8 and 9 on pages 55 and 56 45
75. er in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch is activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch Igniter Sensor senses pilot flame and causes ignition module to turn off main burner and pilot burner gas flow should pilot burner flame extinguish Five to six minutes after shutdown Ignition Module restarts ignition sequence For Electronic Ignition Trouble Shooting Guide see Page 65 For LED Status Codes see Tables 8 and 9 on pages 55 and 56 41 uoniuB BuIA Lp 9 11614 SNIMIM AOZL ANASTI UAAAVT JUHM HM 038 08 A9 3359 M9 M8 37718 78 XOVG 4905 JAIM 3MIM WMV M3L YO ML 3ZIS 39VLIOA 3MIM WMV NM3L YO ML OMY 3215 39VL10A 9501 318 9 UNJO N3MOd 2 81 3ZIS 2501 Q3ONVMIS WMV M3L 3dAL 81 3215 OGNSOWI OLLVWWHOS
76. ered an unconfined space b If result is less than 50 ft 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 sole plates and floors between wall ceiling joints between wall panels at plumbing and electrical penetrations and at other openings 727722 h ALCOVE OUTLINE DIMENSION BOILER MODELS MINIMUM RADIAL CLEARANCE AROUND FLUE 1 de FRONT VIEW RIGHT SIDE VIEW Figure 3 Clearance to Combustible Materials 5 For boiler located in an unconfined space in a Alternate method for boiler located within confined building of other than unusually tight construction adequate combustion and ventilation air 1s normally provided by fresh air infiltration through cracks around windows and doors 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 t
77. ers 71806067 7180607 1 d E ase Leg Assembly 618600 4 E1 ase Leg Included in Key No 3E 71860021 4 4 Nylon Glide Included in Key No 8186006 4 10 4200 ebhe e e e 7206005 72060065 72060085 720600 Fraosens 72060126 71800007 Frisosos Frisosor Frisosor 518600 5196006 73 No El 3 Base 3 Base Assembly Continued E Eg EHE 1 1 718600761 71860086 71860096 71860106 71860116 71860126 Left End Jacket Attachment Bracket 704601 Right End Jacket Attachment Bracket 704601 Base Sealant 620600 Screw Self Tapping Type F Phillips ES Pan Head 1 4 20 x 1 2 Plated 80860700 16 Screw Self Tapping F Hex EZ Head 5 16 18 x 1 1 4 Plated 80860717 4 Washer 5 16 USS 8086060 Hex Lock Nut 5 16 18 80860464 Screw Sheet Metal 8 x 1 2 80860000 NOTE SEE PILOT AND GAS VALVE GROUP A Burner Access Panel 2 1 pes EX EN 15212411 Ea en ER N olo olo 5 6
78. face of boiler water falls to lowest permissible operating level Normal operation resumes when water returns to normal level 1 Normal Operation a Thermostat calls for heat Thermostat Isolation Relay is energized closing contacts Vent Damper if used opens as stated in Vent Damper Sequence of Operation Gas Valve s is energized allowing main gas flow and ignition of Main Burners After Thermostat is satisfied Gas Valve s is de energized extinguishing main flame Vent Damper if used closes 2 Safety Shutdown a Limit Automatically interrupts main burner operation when steam pressure exceeds set point Maximum allowable pressure is 15 psi Normal operation resumes when system pressure falls below set point Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch 1s activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch Thermocouple senses pilot flame and causes gas valve to turn off main burner and pilot burner gas flow should pil
79. fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water STOP Read the safety information above on this label Read the lighting instructions all the way through before starting the procedure If equipped with vent damper set the room thermo stat to highest setting and wait two 2 minutes for the damper to open N o Turn off all electric power to the appliance Set the room thermostat to lowest setting Remove front door POSITION INDICATOR gt x Locate the gas control valve at the end of the gas n going into the gas control knob is the gray or brown plastic knob located on top of the gas control valve GAS INLET GAS CONTROL KNOB SHOWN IN OFF POSITION 8 Push in gas control knob slightly and turn clockwise to OFF NOTE Knob cannot be turned from PILOT to OFF unless knob is pushed in slightly Do not force Wait five 5 minutes to clear out gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you do not smell gas go to the next step NOTE Vent damper must be open during this five 5 minute wait period 1 Set the thermostat to the lowest setting 2 Tur
80. gas The accumulation of sediment eventually isolates the water from contacting the cast iron When this happens the cast iron in that area gets extremely hot and eventually cracks The presence of free oxygen or chloride slats in the boiler corrodes the cast iron from the inside More make up water and higher concentrations of contami nants damage the boiler sooner Our warranty does not cover corrosion and sediment related damage Clearly it is in everyone s best interest to prevent this type of failure You can do your part by ensuring that your system is leak free keeping leakage to less than 2 percent of the total water volume each month 65 66 Honeywell Electronic Ignition Trouble Shooting Guide FAMILIARIZE YOURSELF WITH THE NOTE FOR HEAT 24 SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL CHECK LINE VOLTAGE POWER LOW VOLTAGE TRANSFORMER LIMIT CONTROLLER THERMOSTAT CONTROLLER AND WIRING ALSO CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM IF USED AND THAT THE END SWITCH IF USED IS MADE PULL IGNITION LEAD AND CHECK SPARK AT MODULE REPLACE MODULE ACROSS IGNITER YES CHECK IGNITION CABLE GROUND WIRING CERAMIC INSULATOR AND GAP AND CORRECT CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING TAKE PROTECTIVE ACTION TO SHIELD CABLE AND BOOT FROM EXCESSIVE TEMPERATURES TURN GAS SUPPLY ON AND RECYCLE CALL FOR HEAT CHECK TH
81. gnition after retry delay completed 5 minute retry delay then initiate new trial for ignition Control waits until flame is no longer sensed and then goes to soft lockout Flash code continues Control auto resets from soft lockout after one hour Control auto resets from soft lockout after one hour Heartbeat Constant second bright gt second dim cycles Asingle flash code number signifies that the LED flashes X times at 2Hz remains off for two seconds and then repeats the sequence If system fails to light on next trial for ignition check gas supply pilot burner spark and flame sense wir ing flame rod contamination or out of position burner ground connec tion If system fails to light on next trial for ignition check gas supply pilot burner flame sense wiring flame rod contamination burner ground connection Check for pilot flame Replace gas valve if pilot flame present If no pilot flame cycle Call for Heat If error repeats replace control Check flame sense lead wire for damage or shorting Check that flame rod is in proper position Check flame rod ceramic for cracks damage or tracking Check transformer and AC line for proper input voltage to the control Check with full system load on the transformer Check gas supply pilot burner spark and flame sense wiring flame rod contamination or out of position burner ground connection Check gas supply pilot burner flam
82. h 5 16 locknuts and washers provided See Figure 5 Figure 5 Section Assembly Attachment 4 Loosen nuts on tie rods until only finger tight 5 If Steam boiler or Water boiler less tankless heater proceed to Step C 6 Water Boiler with tankless heater Remove heater opening cover plate and install tankless heater as follows a Place rubber gasket over heater coil and against heater plate Align holes in plate and gasket b Install water heater coil through opening into top nipple ports of boiler and fasten with 3 8 hex head machine screws and flat washers Note If tankless heater is not installed heater opening cover plate must remain in place C Test boiler for leaks before connecting to system and installing controls trim and jacket 1 Attach pressure gauge capable of indicating 30 psi on boiler 2 Attach fill valve and piping to return tapping and purge valve to supply tapping See Figure 6 Figure 6 Hydrostatic Pressure Test 3 Install plugs in remaining tappings 4 Fill boiler completely with water by venting air through purge valve Close purge valve and apply water pressure of at least 10 psi but not exceeding 30 psi gauge pressure 5 Examine boiler carefully inside and outside for leaks or damage due to shipment or handling D Install Canopy 1 Install gt thick x 1 wide ceramic fiber gasket See Figure 7 Figure 7 Canopy Gasket Installation 2 Position canopy on ceram
