Burnham Independence Operating And Service Instructions
,reliobnonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF
.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorp
rebmuNledoMrelioB
____-____NI_
rebmuNlaireSrelioB
_______6
etaDnoitallatsnI
rotcartnoCgnitaeH rebmuNenohP
sserddA
DNAGNITAREPO,NOITALLATSNI
ROFSNOITCURTSNIECIVRES
ECNEDNEPEDNI
®
RELIOBDERIF-SAG
8141049R23.5-4/07 Price - $3.00
The New York City Department of Buildings has approved the Independence® Series boiler:
REGNAD
noitautissuodrazahyltnenimminasetacidnI
,htaednitluserlliw,dediovatonfi,hcihw
ytreporplaitnatsbusroyrujnisuoires
.egamad
NOITUAC
noitautissuodrazahyllaitnetopasetacidnI
nitluseryam,dediovatonfi,hcihw
ytreporproyrujnironimroetaredom
.egamad
GNINRAW
noitautissuodrazahyllaitnetopasetacidnI
,htaednitluserdluoc,dediovatonfi,hcihw
ytreporplaitnatsbusroyrujnisuoires
.egamad
ECITON
,noitallatsninosnoitcurtsnilaicepssetacidnI
erahcihwecnanetniamro,noitarepo
yrujnilanosrepotdetalertontubtnatropmi
.sdrazah
NOITUAC
ecnonahtyltneuqerferomreliobsihtotretawddaotyrassecensiti,noitarepolamrongnirud,fI
metsysykaelA.skaelrofmetsysruoykcehcotnaicinhcetecivresdeifilauqatlusnoc,htnoma
netrohsyltnacifingisnachcihwreliobehtotdeilppusretawpu-ekamfoemulovehtesaercnilliw
ehtnehW.negyxodnaslarenimdevlossideraretawpu-ekamnideniartnE.reliobehtfoefileht
ehtdnatnemidessatuollafslarenimehtreliobehtnidetaehsiretawpu-ekamlooc,hserf
tnemidesfonoitalumuccaehT.efilreliobdecudernitlusernachtoB.sagasasepacsenegyxo
noritsacehtsneppahsihtnehW.noritsacehtgnitcatnocmorfretawehtetalosiyllautnevenac
ehtninegyxoeerffoecneserpehT.kcarcyllautneveyamdnatohylemertxestegaeratahtni
nac,hguonehgihsemocebnoitartnecnocehtfi,hcihwerehpsomtaevisorrocasetaercreliob
fotluseraerasepyteruliafesehtforehtienecniS.edisniehtmorfhguorhtnoritsacehtedorroc
tneverpottseretnitsebs'enoyrevenisiti,ylraelC.ylppatonseodytnarrawehttcefedgnitsaca
.sihteveihcaotdohtemtsebehtsiytirgetnimetsysfoecnanetniamehT.eruliaffoepytsiht
ECITON
.launamsihtfokcabehtnodetnirpsihcihwfoypoca,ytnarrawdetimilasahreliobsihT
yltcerroceraslortnocllatahteesotrotcartnocgnillatsniehtfoytilibisnopserehtsitI
.etelpmocsinoitallatsniehtnehwylreporpgnitarepoeradnadellatsni
llewsassecorpgnirutcafunamehtotdetubirttaebyamsnoitcesnoritsacnotsurecafruS
ehttceffatonseoddnalamronsitsurecafruS.egarotsgnirudnoitasnednocsa
reliobafoytivegnolroecnamrofrep
.
Approval No. MEA 154-93-E Vol. III.
The City of New York requires either a Licensed Master Plumber or a Fire Suppression Piping Contractor 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.
2
GNINRAW
ehtwolloF.ylefasetarepootecivresdnaecnanetniamralugerseriuqerreliobsihT
.launamsihtnideniatnocsnoitcurtsni
ytreporpesuacnacecnanetniamroecivres,noitaretla,tnemtsujda,noitallatsnireporpmI
erofeblaunameritneehtdnatsrednudnadaeR.efilfossolroyrujnilanosrep,egamad
ebtsumecivresdnanoitallatsnI.ecivresro,noitarepopu-trats,noitallatsnignitpmetta
.ycnegaecivresrorellatsnielbaegdelwonkdna,delliks,decneirepxenaybylnodemrofrep
.detnevylreporpebtsumreliobsihT
snoisivorperaerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenreliobsihT
.rianoitalitnevdnanoitsubmocetauqedarof
ehtfotratsehterofebdenaelcdnadetcepsniebtsummetsysgnitnevehtforoiretniehT
ynarofnosaesgnitaehehttuohguorhtyllacidoirepdetcepsniebdluohsdnanosaesgnitaeh
suoixonwollaotyrassecensimetsysgnitnevdetcurtsbonudnanaelcA.snoitcurtsbo
drawotetubirtnoclliwdnaylefastnevotefilfossolroyrujniesuacdluoctahtsemuf
.ycneiciffes'reliobehtgniniatniam
mirTdnagnipiPehteeS.dellatsnisievlav)feiler(ytefasasselnuetelpmoctonsinoitallatsnI
.sliatedroflaunamsihtfonoitceS
tondnanwodtuhsotreliobehtesuacyamhcihwsecivedytefashtiwdeilppussireliobsihT
metsysgnitaeheht,ytilibissopasisepipnezorfoteudegamadfI.ecivrestuohtiwtrats-er
dluohssmraladnasdraugefasetairporpparo;rehtaewdlocnidednettanutfelebtondluohs
.evitareponisireliobehtfiegamadtneverpotmetsysgnitaehehtnodellatsnieb
epipynawercsnutonoD.erusserprednumaetsroretawtohyrevsniatnocreliobsihT
gnirussaylevitisoptuohtiwreliobsihtfostnenopmocynatcennocsidottpmettaronsgnittif
tnempiuqednagnihtolcevitcetorpraewsyawlA.erusserponsahdnaloocsiretaweht
noylertonoD.seirujnidlacstneverpotreliobsihtgnicivresropugnitrats,gnillatsninehw
ehtfoerutarepmetdnaerusserpehtenimretedotseguagerutarepmetdnaerusserpeht
sireliobehtnehwtohyrevemocebhcihwstnenopmocsniatnocreliobsihT.reliob
.loocerayehtsselnustnenopmocynahcuottonoD.gnitarepo
,animulaniatnocleufehtdnanoitsubmocfostcudorp,noitcurtsnocfoslairetamrelioB
rocixotrehtoro/dnasedyhedla,sedixonegortin,edixonomnobrac,slatemyvaeh,acilis
ehtotnwonkerahcihwdnayrujnisuoiresrohtaedesuacnachcihwsecnatsbuslufmrah
esusyawlA.mrahevitcudorperrehtodnastcefedhtrib,recnacesuacotainrofilaCfoetats
ehtybraengnikrowrognicivresnehwtnempiuqednasrotaripser,gnihtolcytefasreporp
.ecnailppa
.htaedroyrujnilanosrepesuacnacredroreporpehtnisnoitcurtsnillawollofoteruliaF
slaunamsrerutcafunamtnenopmocnideniatnocesohtllagnidulcni,snoitcurtsnilladaeR
rogniniatniam,gnitarepo,pugnitrats,gnillatsnierofebreliobehthtiwdedivorperahcihw
.gnicivres
elbammalfrehtodnaenilosag,slairetamelbitsubmocmorfeerfdnaraelcaerareliobpeeK
.sdiuqilrosropav
.semitllataecalpniebtsumsdraugdnaserusolcne,setalprevocllA
NOITUAC
esehthguohtlA!ecnanetniamdnanoitcepsnilaunnaeriuqersecivedffotucretawwolepyteborP
ehtninoitanimatnocelbissopotdesopxesieborpeht,noitareporiehtnietatsdiloserasecived
,etelpmocrofsnoitcurtsnIecivreSffotuCretaWwoLotrefeR.gniluofottcejbusdnaretawreliob
.snoitcurtsnigninaelcdnanoitcepsnipets-yb-pets
3
Figure 1: Dimensional Drawing
4
Dimensional Data
relioB
ledoM
.xorppA
gnippihS
thgieW
.sbL
)sehcnini(snoisnemiD
dednemmoceR
dnuoR.niM
eziSyenmihC
)thgieHxretemaiD(
)1(
saG
.nnoC
)TPN(
).laG(emuloVretaW
'A' 'B' 'C' 'D' 'E' 'F' 'G'
maetS
relioB
retaW
relioB
)3(
3NI 053 2/1-41
04
4/3-33 4
4/1-04
4/3-4
4/1-7 .tf51x"4
"2/1
1.5 8.7 9.3
4NI 024 4/3-71 4/3-43 5 8/7-8 .tf51x"5 5.6 0.01 0.5
5NI 584 12
4/3-53 6 4/1-5
2/1-01
.tf51x"6
9.7 2.21 1.6
ASU6NI
555 ¼42 8/1-21
3.9
4.41 2.7
adanaC6NI
4/3-63 7
2/1-7
.tf51x"7
7NI 026 2/1-72 4/3-31
"4/3
7.01 6.61 3.8
ASU8NI
096 4/3-03 8/3-51 1.21 8.81 4.9
adanaC8NI
4/3-73
8 .tf51x"89NI 067 43 71 5.31 0.12 5.01
ASU01NI
518 ¼73
54 4/3-83 2/1-54
8/5-81
"4/3
)2(
9.41 2.32 6.11
01NI
adanaC
9 .tf51x"9
11NI 588 2/1-04 4/1-02 3.61 4.52 7.21
21NI 559 4/3-34 8/7-12 "1 7.71 6.72 8.31
.yenmihCfopototgninepodooHtfarDfomottobmorfsithgiehyenmihc'51)1(
.TPN1si)toliPgnidnatS(noitingIsuounitnoC11NI-01NInoezisnoitcennocsaG)2(
levelffotucretawwolot)levelretawlamron(LWNmorfemulovretaw:"emulovretawelbamaets"s'reliobmaetS)3(
Heating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water)
Table of Contents
I. Pre-Installation ...............................7
II. Knockdown Boiler Assembly ..........
III. Semi-Pak Boiler Assembly ............
IV. Packaged Boiler Assembly ............
V. Piping and Trim ...........................
VI. Gas Piping ....................................
9
13
16
17
23
VII. Venting .........................................
VIII. Electrical .......................................
IX. System Start-up ............................
X. Service Instructions ......................
XI. Repair Parts ..................................
XII. Appendix
Low Water Cut Off (LWCO) .......