83. he outdoors or spaces crawl or attic freely communicating with the outdoors Locate one opening within 12 inches of top of space Locate remaining opening within 12 inches of bottom of space Minimum dimension of air opening 1s 3 inches Size each opening per following a Direct communication with outdoors Minimum free area of 1 square inch per 4 000 Btu per hour input of all equipment in space b Vertical ducts Minimum free area of 1 square inch per 4 000 Btu per hour input of all equipment in space Duct cross sectional area 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 1 square inch per 1 000 Btu per hour input of all equipment in spaces but not less than 100 square inches 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 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 15 not known assume wood louvers have 20 25 percent free area and me
84. ic fiber gasket See Figure 3 Attach canopy using 4 carriage bolts nuts and washers provided E Inspect joints between sections They were factory sealed If there are any openings due to shipment or handling reseal with boiler putty Install Jacket See Figure 9 1 Models IN7 IN12 steam boilers remove 3 inch diameter knockouts in jacket top panels 2 Raise rear panel under rear flange of canopy and rest on floor Position rear panel and secure to jacket side panels with sheet metal screws For Models IN10 IN12 secure jacket upper rear panels to side panels with sheet metal screws 3 Secure bothjacket side panels to base with sheet metal screws 4 Position front tie bar and secure to jacket side panels with sheet metal screws 5 Position vestibule panel and secure to side panels with sheet metal screws 6 Attach Rating Label and Vent Damper Instruction Label at designated locations on vestibule panel 7 Install top panels by placing over and around outside of side and rear panels Seat fully and secure with sheet metal screws 8 Install black plastic rings into 1 3 32 inch diameter holes located below upper louvers of front removable door REAR TOP FRONT TOP RIGHT SIDE PANEL PANEL PANEL VESTIBULE ASME DATA LABEL ST TE BURNHAM LOGO RATING LABEL 0 PANEL REAR PANEL FREQUENT WATER ADDITION CAUTION LABEL STEAM ONLY LOWEST PERMISSIBLE WATER
85. ic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 F such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures f contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficulty develops Leave the area and move to a location with cle
86. icator to be visible to users Inspect existing chimney before installing boiler Failure to clean or replace perforated pipe or tile lining will cause severe injury or death 4 USA Do not install Non listed vent damper or C Boiler Equipped With Vent Damper other obstruction in vent pipe 1 Open Vent Damper Carton and remove Installation Canada Do not install Non listed vent damper or Instructions Read Installation Instructions other obstruction in vent pipe thoroughly before proceeding 24 D Install Vent Connector from draft hood or vent damper to chimney See Figure 30 1 Do not connect into same leg of chimney serving an open fireplace 2 Vent pipe to chimney must not be smaller than outlet on draft hood or vent damper Type 15 recommended but single wall vent pipe may be used Arrange venting system so boiler is served by vent damper device 3 Where two or more appliances vent into a common vent the area of the common vent should be at least equal to the area of the largest vent plus 5096 of the area in the additional vent s Do not connect the vent of this appliance into any portion of mechanical draft systems operating under positive pressure 4 Horizontal run should be as short as possible The maximum length of an uninsulated horizontal run must not exceed 75 of the height of the chimney 5 Vent pipe should have the greatest possible initial rise above draft hood consistent with headroom a
87. in Drain approximately 5 gallons of boiler water into container Mix in recommended boil out compound Remove safety valve Pour recommended compound into boiler through safety valve opening Reinstall safety valve in Tapping E with spindle in vertical position See Figures 1 and 2 Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Slowly feed water to boiler Water will rise slowly into supply main and back through return main Adjust flow to maintain approximately 180 F water from return main hose Continue until water runs clear from hose for at least 30 minutes j Turn off water to boiler Continue to operate until excess water is removed from boiler and system by steaming and boiler water reaches normal waterline k Follow instructions TO TURN OFF GAS TO APPLIANCE See Figure 48 49 50 or 51 Open all radiator valves Reinstall all supply main air valves Open gate valve in Hartford Loop l Allow boiler to cool until crown sheet is no longer too hot to touch Close drain valves at boiler and in return main Fill boiler slowly to normal waterline m Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Allow boiler to steam for 10 minutes Drain one quart of water from lower Gauge Glass fitting n Drain second quart sample from lower Gauge Glass fitting If sample is not clear repeat cycle of draining boi
88. in excessive boiler cycling and accelerated component failure Burnham DOES NOT warrant failures caused by mis sized boiler applications DO NOT oversize the boiler to the system A Inspect shipment carefully for any signs of damage equipment 15 carefully manufactured inspected and packed Our responsibility ceases upon delivery of boiler to carrier in good condition Any claim for damage or shortage in shipment must be filed immediately against carrier by consignee No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within sixty 60 days after receipt of equipment B 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 CSA B149 1 Installation Codes Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers 51 5 No CSD 1 C Appliance is design certified for installation on combustible flooring Boiler must not be installed on carpeting D Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance See Figure 3 for minimum listed clearance to combustible material Recommended service clearance is 24 inches from left side right side and e front Addition
89. ion switch and does not require leveling See Figure 18 d Install pressure gauge into Tapping H 9 bushed to See Figures and 2 Tighten with wrench applied to square shank on back of gauge DO NOT APPLY PRESSURE ON GAUGE CASE since this may destroy calibration of gauge e Attach Lowest Permissible Water Level Plate with sheet metal screws in location indicated in Figure 9 f Attach Frequent Water Addition Label above the Lowest Permissible Water Level Plate 13 3 All Steam Boilers and Water Boilers except b Install hot water temperature limit and or EZW and WC Controls Cartons combination control Remove well from control Screw well into Tapping NPT See Figure 1 and 2 Install bulb in well as far as possible then tighten set screw a Install Junction Box See Figure 19A i Remove center knockout in rear of Junction Box and insert black plastic snap bushing in c On boilers equipped with a circulator without tankless heater in areas where condensation of flue gases is encountered in boiler flueways a reverse acting circulator control should be installed in supply as close as possible to boiler in order to avoid condensation ii Install mounting bracket to rear of Junction Box with two 2 blunt sheet metal screws provided iii Align center and mounting holes of Junction Box with upper front corner of jacket left side panel E Continue to Section
90. l Consult zone valve manufacturer for assistance D Wire thermostat Provide Class II circuit between thermostat and boiler 1 Steam or Water with gravity circulation or tankless heater Remove transformer from junction box Connect one wire from thermostat to blue wire s Connect additional wire from thermostat to brown wire or red wire for water with tankless heater G Wiring diagram and sequence of operation Locate the system type you are interested in from Table 6 then refer to the page indicated 2 Water with intermittent circulation and without 1 Vent Damper Sequence of Operation See Figure tankless heater Connect one wire from thermostat 34 to Terminal T and additional wire to terminal a Vent Damper is continuously powered at Terminal 1 E Alliance Indirect Water Heater if used b When there is a call for heat the damper relay coil is energized through Terminal 5 if all limits 1 For wiring refer to wiring diagrams located in this ahead of the damper are satisfied section and Alliance Installation Operating and Service Instructions c Relay coil closes contacts energizing damper 2 Attach junction box extension 4 11 16 square to motor causing damper to open junction box on boiler d When the damper blade reaches the fully open 3 Steam Boilers only Verify temperature limit position power is sent back to the boiler limit Honeywell L4006 or equal which is installer m
91. l 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 Years In Service Service Charge as of Retail Price Years In Service Service Charge as of 40 45 50 55 60 65 70 75 Retail Price 18 19 20 21 22 23 24 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 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 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 warra
92. ler and return main and refilling boiler until sample is clear o If after normal operation boiler water becomes dirty from additional system piping sediment returning to boiler i Complete steps 5a through 5n ii Complete steps 3a through 3k 6 Make pH or Alkalinity Test a After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with Hydrion paper which is used in the same manner as litmus paper except it gives specific readings A color chart on the side of the small Hydrion dispenser gives the reading in pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add recommended water treatment chemicals if necessary to bring the pH within the specified range With this lower level of protection care must be exercised to eliminate all of the free oxygen in the system b Boiler is now ready to be put into service N Clean Heating System Water A local qualified water treatment chemical specialist is a suggested source for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations 1 Boiling Out of Boiler and System Oil and grease which accumulate in a new hot water boiler can be washed out in the following
93. ler in operation Correct source of blockage and replace flame roll out switch Thermocouple senses pilot flame and causes gas valve to turn off main burner and pilot burner gas flow should pilot burner flame extinguish 39 TWNYSLNI SNIMIM TWNYSLNI IVNH31X3 AOCL TVNH31X3 NADAT 19 uoniuBi 0r 941614 H3TIVISNI 03114405 51081 00 N31V3H 3ONVITIV S 01 AHVONOO3S N3AHOJSNVHI 349 HOVIIV AINO 7 sN3dWnr HUM 9391433 SS3NSVH ONIMIM 33dWVQ AINO LN3A 5531 83108 303 OLNI 303 6NI NYHL ENI STAGOW 934033 M3dAVO 72 4NqivAnO3 SLI MO NMOHS SV Q30V1d3N 38 LSAW 0391935 38 1SnW SV 3 3HL JO 31 L SALON AINO CN SKMA MOD pu MB m T x iM MR E 1VISOWS3HL F eo lt 549 335 be 1N3A 1 12221 E pot JINON d 2
94. liance Set room thermostat to desired setting TO TURN OFF GAS TO APPLIANCE Set the thermostat to lowest setting 4 Turn off all electric power to the appliance if service is to be performed Remove front door 5 Turn gas control knob clockwise to OFF Do not force CN Replace front door Figure 48 Lighting Instructions Continuous Ignition System VR8200 and VR8300 Gas Valves 51 FOR YOUR SAFETY READ BEFORE LIGHTING WARNING if you do not follow these instructions exactly a fire or explosion may result causing property damage personal i injury or loss of life A This appliance has a pilot which must be lighted by hand When lighting the pilot follow these instruc tions exactly B BEFORE LIGHTING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS e Do not try to light any appliance e Do not touch any electric switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department Use only your hand to push or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a
95. low instructions TO TURN OFF GAS TO APPLIANCE See Figure 48 49 50 or 51 Drain boiler and system piping h Remove drain valve Thoroughly wash boiler water passages with high pressure spray through drain valve tapping 1 Reinstall drain valve in Tapping F See Figures 1 and 2 Second Boil out for Stubborn Cases If all oil and grease 1s not removed a second boilout using surface blow off is necessary a Run pipe from Surface Blow Off Tapping L to open drain Do not install shut off valve or other restriction See Figure 2 b Fill boiler to top of gauge glass c Remove safety valve d Pour recommended boil out compound into boiler through safety valve opening e Reinstall safety valve in Tapping E with spindle in vertical position See Figures 1 and 2 f Follow Lighting or Operating Instructions to place boiler in operation See Figure 48 49 50 or 51 Boil water for approximately 5 hours without producing steam g Open boiler fill shut off valve to produce steady trickle of water from surface blow off pipe Continue boil out for several hours until surface blow off water runs clear 59 60 h Follow instructions TO TURN OFF GAS TO APPLIANCE See Figure 48 49 50 or 51 Drain boiler and system piping Remove drain valve Thoroughly wash boiler water passages with high pressure spray through drain valve tapping Fill boiler to normal waterline If water in gauge glass is not clear
96. lure The maintenance of system integrity is the best method to achieve this NOTICE This boiler has a limited warranty a copy of which is printed on the back of this manual It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete Surface rust on cast sections may be attributed to the manufacturing process as well as condensation during storage Surface rust is normal and does not affect the performance or longevity of a boiler CAUTION Probe type low water cutoff devices require annual inspection and maintenance Although these devices are solid state in their operation the probe is exposed to possible contamination in the boiler water and subject to fouling Refer to Low Water Cutoff Service Instructions for complete step by step inspection and cleaning instructions WARNING This boiler requires regular maintenance and service to operate safely Follow the instructions contained in this manual Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Read and understand the entire manual before attempting installation start up operation or service Installation and service must be performed only by an experienced skilled and knowledgeable installer or service agency This boiler must be properly vented This boiler needs fresh air for saf