25
27
60
73
79
102
5
Figure 2: Section Tappings
gnippaT
eziS
)TPN(
eborPhtiwrelioBmaetS
.O.C.W.L
htiwrelioBmaetS
.O.C.W.LtaolF
relioBretaW
sselknaThtiwrelioBretaW
retaeH
A 2 ylppuS ylppuS ylppuS ylppuS
B ½
¼othsuB
eguaGerusserP
gulP gulP gulP
C ½ ssalGeguaG
,eguaGnoinU½&elppiN
,woblEteertS.O.C.W.L
timiL&nohpyS
hsuBgnippaTrewoLgulP
gnippaTreppU¼ot
eguaG.pmeT/.sserP
othsuBgnippaTrewoLgulP
gnippaTreppU¼
eguaG.pmeT/.sserP
D 2 nruteR nruteR
,woblE,lpN"3,½1othsuB
,egnalF.criC,lpN"2
nruteRrotalucriC,teksaG
,woblE,lpN"3,½1othsuB
,egnalF.criC,lpN"2
nruteRrotalucriC,teksaG
E ¾
woblEteertS&elppiN"3
evlaVfeileRytefaS
woblEteertS&elppiN"3
evlaVfeileRytefaS
woblEteertS&elppiN"3
evlaVfeileRytefaS
woblEteertS&elppiN"3
evlaVfeileRytefaS
F 2
evlaVniarD¾othsuB
nruteRlanoitpOro/dna
evlaVniarD¾othsuB
nruteRlanoitpOro/dna
ro/dnaevlaVniarD¾othsuB
nruteRytivarGlanoitpO
ro/dnaevlaVniarD¾othsuB
nruteRytivarGlanoitpO
G 2
)6-3NI(deggulPyrotcaF
)6-3NI(ylppuSlanoitpO
)21-7NI(ylppuSderiuqeR
)6-3NI(deggulPyrotcaF
)6-3NI(ylppuSlanoitpO
)21-7NI(ylppuSderiuqeR
)6-3NI(deggulPyrotcaF
)21-7NI(gulP
ylppuSytivarGlanoitpO
)6-3NI(deggulPyrotcaF
)21-7NI(gulP
ylppuSytivarGlanoitpO
H ¾
nohpyS&¼othsuB
timiL
¼othsuB
eguaGerusserP
lleW
timiL
lleW
timiL
J ¾ elbacilppAtoN elbacilppAtoN elbacilppAtoN retaeHsselknaT
K ¾ ffotuCretaWwoL gulP gulP gulP
L 1
deggulPyrotcaF
ffO-wolBecafruS
deggulPyrotcaF
ffO-wolBecafruS
deggulPyrotcaF deggulPyrotcaF
M ¼1
deggulPyrotcaF
nruteRecnaillA
deggulPyrotcaF
nruteRecnaillA
deggulPyrotcaF deggulPyrotcaF
N ¼1
deggulPyrotcaF
ylppuSecnaillA
deggulPyrotcaF
ylppuSecnaillA
deggulPyrotcaF deggulPyrotcaF
P ¾
deggulPyrotcaF
timiLecnaillA
deggulPyrotcaF
timiLecnaillA
deggulPyrotcaF deggulPyrotcaF
Table 1: Trim and Control Installation in Section Tappings
6
I. Pre-Installation
GNINRAW
rianoitalitnevdnanoitsubmocetauqedA
reporperussaotdedivorpebtsum
.noitsubmoc
GNINRAW
snoitcurtsniesehtwolloftonoduoyfI
tluseryamnoisolpxeroerifa,yltcaxe
lanosreproegamadytreporpgnisuac
.yrujni
REGNAD
rehtoroenilosagerehwreliobllatsnitonoD
fosecruosro,sdiuqilrosropavelbammalf
,srenaelc,sehcaelb.e.i(snobracordyh
cirbaf,srevomertniap,syarps,slacimehc
.derotsrodesuera).cte,srenetfos
ECITON
,reliobehtfotnetnocretawwolehtoteuD
ehtotdragerhtiwreliobehtfognizis-sim
evissecxenitluserlliwdaolmetsysgnitaeh
tnenopmocdetareleccadnagnilcycreliob
tnarrawTONSEODmahnruB.eruliaf
reliobdezis-simybdesuacseruliaf
otreliobehtezisrevoTONOD.snoitacilppa
.metsyseht
ordinance. See Figure 3 for minimum listed clearance
to combustible material. Recommended service
clearance is 24 inches from left side, right side, and
front. Additional 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 oor as close to chimney as
possible. For basement installation provide a solid base,
such as concrete, steel or masonry if oor is not level or
if water may be encountered on oor around boiler.
F. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, control
replacement, etc.).
G. 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/CGA B149 Installation Codes, Sections 7.2, 7.3
or 7.4.
A. Inspect shipment carefully for any signs of damage. All
equipment is 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 led
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/
CGA B149 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, ANSI/ASME
No. CSD-1.
C. Appliance is design certied for installation on
combustible ooring. Boiler must not be installed on
carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local re
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned 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
7
Figure 3: Clearance to Combustible Materials
c. Caulking or sealants applied in joints around
window and door frames, between sole plates
and oors, between wall-ceiling joints, between
wall panels, at plumbing and electrical
penetrations, and at other openings.
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.
6. For boiler located within unconned space in
building of unusually tight construction or within
conned space, provide outdoor air through two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 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
shall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1 square
inch per 2,000 Btu per hour input of all
8
equipment in space. Duct cross-sectional area
shall be same as opening free area.
Alternate method for boiler located within conned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcient volume such that combined volume of all
spaces meet criteria for unconned 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.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be xed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
H. Do not install boiler where gasoline or other ammable
vapors or liquids, or sources of hydrocarbons (i.e.
bleaches, cleaners, chemicals, sprays, paint removers,
fabric softeners, etc.) are used or stored.