97. main burner flames through observation port 1 Check pilot flame a Continuous Ignition Standing Pilot Models IN3 through IN7 See Figure 53 Pilot burner produces a single flame Flame should be steady medium hard blue enveloping 3 8 to inch of thermocouple b Continuous Ignition Standing Pilot Models IN8 through IN12 See Figure 54 Pilot burner produces three 3 flames Center flame should be steady medium hard blue enveloping 3 8 to inch of thermocouple c Electronic Ignition EI Models IN3 through IN12 See Figure 55 Pilot should be lit only after completing Step 3 Pilot burner produces three 3 flames Center flame should be steady medium hard blue enveloping 3 8 to inch of sensing probe CAUTION Avoid operating this boiler in an environment where saw dust loose insulation fibers dry wall dust etc are present If boiler is operated under these conditions the burner interior and ports must be cleaned and inspected daily to insure proper operation 57 2 Adjust thermostat to highest setting 3 Check main burner flames See Figure 56 or 57 Flame should have clearly defined inner cones with no yellow tipping Orange yellow streaks caused by dust should not be confused with true yellow tipping 4 Adjust thermostat to normal setting G Check thermostat operation Raise and lower temperature setting to start and stop boiler operation H Check ignition system shutoff Gas valve sho
98. n both gas and oil hot water boilers 15 above the boiler in either the supply or return piping The minimum safe water level of a water boiler is at the uppermost top of the boiler that is it must be full of water to operate safely What Kind Typically in residential applications a probe type LWCO is used instead of a float type due to their relative costs and the simplicity of piping for a probe LWCO How to Pipe A tee 18 commonly used to connect the probe to the supply or return piping as shown below SYSTEM SUPPLY RETURN p SS 8 9 252 K IF AVAILABLE w 2 MINIMUM SAFE ES E WATER LINE S 5 3 ho lt Y CUN P LWCO Location Select the appropriate size tee using the manufacturer s instructions Often the branch connection must have a minimum diameter to prevent bridging between the probe and the tee Also the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee Ideally manual shutoff valves should be located above the LWCO and the boiler to allow for servicing This will allow probe removal for inspection without draining the heating system Many probe manufacturers recommend an annual inspection of the probe How to Wire LWCO s are available in either 120 VAC
99. n off all electric power to the appliance if service is to be performed 3 Remove front door LIGHTING INSTRUCTIONS 10 Remove burner access panel Pilot Burner 11 Find the pilot by following Thermocouple the aluminum tube from the gas control valve to the pilot located between the steel m tube bumers 12 Turn gas control knob counterclockwise to PILOT position 13 Push in control knob all the way and hold in Immed my ht the pilot with a match Continue to hold the control knob for about one 1 minute after the pilot is lit Release knob and it will pop back up Pilot should remain lit If it goes out repeat steps 8 13 If knob does not pop up when released stop and immediately call your service technician or gas supplier If the pilot will not stay lit after several tries turn gas control knob to OFF and call your service tech nician or gas supplier 14 Replace burner access panel 15 Tum gas control knob counterclockwise P to ON position 16 Replace front door 17 Tum on all electric power to the appliance 18 Set room thermostat to desired setting TURN OFF GAS APPLIANCE 4 Push gas control knob slightly and turn clockwise to OFF Do not force 5 Replace front door Figure 49 Lighting Instructions Continuous Ignition System 7000 ERHC Gas Valve 52 FOR YOUR SAFETY READ BEFORE OPERATING WARNING A This applia
100. n the safety valve to relieve all internal pressure prior to proceeding Safety valve discharge piping must be piped such that the potential for burns is eliminated d Unscrew probe from Tapping K Inspect for scale and sediment buildup 62 e Remove light deposits with damp cloth soaked with vinegar f Remove stubborn deposits using diluted phosphoric acid H PO solution 3 parts water to 1 part phosphoric acid Normal operation will occur with up to 0 2 inch of contamination If scale or contamination exceeds 0 2 inches clean probe more frequently g Clean Tapping K to remove old pipe dope and other foreign matter h Apply moderate amount of good quality pipe dope to probe threads leaving two end threads bare Install probe in Tapping K Mount control on probe Attach wire s between control and probe i Fill boiler to normal waterline Add water treatment as needed McDonnell amp Miller 67 Float Style Only a Weekly or more frequently if necessary Open blow off valve to flush sediment chamber Follow instructions on Blow Down Card affixed to Jacket adjacent to low water cutoff b Annually Dismantle to extent necessary to remove obstructions and insure proper function of working parts VENT DAMPER IN3 INS BLDCKED VENT USED FRONT REMOVABLE DOOR CANDPY DRAFT HOOD ASSEMBLY IN10 IN12 BLOCKED VENT SWITCH BURNER ACCESS PANEL
101. nce is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS gt Do try to light any appliance Do not touch any electric switch do not use any phone in your building gt Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions C If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life gt If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Setthe thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition
102. ng or brazing pastes and fluxes that end up in the system can cause poor heat transfer surging an unsteady water line and wet steam if not thoroughly removed during the boil out procedure and 4 galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water chemistries if dielectric unions are not used pue suonenjon esiou ulajs S 59 siu payioeds edid eun rej 018101 Buidig weas pz 91614 831106 331 839914 3155 N31I08 9 5 114 M04 S3ATVA OL Nuni3s I34 Wv3ls QOHL3A SNIdld 31VNH3LTV 31 9 AWO 224 NO 35010 SNIdld 31VNM3LTV 1 ONidid 03843438 0 c NOLLO3NNOO Nanay QuOA414VH 5 LON SI 4 38 1509 IVNOUdO M3SlM AlddnS 0 0235 i z z i z i 0 VAN z z 2 1V MO 30 401 340 38 OL NVW Alddns LINI OLNI GNI 8NI ZNI 9NI GNI TNI SNI 3ZIS 82 5531 LON 38 OL 14818 40 INIOd
103. nro 5 gt 5 e Bushing 3 4 NPT x 1 4 NPT D Syphon 1 4 NPT x 180 11B Drain Valve Conbraco 31 612 02 11C Bushing 2 NPT x 3 4 Part No 81660530 806601502 806600002 80160720 80160725 80160517 80160629 8056128 8056020 80160369 806603010 806600508 806603030 8056010 806603012 806600515 Quantity Description IN10 IN11 f IN12 z o2 Water Trim Safety Relief Valve 3 4 NPT 30 psi Conbraco 10 407 05 Elbow 3 4 NPT 80660152 Nipple 3 4 NPT x 3 80660000 Circulator Bell amp Gossett NRF 22 with Gaskets Circulator Grundfos UP 15 42F 81660363 E x Jupes ee s ES ES 00222208 2122 2148 000 01210 Esos Jn 1 20124 121210 4 is SEES sre Sm E oe d deest a D 21216 21010 220815 7B 7C N o 8056174 2 8056044 8056007 806602029 806602016 806602006 806602014 8086130 80860406 6031201 603600 6031202 603120 7036001 8036020 80860600 80861337 Circulator Taco 007 Gasket Bell amp Gossett NRF 22 Gasket Grundfos 510179 Gasket Taco 00 Series Flange 1 1 2 NPT Screw Cap Hex Head 7 16 14 x 1 1 2 Nut Hex 7 16 14 Tankless Heater A 62 Tankless Heater 222 Tankless Heater A 51 Tankless Heater A 53 Heater Cover Plate Gasket Washer 3 8
104. nty if any 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 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 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 war
105. o normal level Blocked Vent Switch Automatically interrupts main burner operation when excessive vent system blockage occurs Control is a multiple use device If blocked vent switch is activated do not attempt to place boiler in operation Correct source of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch 1s activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch lgniter Sensor senses pilot flame and causes ignition module to turn off main burner and pilot burner gas flow should pilot burner flame extinguish Five to six minutes after shutdown Ignition Module restarts ignition sequence For Electronic Ignition Trouble Shooting Guide see Page 65 For LED Status Codes see Tables 8 and 9 on pages 55 and 56 37 JUI IWI9 U uoniuB 9 6 9 1614 OL AMVQNOO3S M3ARHOJSNVHI 3389 AINO Q39v1d3N SS3NNVH AINO N3dWVG IN3A 5537 43108 303 NYHL OLNI 303 TVNOILdO 6NI NYHL 1300 303 IN
106. one in your building gt Immediately call your gas supplier from a neigh bor s phone Follow the gas supplier s instructions If you do not follow these instructions exactly afire or explosion may result causing property damage personal injury or loss of life gt If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to ins pect the appliance and to replace any part of the control system and any gas control which has been under water LIGHTING INSTRUCTIONS STOP Read the safety information above 11 Read the lighting instructions all the way through before starting the procedure If equipped with a vent damper set the room thermo stat to highest setting and wait two 2 minutes for the 12 damper to open Turn off all electric power to the appliance 13 Set the room thermostat to lowest setting POSITION INDICATOR Remove front door Bas CENTRAL Locatethe gas control valve at the end of the gas supply pipe going into the boiler The gas control knob is the blue or brown plastic knob located on top of the gas control valve RED R
107. onnections of the boiler or building Lock out all electrical boxes with padlock once power is turned off B 26 WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm electrical work Electrical power may be from more than one source Make sure all power is off before attempting any Each boiler must be protected with a properly fused disconnect Never jump out or make inoperative any safety or operating controls General Install wiring and ground boiler in accordance with requirements of authority having jurisdiction or in absence of such requirements the National Electrical Code ANSI NFPA 70 and or CSA C22 1 Electrical Code Wire Vent Damper if used 1 Steam or Water with gravity circulation or tankless heater a Remove one 1 7 8 knockout from junction box Carefully remove transformer avoid undue strain on wires b Install Vent Damper Harness into top of junction box c Remove factory installed jumper plug if so equipped from Vent Damper Receptacle Plug Vent Damper Harness into Vent Damper Receptacle See Figure 31 Figure 31 Vent Damper Connection Detail d Install cable clamp around flexible Vent Damper Harness Attach to jacket top panel See Figure 32 Figure 32 Vent Damper Harness to Junction Box 2 Water with intermittent circulation and without tankless heater a Remove 7 8 knockout and cover from limit control
108. or 24 configurations The 120 VAC configuration can be universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler after the service switch 1f so equipped The presence of water in a properly installed LWCO will cause the normally open contact of the LWCO to close thus providing continuity of the 120 VAC service to the boiler It is recommended to supply power to the probe LWCO with the same line voltage boiler service as shown below Wiring of Typical 1 24 LWCO 15 used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler However a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application How to Test Shut off fuel supply Lower water level until water level is BELOW the LWCO Generate a boiler demand by turning up thermostat Boiler should not attempt to operate Increase the water level by filling the system The boiler should attempt to operate once the water level is above the LWCO Limited Warranty FOR RESIDENTIAL GRADE WATER BOILERS Subject to the terms and conditions set forth below U S Boiler 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 ONE YEAR LIMITED WARRANTY ON RES
109. or or other approved method Check that boiler gas piping valves and all other components are leak free Eliminate any C Pressure Test The boiler and its gas connection must leaks be leak tested before placing boiler in operation 1 Protect boiler gas valve For all testing over psig DANGER 14 2 valve in d Doe not use matches candles open flames or IsConnected S ppiy piping Por testing at other ignition source to check for leaks Table 3 Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0 5 psig or Less Length 0 3 inch w c Pressure Drop 0 5 inch w c Pressure Drop Feet 40 84 53 Table 5 Specific Gravity Correction Factors for Natural Gas Table 4 Fitting Equivalent Lengths Specific Correction Specific Correction Gravity Factor Gravity Factor ES Nominal Pipe Size ting o o 9 e o l ud USA boilers built for installation at altitudes greater than 2 000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1 000 feet above sea level per the National Fuel Gas Code NFPA 54 ANSI Z223 1 Canadian boilers orifice sizing is indicated on the rating label High altitude boiler models are identifiable by the third digit in the model number suffix on the rating label _IN_ _ _ 2 less than 2000 ft elevation _IN_ _ 4 2000 to 4500 ft elevation Canada _IN___ __ 5
110. ot avoided may result in moderate or minor injury or substantial property damage injury or property damage WARNING NOTICE Indicates a potentially hazardous situation which Indicates special instructions on installation if not avoided could result in death serious injury operation or maintenance which are important or substantial property damage but not related to personal injury hazards CAUTION If during normal operation it is necessary to add water to this boiler more frequently than once a month consult a qualified service technician to check your system for leaks A leaky system will increase the volume of make up water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up water are dissolved minerals and oxygen When the fresh cool make up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas Both can result in reduced boiler life The accumulation of sediment can eventually isolate the water from contacting the cast iron When this happens the cast iron in that area gets extremely hot and may eventually crack The presence of free oxygen in the boiler creates a corrosive atmosphere which if the concentration becomes high enough can corrode the cast iron through from the inside Since neither of these failure types are a result of a casting defect the warranty does not apply Clearly it is in everyone s best interest to prevent this type of fai
111. ot burner flame extinguish 31 13 uoniuB 9 4 H3TIVISNI 03114405 STOYLNOD 331V3H 3ONVITIV A339S 9 N33N9 Ol ANVONOO3S 43ANOJSNVMI 043 HOVIIV AINO VGVNVO Q39v1d334 ZINI OLNI 303 S v SS3NNVH N3dAVG LN3A AINO N3dWVGO 1N3A 5531 33708 303 4 INJA 6NI 513004 303 49311033 1N3A IN31VAInO3 5 SV 032 143 38 LSNW 38 15 03114405 SV JHL 30 dl AlddNS N3MOd 09 021 2 002 3215 009 5 TVIN3NILNOO QNnOMN9 2 052 318 2 9 lt 008 6 lt 113 MNOSN3S N3LIN9I WMV M3L NO 8 3215 39 WMV M3l NO ML 3dAL 3215 39V110A 2 501 5 318VO G3LINM 33MOd 2 81 3215 39 2 60 3NIM 5 WMV M3l 9MV 3715 39 110 38088 SNISN3S QN3931 WV39VIG SS3NMNVH 1N3A 319V1d323M 1N3A 310N 335 1N3A 310N 335 S31
112. ource of blockage and reset blocked vent switch Flame Roll out Switch Automatically interrupts boiler operation when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch 1s activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch Thermocouple senses pilot flame and causes gas valve to turn off main burner and pilot burner gas flow should pilot burner flame extinguish 35 1 014 I3 uoniuB 86 9 1614 SNIMIM WVA VIA MOTA JUHM HM QN AVNO AD N33N9 NMONB amg 18 3ovHl HM 8 XOv18 2 002 3MIM 8L 3215 5 VIN3NIINOO 8 4 2 092 318 2 9 lt 008 66 T3MA3NOH MOSN3S H3IIN9I WNMV NG3L ML OMY 3715 39VI10A WMV M3L ML 3dAL vL 3ZIS 250 41 318 29 LINDYIO 43MOd 2 8 3215 9 301 3MIM 5 3dAL OMY 81 375 39 OLLVAWHOS M3TIVISNI A8 03189905 51081 331V3H