II. Knocked-Down Boiler Assembly
GNINRAW
ebdluohsreliobsihtfonoitallatsnI
delliksdnadeniartybylnonekatrednu
.ycnegaecivresdeifilauqamorflennosrep
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: PreInstallation).
B. Install assembled cast iron sections on base assembly:
1. Install (4) 5/16" x ¼" self-tapping screws through
(4) holes in upper base ange with screw heads on
underside of ange. Note: Screws are located in
ber gasket parts bag.
2. Install ceramic ber gasket. See Figure 4.
4. Loosen nuts on tie rods until only nger 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 at 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 ll valve and piping to return tapping and
purge valve to supply tapping. See Figure 6.
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 ber gasket. Secure with 5/16"
locknuts and washers provided. See Figure 5.
Figure 5: Section Assembly Attachment
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.
9
D. Install Canopy.
1. Install ½" thick x 1" wide ceramic ber gasket. See
Figure 7.
Figure 7: Canopy Gasket Installation
2. Position canopy on ceramic ber gasket. See Figure
8.
3. Attach canopy using ¼" 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.
F. 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 ange of canopy and rest
on oor. Position rear panel and secure to jacket side
panels with sheet metal screws. For Models IN10IN12, secure jacket upper rear panels to side panels
with sheet metal screws.
3. Secure both jacket 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.
Figure 8: Canopy Installation
10
Figure 9: Jacket Assembly
9. Install front removable door by engaging upper side
edges of panel with side receiving anges, sliding
up and under top panel ange - seating front door
fully - then sliding down to engage bottom ange
behind lower front tie bar.
G. Install Pilot/Burner Assembly (shipped in Gas
Controls Carton). See Figure 10.
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 orice.
NOTE: The burner to the right may need to
be lifted from the orice to install pilot/
burner assembly. Reinstall lifted burner
over the orice.
c. Reinstall burner access panel.
H. Install Gas Valve on main gas burner assembly (if not
factory assembled). See Figure 11, 12, 13, 14 or 15.
1. Connect gas valve to manifold.
2. Connect pilot tubing from pilot burner to gas valve
pilot tapping.
3. Continuous Ignition (standing pilot): connect
thermocouple to gas valve.
Figure 12: Pilot and Gas Piping, Continuous
Ignition (Standing Pilot) (IN10 through IN12 Only)
Figure 13: Pilot and Gas Piping, Intermittent
Ignition (EI) (IN3 through IN11 Only)
Figure 11: Pilot and Gas Piping, Continuous
Ignition (Standing Pilot) (IN3 through IN9 Only)
Figure 14: Pilot and Gas Piping, Intermittent
Ignition (EI) (IN12 Only)
11
Figure 15: Pilot and Gas Piping, Intermittent
Ignition (HSP) (IN3 Through IN9)
I. Install Blocked Vent Switch with sheet metal screws.
1. Models IN3 - IN9. Install on rear ange of canopy.
See Figure 16.
2. Models IN10 - IN12. Install on right side of draft
hood. See Figure 17. Reset switch must face away
from draft hood relief opening.
Figure 17: Blocked Vent Switch Installation,
IN10 through IN12
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.
5. Insert harness through ¾ inch hole in right side
jacket panel. Secure with strain relief bushing
Figure 16: Blocked Vent Switch Installation,
IN3 through IN9
J. Intermittent Ignition (EI): Install Ignition Module.
1. Mount ignition module mounting bracket to inside
of right side panel using (2) #6 x ¾" sheet metal
screws provided.
2. Mount ignition module to bracket using (2) #8 x ½"
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.
12
III. Semi-Pak Boiler Assembly
GNINRAW
ebdluohsreliobsihtfonoitallatsnI
delliksdnadeniartybylnonekatrednu
.ycnegaecivresdeifilauqamorflennosrep
ECITON
aniyrucremniatnocstimiLerusserPA404L
oD.ebutdelaes ton hsartehtnitimilecalp
.efillufesustifodneehtta
sniatnoctahttimilagnicalpersitimilsihtfI
od,ebutdelaesaniyrucrem ton ruoyecalp
.hsartehtnitimildlo
tnemeganametsawlacolruoytcatnoC
gnidragersnoitcurtsnirofytirohtua
sihtfolasopsidreporpehtdnagnilcycer
niyrucremgniniatnoctimildlonaforo,timil
.ebutdelaesa
ta.cnIllewyenoHllac,snoitseuqevahuoyfI
.2051-864-008-1
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 oor. Do not bump boiler jacket against
oor.
3. Do not drop boiler at any time.
B. Move Boiler To Permanent Position. Refer to Section
I: Pre-Installation.
C. 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:
l. 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.
D. 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 "H"
with siphon, ¾" x ¼" hex bushing, ¾" elbow and
¾" x 3" nipple provided. See Figures 1 and 2.
DO NOT TWIST CONTROL. Use wrench on
hex tting located at bottom of control. See
Figure 18A or 18B.
b. Level the L404A pressure limit by carefully
bending the syphon until the limit's leveling
indicator hangs freely with its pointer directly
over the index mark inside the back of the case.
See Figure 18A.
c. The L404F pressure limit employs a snap action
switch and does not require leveling. See Figure
18B.
d. Install pressure gauge into Tapping "B" (½ NPT
bushed to ¼ NPT). 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.
e. Install Low Water Cutoff Probe into Tapping "K"
(¾ NPT). HANDLE PROBE WITH CARE.
f. Attach Low Water cutoff Control to Probe by
following instructions packed with control.
g. Install gauge glass ttings into Tappings "C"
(½ NPT). See Figures 1 and 2. Lower tting has
small drain valve.