113. ovg 8 A100 INIM x MO ML 81 3215 INN YO ML 3dAL OMY 3215 2501 6 NAYI Q31An 43MOd 2 81 3215 1 25501 ONOS WMv M3L OMY 81 3ZIS MOT 9 601 5 WMV NGL OMY 81 3215 ANADAI 310N 335 SS3NNVH ONIHIM S o M3dWVO IN3A 0v143338 INJA 532 98 584 ra gi HOLIMS L 5 100 1108 N3 SOJSNVHL 1 1822 8 a 5 ome sag SNWA 299 HOLIMS 5 AN3A g A 0112018 221 z 11 ZEE K 1 HL a Alddns HIV N3MOd 5 9 5 9 XWO OLNI 6NI 46 P Water Boiler with Continuous Ignition Standing Pilot and Tankless Heater See Figure 43 1 Normal Operation a Thermostat calls for heat or low limit senses water temperature below set point Vent Damper if used opens as stated in Vent Damper Sequence of Operation Gas Valve s 1s energized allowing main gas flow and ignition of Main Burners After Thermostat or low limit is satisfied Gas Valve s is de energized extinguishing main flame Vent
114. personnel from a 1 Locate and open Rear Draft Hood Carton qualified service agency 2 Position Draft Hood on Canopy Rear Flange See Y Figure 21 Top canopy flange must fully engage A Remove crate and move boiler to permanent position U shaped draft hood flange for proper installation as detailed in Section III Semi Pak Boiler Assembly and operation Care must be taken to assure that draft hood is level 3 Secure Rear Draft Hood to Canopy with wing nuts C Remove poly bag from vestibule area provided See Figure 22 B Remove Jacket Front Panel See Figure 45 D OnSteam Boilers with probe low water cutoff the L404 pressure limit control has been packed in the vestibule area 1 Screw the pressure limit control onto the syphon DO NOT TWIST CONTROL Use wrench on hex fitting at bottom of control See Figure 18 2 Snap the electrical conduit from the adjacent junction box into the hole in the control 3 Open the control s clear cover and attach the two 2 wires in the conduit to the two 2 unused screw terminals Figure 22 Securing Draft Hood to Canopy WARNING Do not alter boiler draft hood or place any obstruction or non approved damper in the breeching or vent system Flue gas spillage can occur ETL ETLC certification will become void Figure 21 Draft Hood Attachment 15 V Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or st
115. qualified service agency A Remove Crate 1 Remove all hold down screws and brackets 2 Slide boiler to rear of skid and carefully remove from crate skid onto 2 inch thick piece of wood and then onto floor Do not bump boiler jacket against floor 3 Do not drop boiler at any time B Move Boiler To Permanent Position Refer to Section C I Pre Installation Identify Trim and Controls FIRST Determine controls ordered with boiler and refer to appropriate section s following There are two ordering methods for trim and controls 1 EZ Connect Carton either steam or water includes trim controls wiring and wiring instructions for installation 2 Separate Trim Carton steam or water and Control Carton steam or water Only wiring requiring special connections is provided For wiring requirements refer to Section VIII Electrical and appropriate wiring diagram Install Trim and Controls Refer to appropriate paragraphs following for trim and controls to be installed 1 Steam Boiler with Probe Low Water Cutoff a Install pressure limit control into Tapping with siphon 94 x 1 4 hex bushing 94 elbow and 34 x 3 nipple provided See Figures 1 and 2 DO NOT TWIST CONTROL Use wrench on hex fitting located at bottom of control See Figure 18 R MAIN LI BRASS Figure 18 L404F Pressure Limit Control b The L404F pressure limit employs a snap action switch and does not
116. r is still overfired contact your Governale distributor or Regional Office for replacement Gas Orifice b Increase input rate if less than 98 of Rating Label input Increase manifold gas pressure no more than 0 3 inch w c If measured input rate is still less than 98 of rated input i Remove Main Burners per procedure in Section X Service Instructions ii Remove gas orifices Drill one 1 drill size larger drill size 15 stamped on orifice iii Reinstall gas orifices and main burners Measure input rate 6 Recheck Main Burner Flame 7 Return other gas fired appliances to previous conditions of use Table 10 Input Rate forOne One Two Five 240 600 225 563 212 529 200 50 9 to 4 a 1 ow 36 5 t _ 3 we s 1 s me 5 nz 260 231 4 25 L Adjust gas input rate to boiler LP Propane 1 Set thermostat to highest setting 2 Adjust tank regulator for gas valve inlet pressure of 13 5 inches w c or less 3 Gas valve has step opening regulator which initially opens to 1 4 or 2 5 inch w c and steps to full pressure after approximately 30 seconds Check manifold pressure after step has occurred Adjust gas valve pressure regulator as necessary for 10 0 inches w c turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure If 10 0
117. ranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties 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 circum stances 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 whatso ever 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
118. re Manifold pressure is listed on Rating Label a Models IN3 IN12 with Standing Pilot IN3 IN9 with Hot Surface to Pilot and IN3 IN11 with Electronic Ignition Adjust gas valve pressure regulator as necessary turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure If pressure can not be attained check gas valve inlet pressure If less than minimum gas supply pressure listed on Rating Label contact gas supplier for assistance b Model IN12 with Electronic Only i Turn off gas valve not having pilot control ii On gas valve with pilot control adjust gas valve pressure regulator to obtain required manifold pressure or 1f unattainable highest pressure without forcing adjustment screw turn adjustment screw counterclockwise to decrease manifold pressure or clockwise to increase manifold pressure iii Turn on gas valve not having pilot control Adjust gas valve pressure regulator to obtain required manifold pressure Manifold pressure may not change during initial turns of adjustment screw 3 Clock gas meter for at least 30 seconds Use Table 10 to determine gas flow rate in Cubic Feet per Hour 4 Determine Input Rate Multiply gas flow rate by gas heating value 5 Compare measured input rate to input rate stated on Rating Label a Boiler must not be overfired Reduce input rate by decreasing manifold pressure Do not reduce more than 0 3 inch w c If boile
119. require leveling See Figure 18 c Install pressure gauge into Tapping B bushed to 1 4 See Figures 1 and 2 Tighten with wrench applied to square shank on back of gauge DO NOT APPLY PRESSURE ON GAUGE CASE since this may destroy calibration of gauge d Install Low Water Cutoff Probe into Tapping K Q4 NPT HANDLE PROBE WITH CARE e Attach Low Water cutoff Control to Probe by following instructions packed with control f Install gauge glass fittings into Tappings C See Figures 1 and 2 Lower fitting has small drain valve 2 Install gauge glass and protective rods in fittings h Attach Lowest Permissible Water Level Plate with sheet metal screws in location indicated in Figure 9 1 Attach Frequent Water Addition Label above the Lowest Permissible Water Level Plate Steam Boiler with McDonnell amp Miller 67 Float Low Water Cutoff a Install Low Water Cutoff see instructions packed with control i Screw brass nipples with union halves into Tappings C See Figure 1 and 2 ii Attach Gauge Glass Low Water Cutoff Assembly to union halves iii Affix Blow Down Card to Jacket Left Side Panel adjacent to low water cutoff iv Provide blow down discharge piping b Attach street elbow siphon and pressure limit control to low water cutoff DO NOT TWIST CONTROL Use wrench on hex fitting located at bottom of control The L404F pressure limit employs a snap act