Figure 18A: L404A Pressure Limit Control
Figure 18B: L404F Pressure Limit Control
13
h. Install gauge glass and protective rods in ttings.
i. Attach "Lowest Permissible Water Level" Plate
with sheet metal screws in location indicated in
Figure 9.
j. Attach "Frequent Water Addition" Label above
the "Lowest Permissible Water Level" Plate.
2. Steam Boiler with McDonnell & 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" (½ NPT). See Figure 1 and 2.
ii. Attach Gauge Glass/Low Water Cutoff
Assembly to union halves.
iii. Afx 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 tting located at
bottom of control.
c. Level the L404A pressure limit by carefully
bending the syphon until the limit's levelling
indicator hangs freely with its pointer directly
over the index mark inside the back of the case.
See Figure 18A.
d. The L404F pressure limit employs a snap action
switch and does not require leveling. See Figure
18B.
e. Install pressure gauge into Tapping "H" (¾ NPT
bushed to ¼ NPT). 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.
f. Attach "Lowest Permissible Water Level" Plate
with sheet metal screws in location indicated in
Figure 9.
g. Attach "Frequent Water Addition" Label above
the "Lowest Permissible Water Level" Plate.
3. All Steam Boilers and Water Boilers except
"EZW" and "WC" Controls Cartons
a. Install Junction Box. See Figure 19A.
i. Remove center knockout in rear of Junction
Box and insert black plastic snap bushing in
hole.
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.
iv. Install Junction Box to jacket from inside
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 19B.
Figure 19B: Junction Box and Transformer
Assembly
c. Fork connector on yellow and blue (HSP only)
wire(s) 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.
Figure 19A: Junction Box and Mounting Bracket
Assembly
14
Figure 20: Thermostat Isolation Relay Attachment
e. Water with tankless heater only (EZWT and
WCT). Secure R8225D relay to Junction Box.
See Figure 1.
Water Boiler
4.
a. Install Temperature/Pressure Gauge into upper
Tapping "C" (½ NPT bushed to ¼ 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.
b. Install hot water temperature limit and/or
combination control. Remove well from control.
Screw well into Tapping "H" (¾ NPT). See
Figure 1 and 2. Install bulb in well as far as
possible, then tighten set screw.
c. On boilers equipped with a circulator without
tankless heater in areas where condensation of
ue gases is encountered in boiler ueways, a
reverse-acting circulator control should be
installed in supply as close as possible to boiler
in order to avoid condensation.
E. Continue to Section IV. Packaged Boiler Assembly,
Paragraph E.
15
IV. Packaged Boiler Assembly
GNINRAW
ebdluohsreliobsihtfonoitallatsnI
delliksdnadeniartybylnonekatrednu
.ycnegaecivresdeifilauqamorflennosrep
GNINRAW
ynaecalprodoohtfardreliobretlatonoD
ehtnirepmaddevorppa-nonronoitcurtsbo
egallipssageulF.metsystnevrognihceerb
lliwnoitacifitrecCLTE/LTE.rucconac
.diovemoceb
A. Remove crate and move boiler to permanent position
as detailed in Section III: Semi-Pak Boiler Assembly.
B. Remove Jacket Front Panel. See Figure 50.
C. Remove poly bag from vestibule area.
D. On Steam 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
tting at bottom of control. See Figures 18A or
18B.
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.
E. Install Jacket Front Panel.
F. Install Draft Hood. Models IN3 through IN9.
1. Locate and open "Rear Draft Hood Carton".
2. Position Draft Hood on Canopy Rear Flange. See
Figure 21. Top canopy ange must fully engage
"U"-shaped draft hood ange for proper installation
and operation. Care must be taken to assure that
draft hood is level.
3. Secure Rear Draft Hood to Canopy with wing nuts
provided. See Figure 22.
Figure 21: Draft Hood Attachment
Figure 22: Securing Draft Hood to Canopy
16
V. Piping and Trim
GNINRAW
tsumgnipipegrahcsidevlav)feiler(ytefaS
erevesfolaitnetopehttahthcusdepipeb
ynaniepipTONOD.detanimilesisnrub
TONOD.ruccodluocgnizeerferehwaera
.spacrosgulp,sevlavffo-tuhsynallatsni
egrahcsidreporprofsedoClacoLtlusnoC
.tnemegnarragnipip
GNINRAW
roreliobotegamaddnanoitareporeporpminitluseryamreliobepipylreporpoteruliaF
.erutcurts
ECITON
hserfnieiT.tluserlliwnoisorrocreliobdetareleccA.sreliobmaetsniretawdenetfosesutonoD
.renetfosretawafomaertspureliobehtotylppusretaw
dna,stnenopmocreliobleetsdnanorifonoisorrocesuaclliwretawreliobfonoitanimatnocnegyxO
negyxoybdesuacsmelborprevoctonseodytnarraWdradnatSs'mahnruB.eruliafreliobotdaelnac
.retawfonoitiddatneuqerfybdesuacpu-dliub)emil(elacsroretawreliobfonoitanimatnoc
:gnipipreppocfoscitsiretcarahcgniwollofehtredisnoc,gnipipmaetsrofreppocgnisuerofeB
)1 esuacdnasessertslacinahcemecudninacnoisnapxelamrehtfotneiciffeochgih
,noitallatsnidnangisedmetsysgnipipehtnirofdetnuoccatonfisesionnoitcartnoc/noisnapxe
)2 ehtnidedulcniebtsumgnipipreppocdetalusninufo)ssoltaeh(etarrefsnarttaehhgih
,reliobehtezisotdesusrotcafpukcipdnagnipiplamron
)3 ,refsnarttaehroopesuacnacmetsysehtnipudnetahtsexulfdnasetsapgnizarbrogniredlos
tuoliobehtgniruddevomerylhguorohttonfimaetstewdnaenilretawydaetsnuna,gnigrus
,dnaerudecorp
)4 retawniatrecnislatemralimissidoteudruccoyamlatemgniniojdaehtfonoisorroccinavlag
.desutonerasnoinucirtceleidfiseirtsimehc
A. Design and install boiler and system piping to prevent
oxygen contamination of boiler water. Sources of
oxygen contamination are system leaks requiring
addition of makeup water, ttings, and oxygen
permeable materials in distribution system. Eliminate
oxygen contamination by repairing system leaks,
repairing ttings, using nonpermeable materials in
distribution system, and eliminating open tanks in
system, or isolating boiler from system with heat
exchanger.
B. Install Safety (Relief) Valve in Tapping "E" (¾ NPT).
See Figure 23. Use ¾ NPT x 3" nipple and ¾ NPT
elbow provided. Safety (Relief) Valve must be installed
with spindle in vertical position.
Figure 23: Trim Installation
C. Install Drain Valve in Tapping "F" (2 NPT bushed to
¾ NPT). See Figure 23.
D. Connect supply and return piping to heating system.
Maintain minimum ½ 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.
3. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled
medium piped in parallel with heating boiler using
appropriate valves to prevent the chilled medium
from entering the boiler. See Figure 26. Also
consult I=B=R Installation and Piping Guides.
4. If boiler is connected to heating coils located in air
handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
ow control valves to prevent gravity circulation of
boiler water during cooling system operation.
17
ECITON
enilretaw,esionmetsysevissecxenitluseryamlaunamsihtnideificepssareliobepipoteruliaF
.revoyrracretawdnasnoitautculf
Figure 24: Steam Boiler Piping (Minimum)
18
Figure 25: Recommended Water Piping for Circulator Zoned Heating System
19
20
Figure 25A: Recommended Water Piping for Zone Valve Zoned Heating System
Figure 26: Recommended Piping for Combination
GNINRAW
sselknattaevlavgniximcitamotuallatsnI
rosnrubfoksirdiovaotteltuoretaeh
taretawtohylevissecxeoteudgnidlacs
.serutxif
Heating and Cooling (Refrigeration) Systems
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" (1¼ NPT) and return
piping to Tapping "M" (1¼ 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" (¾ NPT). See Figure 2. Set at 180°F to
prevent steam production during non-space
heating periods.
Figure 27: Recommended Piping for
Indirect Water Heater
5. Use boiler bypass if boiler is operated in system
which has a large volume or excessive radiation
where low boiler water temperatures may be
encountered (i.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 regulate water ow 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. If a tankless heater coil is used, connect water lines
to ¾ NPT tappings in coil plate.
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 xtures.
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.
2. Install ow 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.
21
G. If a long term pressure test of the hydronic system is
required, the boiler should rst be isolated to avoid a
pressure loss due to the escape of air trapped in the
boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must rst be removed from the
boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained
trapped air.
22
VI. Gas Piping
GNINRAW
otylppussagepipylreporpoteruliaF
dnanoitareporeporpminitluseryamreliob
syawlA.erutcurtsroreliobehtotegamad
eerfkaelyletulosbasignipipsagerussa
ehtrofepytdnaezisreporpehtfodna
.daoldetcennoc
yamrotalugererusserpsaglanoitiddanA
.reilppussagtlusnoC.dedeeneb
GNINRAW
nosdnuopmocdaerhtreporpesuoteruliaF
foskaelnitluseryamsrotcennocsaglla
.sagelbammalf
GNINRAW
ebtsummetsysdnareliobotylppussaG
rognillatsniotroirpffotuhsyletulosba
.gnipipsagreliobgnicivres
relioB
ledoM
rebmuN
yticapaCdetaR
]ruohrepteefcibuc[
saG
noitcennoC
eziS
larutaN enaporP/PL
3NI 26 ¾42 ½
4NI 501 24 ½
5NI 041 65 ½
6NI 571 07 ½
7NI 012 48 ¾
8NI 542 89 ¾
9NI 082 211 ¾
01NI 513 621 *¾
11NI 943 ½931 *¾
21NI 583 451 1
11NIdna01NIno"1siezisnoitcennocsaG*
)toliPgnidnatS(noitingIsuounitnoC
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 is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure is 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 (i.e. water heater, cooking
equipment).
Table 2: Rated Input
jurisdiction species a gravity factor be applied. For
specic gravity greater than 0.70, apply gravity
factor from Table 5. If exact specic gravity is not
shown choose next higher value.
For materials or conditions other than those listed
above, refer to the National Fuel Gas Code, NFPA
54/ANSI Z223.1 and/or CAN/CGA B149
Installation Codes, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
B. Connect boiler gas valve to gas supply system.
1. 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/CGA B149 Installation Codes.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liqueed 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.
3. Length of piping and number of ttings. Refer to
Table 3 for maximum capacity of Schedule 40 pipe.
Table 4 lists equivalent length for standard ttings.
4. Specic gravity of gas. Gas piping systems for gas
with a specic gravity of 0.70 or less can be sized
directly from Table 3, unless authority having
Figure 29: Recommended Gas Piping
23
4. All above ground gas piping upstream from manual
REGNAD
semalfnepo,seldnac,sehctamesutonoD
.skaelrofkcehcotecruosnoitingirehtoro
ECITON
neebevahlevelaesevobateef000,2nahtretaergsedutitlatanoitallatsniroftliubsreliobASU
ehtreplevelaesevobateef000,1reptnecrep4etartupnisagecuderotdecifiroyllaiceps
'sreliobnaidanaC.FxidneppAdna2.1.8noitceS,1.322ZISNA/45APFN,edoCsaGleuFlanoitaN
ehtybelbaifitnedierasledomreliobedutitlahgiH.lebalgnitarehtnodetacidnisignizisecifiro
:lebalgnitarehtnoxiffusrebmunledomehtnitigiddriht
noitavele.tf0002nahtssel2__-___NI_
)adanaC(noitavele.tf0054ot00024__-___NI_
)ASU(noitavele.tf0005ot00025__-___NI_
htgneL
]teeF[
porDerusserP.c.whcni3.0 porDerusserP.c.whcni5.0
½ ¾ 1 ¼1 ½ ¾ 1 ¼1
01 231 872 025 050,1 571 063 086 004,1
02 29 091 053 037 021 052 564 059
03 37 251 582 095 79 002 573 077
04 36 031 542 005 28 071 023 066
05 65 511 512 044 37 151 582 085
06 05 501 591 004 66 831 062 035
07 64 69 081 073 16 521 042 094
08 34 09 071 053 75 811 022 064
09 04 48 061 023 35 011 502 034
001 83 97 051 503 05 301 591 004
gnittiF
eziSepiPlanimoN
½ ¾ 1 ¼1
llE°54 7.0 1 2.1 6.1
llE°09 6.1 1.2 6.2 5.3
sA(eeT
)woblE
1.3 1.4 2.5 9.6
cificepS
ytivarG
noitcerroC
rotcaF
cificepS
ytivarG
noitcerroC
rotcaF
05.0 01.1 03.1 70.1
55.0 40.1 04.1 40.1
06.0 00.1 05.1 00.1
56.0 69.0 06.1 79.0
07.0 39.0 07.1 49.0
57.0 09.0
08.0 78.0
gas valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as a grounding electrode. Refer to the
National Electrical Code, ANSI/NFPA 70 and/or
CSA C22.1 Electrical Code.
C. Pressure Test. The boiler and its gas connection must
½ psig or less, isolate boiler from gas supply piping
by closing boiler's individual manual shut-off valve.
2. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method. Check that boiler gas piping valves, and all
other components are leak free. Eliminate any
leaks.
be leak tested before placing boiler in operation.
1. Protect boiler gas valve. For all testing over ½ psig,
boiler an its individual shut-off valve must be
disconnected from gas supply piping. For testing at
Table 3: Maximum Capacity of Schedule 40 Pipe in CFH for Gas Pressures of 0.5 psig or Less
Table 4: Fitting Equivalent Lengths
24
Table 5: Specic Gravity Correction Factors
VII. Venting
REGNAD
gnillatsnierofebyenmihcgnitsixetcepsnI
detarofrepecalperronaelcoteruliaF.reliob
royrujnierevesesuaclliwgninilelitroepip
.htaed
GNINRAW
eraerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenecnailppasihT
.rianoitalitnevdnanoitsubmocetauqedarofsnoisivorp
-erPehtnideniatnocsnoitcirtsernoitcurtsnirianoitsubmocwollofdnadnatsrednu,daeR
.launamsihtfosnoitcurtsninoitallatsnI
fosecruosro,sdiuqilrosropavelbammalfrehtoroenilosagerehwecnailppaetarepotonoD
,srenetfoscirbaf,srevomertniap,syarps,slacimehc,srenaelc,sehcaelb.e.i(snobracordyh
.riaehtnitneserpro/dnaderots,desuera).cte
NOITUAC
lortnocotrepmadtnevenoesutonoD
.secnailppagnitaehowt
rofecnaraelcetauqedaedivorP
ecnaraelcmuminim"6-gnicivres
elbitsubmocdnarepmadneewteb
.noitcurtsnoc
ECITON
ehtrevorepmadtnevehtecrofTONOD
.rallocdoohtfardehtnodaebdellor
ehtnotserdluohsrepmadtnevehT
.daebdellor
,snoitacificepsehtotreferesaelP
elbuortdnasnoitcurtsninoitallatsni
tnevehtnidekcapediuggnitoohs
deliatedetelpmocrofnotracrepmad
.snoitcurtsninoitallatsni
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
7, Venting of Equipment and/or CAN/CGA B149
Installation Codes, Part 5, Venting Systems and Air
Supply for Appliances. Install any of the following for
this Independence Series Category I, draft hood
equipped appliance:
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, ANSI/NFPA 211 and/or
National Building Code of Canada.
Masonry chimney must be lined with approved clay
ue lining or listed chimney lining system except as
provided in ANSI Z223.1/NFPA 54, Paragraph
7.5.4(a): 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 efciency.
3. Single wall metal vent. Allowed by ANSI Z223.1/
NFPA 54 under very restrictive conditions.
B. Inspect chimney and remove any obstructions or
restrictions. Clean chimney if previously used for solid
or liquid fuel-burning appliances or replaces.
C. Boiler Equipped With Vent Damper
1. Open Vent Damper Carton and remove Installation
Instructions. Read Installation Instructions
thoroughly before proceeding.
2. Vent damper should be same size as draft hood
outlet. See Figure 1. Unpack vent damper carefully
- DO NOT FORCE CLOSED! Forcing vent
damper may damage gear train and void warranty.
Vent damper assembly includes pre-wired
connection harness with polarized plug for use on
all 24V standing pilot or intermittent ignition (EI or
HSP) control systems.
3. Mount vent damper assembly on draft hood without
modication to either (Refer to instructions packed
with vent damper for specic instructions). Vent
damper position indicator to be visible to users.
4. U.S.A. - Do not install Non-listed vent damper or
other obstruction in vent pipe.
Canada - Do not install Non-listed vent damper or
other obstruction in vent pipe.
25
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 replace.
2. Vent pipe to chimney must not be smaller than outlet
on draft hood or vent damper. Type B is
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 50% 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
available 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.
E. 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
deciencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
replace dampers.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use the
ame of a match or candle, or smoke from a
cigarette, cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas-burning appliance to their previous
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/ANSI Z223.1. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 11 in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.
26
Figure 30: Typical Vent Installation
VIII. Electrical
REGNAD
ronoitallatsnignitpmettaerofebderewopnuerasnoitcennoclacirtcelellaerussaylevitisoP
lacirtcelellatuokcoL.gnidliubroreliobehtfosnoitcennocrostnenopmoclacirtcelefoecivres
.ffodenrutsirewopecnokcoldaphtiwsexob
GNINRAW
lacisyhpsuoiresnitluseryamreliobehtotsnoitcennoclacirtceleeriwylreporpoteruliaF
.mrah
erofebffosirewopllaerusekaM.ecruosenonahterommorfebyamrewoplacirtcelE
.krowlacirtceleynagnitpmetta
.tcennocsiddesufdezisylreporpahtiwdetcetorpebtsumreliobhcaE
.slortnocgnitareporoytefasynaevitareponiekamrotuopmujreveN
A. 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.
B. 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 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.
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 exible 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.
Figure 31: Vent Damper Connection Detail
d. Install cable clamp around exible Vent Damper
Harness. Attach to jacket top panel. See Figure
32.
C. Install thermostat. Locate on inside wall
approximately 4 feet above oor. Do not install on
outside wall, near replace, or where inuenced by
drafts or restricted air ow, hot or cold pipes, lighting
xtures, television, or sunlight. Allow free air
movement by avoiding placement of furniture near
thermostat.
27
Set heat anticipator to match system requirements. See
epyTmetsyS
metsySnoitingI
taeH
rotapicitnA
)1(gnitteS
suounitnoC
)toliPgnidnatS(
)IE(tnettimretnI )PSH(tnettimretnI
eborPhtiwmaetS
ro208-SPrelliM&llennoDcM(
)004-BGClevelordyH
ffotuCretaWwoL
egaP,53erugiF
03
3egaP,63erugiF
2
3egaP,73erugiF
4
8.0
taolFhtiwmaetS
)76relliM&llennoDcM(
ffotuCretaWwoL
3egaP,83erugiF
6
3egaP,93erugiF
8
egaP,04erugiF
04
8.0
)noitalucriCtnettimretnI(retaW
4egaP,14erugiF
2
4egaP,24erugiF
4
4egaP,34erugiF
6
3.0
)noitalucriCytivarG(retaW
4egaP,44erugiF
8
egaP,54erugiF
05
5egaP,64erugiF
2
3.0
retaeHsselknaThtiwretaW
5egaP,74erugiF
4
5egaP,84erugiF
6
5egap,94erugiF
8
6.0
1.0ybgnittesrotapicitnataehecuder,gnitteserutarepmets'tatsomrehtevobataehrevootsdnetmetsysfI)1(
taehesaercni,erutarepmetmoorderisedgnihcaertuohtiwelcyctrohsotsdnetmetsysfI.spma2.0ro
.spma2.0ro1.0ybgnittesrotapicitna
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.
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.
2. Water with intermittent circulation and without
tankless heater. Connect one wire from thermostat
to Terminal "T" and additional wire to terminal
"TV".
E. Alliance Indirect Water Heater (if used).
1. For wiring refer to wiring diagrams located in this
section and Alliance Installation Operating and
Service Instructions.
2. Attach junction box extension (4 - 11/16 square) to
junction box on boiler.
3. Steam Boilers only. Verify temperature limit
(Honeywell L4006 or equal, which is installer
supplied) is installed in Tapping "P", refer to
Section V: Piping and Trim.
F. Wire control circuit as shown in the appropriate
wiring diagram. See Table 6.
1. A separate electrical circuit must be run from the
main electrical service with an over-current device/
disconnect in the circuit. A service switch is
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 control. Consult zone valve manufacturer
for assistance.
G. Wiring diagram and sequence of operation. Locate
the system type you are interested in from Table 6, then
refer to the page indicated.
Vent Damper Sequence of Operation. See Figure
1.
34.
a. Vent Damper is continuously powered at
Terminal 1.
b. When there is a call for heat, the damper relay
coil is energized through Terminal 5 if all limits
ahead of the damper are satised.
c. Relay coil closes contacts, energizing damper
motor, causing damper to open.
d. When the damper blade reaches the fully open
position, power is sent back to the boiler limit/
ignition circuit through Terminal 2 and the
damper motor is de-energized.
e. When the call for heat is satised, 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.
Table 6: Thermostat Heat Anticipator Settings
28
Figure 33: Vent Damper Harness to Limit
Figure 34: Vent Damper Schematic Wiring Diagram
29
30
Figure 35: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low Water Cutoff
Loading...