120. rranty to be effective a The boiler must have been properly installed in a single or two family residential dwelling This warranty does not apply to boilers installed in apartments or to commercial or industrial installation b The boiler must have been assembled in strict compliance with installation instructions furnished with the boiler by U S Boiler Company Inc Boiler components must not have been damaged in handling during shipment or installation The 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 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 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 the remedy for breach of this warranty or for negligence does not extend to liability for incidental special or consequential damages or losses Such as loss of the use of the materials inconvenience or loss of time 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 This warranty is in lieu of all others and any and all express or implied warranties including without limi
121. ructure A Design and install boiler and system piping to prevent oxygen contamination of boiler water Sources of WARNING oxygen contamination are system leaks requiring addition of makeup water fittings and oxygen permeable materials in distribution system Eliminate oxygen contamination by repairing system leaks repairing fittings using nonpermeable materials in distribution system and eliminating open tanks in system or isolating boiler from system with heat exchanger C Install Drain Valve in Tapping F 2 NPT bushed to B Install Safety Relief Valve Tapping E 4 See Figure 23 See Figure 23 Use 4 NPT x 3 nipple and elbow provided Safety Relief Valve must be installed with spindle in vertical position Safety relief valve discharge piping must be piped such that the potential of severe burns is eliminated DO NOT pipe in any area where freezing could occur DO NOT install any shut off valves plugs or caps Consult Local Codes for proper discharge piping arrangement D Connect supply and return piping to heating system Maintain minimum inch clearance from combustible materials 1 For STEAM HEATING see Figure 24 Consult I B R Installation and Piping Guides 2 For HOT WATER HEATING with Circulator forced see Figure 25 and 25A Consult I B R Installation and Piping Guides SS 3 If boiler is used in connection with refrigeration system
122. s boiler must be installed with chilled WITH BOILER medium piped in parallel with heating boiler using ere MTS lt appropriate valves to prevent the chilled medium HAS D Cs from entering the boiler See Figure 26 Also N 5 consult I B R Installation and Piping Guides SS 4 If boiler is connected to heating coils located in air SS handling units where they may be exposed to refrigerated air boiler piping must be equipped with flow control valves to prevent gravity circulation of Figure 23 Trim Installation boiler water during cooling system operation NOTICE Do not use softened water in steam boilers Accelerated boiler corrosion will result Tie in fresh water supply to the boiler upstream of a water softener Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components and can lead to boiler failure Burnham s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale lime build up caused by frequent addition of water Before using copper for steam piping consider the following characteristics of copper piping 1 high coefficient of thermal expansion can induce mechanical stresses and cause expansion contraction noises if not accounted for in the piping system design and installation 2 high heat transfer rate heat loss of uninsulated copper piping must be included in the normal piping and pickup factors used to size the boiler 3 solderi
123. s if necessary 3 Remove Jacket Top Panels 4 Remove Canopy from top of boiler 5 Thoroughly clean the flueways with flue brush See Figure 58 6 Clean boiler heating surface accessible from combustion chamber with straight handle wire brush Reinstall burners and connect gas train See Paragraphs F amp G 7 Place boiler in operation in accordance with Lighting or Operating instructions Test gas line for leaks in accordance with Section VI Gas Piping Paragraph C 8 Replace Jacket Front Removable Door 63 CAUTION When necessary to remove burners be sure to reinstall them in the original manner by engaging the orifice and locating hole in the rear of the burner tray Burners must be aligned with the burner manifold F Remove Burners for cleaning changing orifice plugs or repairs 1 Turn off electric service to boiler Turn off gas supply to boiler Remove jacket front panel Disconnect pilot tubing at gas valve Qn ode 55 IS Disconnect thermocouple tubing at gas valve Continuous Ignition only Disconnect igniter sensor cable and ground wire at ignition module Intermittent Ignition EI only Disconnect flame roll out switch wires 6 Remove burner access panel 7 Mark location of pilot main burner on manifold 8 Hold burner on throat Lift slightly to clear orifice Pull burner from combustion chamber See Figure 10 Pilot main burner can only be removed by lifting at 45 angle after adjacent
124. tal louvers and grilles have 60 75 percent free area H Do not install boiler where gasoline or other flammable vapors or liquids or sources of hydrocarbons bleaches cleaners chemicals sprays paint removers fabric softeners etc are used or stored c Horizontal ducts Minimum free area of 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 Knocked Down Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency A Install Base Burner Manifold Assembly 1 Base Burner Manifold is shipped assembled from factory Gas Valve and Pilot Burner Assembly is shipped in the Gas Controls Carton 2 Unpack base assembly and place in location where boiler is to be installed Refer to Section I Pre Installation B Install assembled cast iron sections on base assembly 1 Install 4 5 16 x 1 4 self tapping screws through 4 holes in upper base flange with screw heads on underside of flange Note Screws are located in fiber gasket parts bag 2 Install ceramic fiber gasket See Figure 4 Figure 4 Base Gasket Installation 3 Position boiler above base with lugs cast in boiler sections centered over screws protruding from top of base Lower boiler onto base taking care not to disturb ceramic fiber gasket Secure wit
125. tation any implied warranties of merchantability or fi tness for a particular purpose are expressly limited in duration to the period of the warranty as previously stated herein Some states do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you 10 Not withstanding any of the above provisions U S Boiler Company Inc liability under this warranty shall not exceed the selling price of the product found to be defective PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the homeowner 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 homeowner s rights under this warranty Upon discovery of a condition believed to be related to a defect in material or workmanship covered by this warranty statement the homeowner 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 homeowner should write to U S Boiler Company Inc at P O Box 3079 Lancaster PA 17604 giving full particulars in support of the claim The homeowner is required to make available for inspection by U S Boiler Company Inc or its representative the parts claimed to be defective and if requested by U S Boiler Company Inc to ship said parts prepaid to Burnham Hydronics at th
126. teps B through L and Step O from Section IX System Start up K Conversion Kits Follow all instructions provided with kits Note that Rating Label provided in kit must be used Apply over or beside original Rating Label allowing the original Serial Number to remain visible L Tankless Heater 1 Flushing of Heater All water contains some sediment which settles on inside of coil Consequently heater should be periodically backwashed See Figure 28 Allow water at city pressure to run into hosebib A through heater and out hosebib B until discharge 15 clear The tees in which the hosebibs are located should be the same size as heater connections to minimize pressure drop 2 Adjust and maintain mixing valve tempering valve in accordance with manufacturer s instructions M Excessive Make Up Water CAUTION IF DURING NORMAL OPERATION IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS wo o o 0 A leaky system will increase the volume of make up water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up water are dissolved minerals salts and oxygen When the fresh cool make up water 1s heated in the boiler the minerals fall out as sediment the salts coat the inside of the boiler and the oxygen escapes
127. tinuous Ignition standing pilot connect thermocouple to gas valve PIPING SHOWN IN HIDDEN OUTLINE 7 NOT FURNISHED BY MANUFACTURER THERMOCOUPLE 4 PILOT BURNER GAS CONTROL f VALVE _ D PILOT TUBING J 1 9 el CA iX THERMDCDUPLE 6 MANIFOLD Figure 11 Pilot and Gas Piping Continuous Ignition Standing Pilot IN3 through IN9 Only ROBERTSHAW GAS VALVE ITT GAS VALVE PIPING SHOWN IN HIDDEN OUTLINE NOT FURNISHED BY MANUFACTURER THERMOCOUPLE ry di 33274 PILOT BURNER 7 Figure 12 Pilot and Gas Piping Continuous Ignition Standing Pilot IN10 through IN12 Only IN HIDDEN OUTLINE PIPING SHOWN NOT FURNISHED BY MANUFACTURER IGNITION ELECTRODE FLAME SENSOR CONTROL VALVE PILOT TUBING HONEYWELL 0348 PILOT BURNER 223 MANIFDLD 1 D I AN 1 N GROUND WIRE TD IGNITION MODULE NL GNITION SENSOR LEAD Y TO IGNITION MODULE 1 an 2 Figure 13 Pilot and Gas Piping Intermittent Ignition El IN3 through IN 11 Only rPILDT DUTLET PLUG PIPING SHOWN IN HIDDEN OUTLINE NOT FURNISHED BY MANUFACTURER IGNITION ELECTRODE gt 322 8 FLAME TT us Tu 17 GAS VALVES HONEYWELL 20 0348 PILOT 1 BURNER 1 MANUAL SHUT OFF NS VALVE N 2 9 GROUND WIRE TD IGNITION MODULE A UNA ma 1 c PI
128. tion when flames or excessive heat are present in vestibule Control is single use device If flame roll out switch 1s activated do not attempt to place boiler in operation Correct source of blockage and replace flame roll out switch lgniter Sensor senses pilot flame and causes ignition module to turn off main burner and pilot burner gas flow should pilot burner flame extinguish Five to six minutes after shutdown Ignition Module restarts ignition sequence For Electronic Ignition Trouble Shooting Guide see Page 65 For LED Status Codes see Tables 8 and 9 on pages 55 and 56 33 uoniub 9 6 9 11 614 APZ MOTA SLIHM HM gay 08 AD N3389 39 NAONS 88 ama 3ovsL JUHM xOv18 9 400 3MIM NMV M3L ML 81 3ZIS 39VL10A WMV M3L ML 1 3215 JOVLIOA 2 801 81 3182 43MOd OMV 2 81 3215 39VL10 2 501 5 NMV N3L 3dAL SW 81 3215 WVIDVIG OLLVAWHOS H3TIVISNI 03114405 51081 Y3LV3H
129. uld close and pilot and main burners extinguish 1 Continuous Ignition Standing Pilot disconnect thermocouple from gas valve 2 Electronic Ignition EI disconnect igniter sensor cable from ignition module terminal 9 I Checklow water cutoff steam only 1 Adjust thermostat to highest setting 2 With boiler operating open drain and slowly drain boiler CAUTION Do not drain below gauge glass 3 Main burners will extinguish when water level drops below low water cutoff Water should still be visible in gauge glass Verify limit thermostat or other controls have not shut off boiler 4 Adjust thermostat to lowest setting Refill boiler to normal water line J Check Limit 1 Adjust thermostat to highest setting 2 Steam Observe pressure gauge When pressure is indicated adjust limit to setting below observed pressure Main burners should extinguish WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance Improper and unsafe boiler operation may result 3 Water Observe temperature gauge When temperature exceeds limit set point main burners should extinguish 4 Adjust limit to setting above observed reading Main burners should reignite 5 Adjust thermostat to lowest setting Adjust limit to desired setting 58 K Adjust gas input rate to boiler Natural Gas 1 Adjust thermostat to highest setting 2 Check manifold gas pressu
130. vailable and required clearance from adjacent combustible building structure Vent pipe should be installed above bottom of chimney to prevent blockage 6 Vent pipe should slope upward from draft hood to chimney not less than one inch in four feet No portion of vent pipe should run downward or have dips or sags Vent pipe must be securely supported 7 Vent pipe must be inserted into but not beyond inside wall of chimney liner Seal tight between vent pipe and chimney If an Existing Boiler is Removed 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 appliances remaining connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance 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 blockage 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
131. val or reinstallation The homeowner will be responsible for the cost of removing and reinstalling the defective part or its replacement and all labor and material connected therewith Replacement material will be invoiced to the distributor in the usual manner and will be subject to adjustment upon proof of defect This warranty in no way can be considered as a guarantee of workmanship of an installer connected with the installation of the U S Boiler Company Inc boiler or as imposing on U S Boiler Company Inc liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed This warranty will not be applicable if the boiler is used or operated over its rated capacity or installed for uses other than home heating or is not maintained in accordance with U S Boiler Company Inc recommendation or accepted good practice as determined by hydronics industry standards This warranty will not be applicable if the boiler has been damaged as a result of being improperly serviced or operated including but not limited to the following operated with insufficient water allowed to freeze subject to flood conditions or operated with water conditions and or fuels or additives which cause unusual deposits or corrosion in or on the heat exchanger This warranty applies only to boilers installed within the United States and Canada In order for this wa
132. y to boiler may result in improper operation and damage to the boiler or structure Always assure gas piping is absolutely leak free and of the proper size and type for the connected load An additional gas pressure regulator may be needed Consult gas supplier A Size gas Piping Design system to provide adequate gas supply to boiler Consider these factors 1 Allowable pressure drop from point of delivery to boiler Maximum allowable system pressure 5 psig Actual point of delivery pressure may be less contact gas supplier for additional information Minimum gas valve inlet pressure 1s indicated on Rating Label located on the vestibule panel 2 Maximum gas demand Table 2 lists boiler input rate Also consider existing and expected future gas utilization equipment 1 e water heater cooking equipment Table 2 Rated Input Boiler Rated Capacity Gas Model cubic feet per hour Connection Natural LP Propane 105 IN10 315 126 IN11 1397 Gas connection size is 1 on IN10 and IN11 Continuous Ignition Standing Pilot 3 Length of piping and number of fittings Refer to Table 3 for maximum capacity of Schedule 40 pipe Table 4 lists equivalent length for standard fittings 4 Corrections for the specific gravity of natural gas can be found in Table 5 22 For materials or conditions other than those listed above refer to the National Fuel Gas Code NFPA 54 ANSI 7223 1 and or CAN C

Burnham Independence IN10 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents