Burnham Independence Operating And Service Instructions

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RELIOBDERIF-SAG

8141049R23.5-4/07 Price - $3.00

The New York City Department of Buildings has approved the Independence® Series boiler:

REGNAD

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ECITON

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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.

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Figure 1: Dimensional Drawing

Dimensional Data

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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 ....................................

VII. Venting .........................................

VIII. Electrical .......................................

IX. System Start-up ............................

X. Service Instructions ......................

XI. Repair Parts ..................................

XII. Appendix

Low Water Cut Oﬀ (LWCO) .......

102

Figure 2: Section Tappings

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Table 1: Trim and Control Installation in Section Tappings

I. Pre-Installation

GNINRAW

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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 certied 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 unconned space.

b. If result is less than 50 ft³ per 1,000 Btuh, space

is considered a conned 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

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 unconned space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally

provided by fresh air inltration through cracks

around windows and doors.

6. For boiler located within unconned space in building of unusually tight construction or within conned 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

equipment in space. Duct cross-sectional area shall be same as opening free area.

Alternate method for boiler located within conned

space. Use indoor air if two permanent openings communicate directly with additional space(s) of

sufcient volume such that combined volume of all spaces meet criteria for unconned 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

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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.

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

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

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 orice.

NOTE: The burner to the right may need to

be lifted from the orice to install pilot/

burner assembly. Reinstall lifted burner

over the orice.

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)

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.

III. Semi-Pak Boiler Assembly

GNINRAW

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.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

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. Afx 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

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.

IV. Packaged Boiler Assembly

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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

V. Piping and Trim

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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.

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Figure 24: Steam Boiler Piping (Minimum)

Figure 25: Recommended Water Piping for Circulator Zoned Heating System

Figure 25A: Recommended Water Piping for Zone Valve Zoned Heating System

Figure 26: Recommended Piping for Combination

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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.

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.

VI. Gas Piping

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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 species a gravity factor be applied. For specic gravity greater than 0.70, apply gravity factor from Table 5. If exact specic 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 liqueed 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. Specic gravity of gas. Gas piping systems for gas with a specic gravity of 0.70 or less can be sized

directly from Table 3, unless authority having

Figure 29: Recommended Gas Piping

4. All above ground gas piping upstream from manual

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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

Table 5: Specic Gravity Correction Factors

VII. Venting

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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 efciency.

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

modication to either (Refer to instructions packed with vent damper for specic 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.

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

deciencies 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.

Figure 30: Typical Vent Installation

VIII. Electrical

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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 inuenced 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.

Set heat anticipator to match system requirements. See

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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

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 satised.

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 satised, 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

Figure 33: Vent Damper Harness to Limit

Figure 34: Vent Damper Schematic Wiring Diagram

Figure 35: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low Water Cutoff

H. Steam Boiler with Continuous Ignition (Standing Pilot)

and Probe Low Water Cutoff. See Figure 35.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve(s) is energized allowing main gas ow

and ignition of Main Burners.

d. After Thermostat is satised Gas Valve(s) is de-

energized, extinguishing main ame. Vent

Damper (if used) closes.

Safety Shutdown

2. 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.

b. 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.

c. 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.

d. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

e. Thermocouple: senses pilot ame and causes gas

valve to turn off main burner and pilot burner gas

ow should pilot burner ame extinguish.

Figure 36: Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low Water Cutoff

I. Steam Boiler with Intermittent Ignition (EI) and Probe

Low Water Cutoff. See Figure 36.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Ignition Module is energized. Pilot Valve opens

and Igniter is energized to ignite Pilot Burner.

d. Sensor proves presence of pilot ame. Main

Valve(s) opens and ignites Main Burners.

e. After Thermostat is satised Ignition Module is

de-energized, extinguishing pilot and main

ame. 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.

b. 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.

c. Blocked Vent Switch. Automatically interrupts

d. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

e. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown, Ignition Module restarts ignition sequence.

For Electronic Ignition Trouble Shooting Guide, see

Page 74.

Figure 37: Wiring Diagrams, Steam, Intermittent Ignition (HSP), Probe Low Water Cutoff

J. Steam Boiler with Intermittent Ignition (HSP) and

Probe Low Water Cutoff. See Figure 37.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve is energized. Igniter is energized and

Pilot Valve opens to ignite Pilot Burner.

d. Sensor proves presence of pilot ame and Gas

Valve de-energizes igniter. Main Valve opens and ignites Main Burners.*

e. After Thermostat is satised Gas Valve is de-

energized, extinguishing pilot and main ame.

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.

b. 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.

c. 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.

d. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

e. Sensor: senses pilot ame and causes Gas Valve

to interrupt main burner and pilot burner gas

ow should pilot burner ame extinguish.

For Hot Surface to Pilot Trouble Shooting Guide, see

Page 75.

* • SV9500 and SV9600 Gas Valves:

The igniter and pilot gas valve will stay

energized until either the pilot lights or the call for heat ends.

• SV9501 and SV9601 Gas Valves: If the pilot fails to light after a 90 second trial for

ignition, the igniter will be de-energized and the pilot gas valve will close. After a 5 minute delay, the igniter will be re-energized and the pilot gas valve will re-open. This continuous retry cycle will end either when the pilot lights or the call for heat ends.

Figure 38: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Float Low Water Cutoff

K. Steam Boiler with Continuous Ignition (Standing Pilot)

and Float Low Water Cutoff. See Figure 38.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve(s) is energized allowing main gas ow

and ignition of Main Burners.

d. After Thermostat is satised Gas Valve(s) is de-

energized, extinguishing main ame. Vent

Damper (if used) closes.

Safety Shutdown

2. 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.

b. 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.

c. Blocked Vent Switch. Automatically interrupts

d. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

e. Thermocouple: senses pilot ame and causes gas

valve to turn off main burner and pilot burner gas

ow should pilot burner ame extinguish.

Figure 39: Wiring Diagrams, Steam, Intermittent Ignition (EI), Float Low Water Cutoff

L. Steam Boiler with Intermittent Ignition (EI) and Float

Low Water Cutoff. See Figure 39.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Ignition Module is energized. Pilot Valve opens

and Igniter is energized to ignite Pilot Burner.

d. Sensor proves presence of pilot ame. Main

Valve(s) opens and ignites Main Burners.

e. After Thermostat is satised Ignition Module is

de-energized, extinguishing pilot and main

ame. 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.

b. 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.

c. Blocked Vent Switch. Automatically interrupts

d. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

e. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown, Ignition Module restarts ignition sequence.

For Electronic Ignition Trouble Shooting Guide, see

Page 74.

Figure 40: Wiring Diagrams, Steam, Intermittent Ignition (HSP), Float Low Water Cutoff

M. Steam Boiler with Intermittent Ignition (HSP) and Float

Low Water Cutoff. See Figure 40.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve is energized. Igniter is energized and

Pilot Valve opens to ignite Pilot Burner.

d. Sensor proves presence of pilot ame and Gas

Valve de-energizes igniter. Main Valve opens and ignites Main Burners.*

e. After Thermostat is satised Gas Valve is de-

energized, extinguishing pilot and main ame.

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.

b. 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.

c. 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.

d. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

e. Sensor: senses pilot ame and causes Gas Valve

to interrupt main burner and pilot burner gas

ow should pilot burner ame extinguish.

For Hot Surface to Pilot Trouble Shooting Guide, see

Page 75.

* • SV9500 and SV9600 Gas Valves:

The igniter and pilot gas valve will stay

energized until either the pilot lights or the call for heat ends.

• SV9501 and SV9601 Gas Valves: If the pilot fails to light after a 90 second trial for

Figure 41: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Intermittent Circulation

N. Water Boiler with Continuous Ignition (Standing Pilot)

and Intermittent Circulation. See Figure 41.

1. Normal Operation a. Thermostat calls for heat. b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve(s) is energized allowing main gas ow

and ignition of Main Burners.

d. After Thermostat is satised Gas Valve(s) is de-

energized, extinguishing main ame. Vent

Damper (if used) closes.

Safety Shutdown

2. 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.

b. Blocked Vent Switch. Automatically interrupts

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Thermocouple: senses pilot ame and causes gas

valve to turn off main burner and pilot burner gas

ow should pilot burner ame extinguish.

Figure 42: Wiring Diagrams, Water, Intermittent Ignition (EI), Intermittent Circulation

O. Water Boiler with Intermittent Ignition (EI) and

Intermittent Circulation. See Figure 42.

1. Normal Operation a. Thermostat calls for heat. b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Ignition Module is energized. Pilot Valve opens

and Igniter is energized to ignite Pilot Burner.

d. Sensor proves presence of pilot ame. Main

Valve(s) opens and ignites Main Burners.

e. After Thermostat is satised Ignition Module is

de-energized, extinguishing pilot and main

ame. 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.

b. Blocked Vent Switch. Automatically interrupts

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown, Ignition Module restarts ignition sequence.

For Electronic Ignition Trouble Shooting Guide, see

Page 74.

Figure 43: Wiring Diagrams, Water, Intermittent Ignition (HSP), Intermittent Circulation

P. Water Boiler with Intermittent Ignition (HSP) and

Intermittent Circulation. See Figure 43.

1. Normal Operation a. Thermostat calls for heat. b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve is energized. Igniter is energized and

Pilot Valve opens to ignite Pilot Burner.

d. Sensor proves presence of pilot ame and Gas

Valve de-energizes igniter. Main Valve opens and ignites Main Burners.*

e. After Thermostat is satised Gas Valve is de-

energized, extinguishing pilot and main ame.

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.

b. 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.

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Sensor: senses pilot ame and causes Gas Valve

to interrupt main burner and pilot burner gas

ow should pilot burner ame extinguish.

For Hot Surface to Pilot Trouble Shooting Guide, see

Page 75.

* • SV9500 and SV9600 Gas Valves:

The igniter and pilot gas valve will stay

energized until either the pilot lights or the call for heat ends.

• SV9501 and SV9601 Gas Valves:

If the pilot fails to light after a 90 second trial for

Figure 44: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Gravity Circulation

Q. Water Boiler with Continuous Ignition (Standing Pilot)

and Gravity Circulation. See Figure 44.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve(s) is energized allowing main gas ow

and ignition of Main Burners.

d. After Thermostat is satised Gas Valve(s) is de-

energized, extinguishing main ame. Vent

Damper (if used) closes.

Safety Shutdown

2. 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.

b. Blocked Vent Switch. Automatically interrupts

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Thermocouple: senses pilot ame and causes gas

valve to turn off main burner and pilot burner gas

ow should pilot burner ame extinguish.

Figure 45: Wiring Diagrams, Water, Intermittent Ignition (EI), Gravity Circulation

R. Water Boiler with Intermittent Ignition (EI) and Gravity

Circulation. See Figure 45.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Ignition Module is energized. Pilot Valve opens

and Igniter is energized to ignite Pilot Burner.

d. Sensor proves presence of pilot ame. Main

Valve(s) opens and ignites Main Burners.

e. After Thermostat is satised Ignition Module is

de-energized, extinguishing pilot and main

ame. 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.

b. Blocked Vent Switch. Automatically interrupts

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown, Ignition Module restarts ignition sequence.

For Electronic Ignition Trouble Shooting Guide, see

Page 74.

Figure 46: Wiring Diagrams, Water, Intermittent Ignition (HSP), Gravity Circulation

S. Water Boiler with Intermittent Ignition (HSP) and

Gravity Circulation. See Figure 46.

1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation

Relay is energized, closing contacts.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve is energized. Igniter is energized and

Pilot Valve opens to ignite Pilot Burner.

d. Sensor proves presence of pilot ame and Gas

Valve de-energizes igniter. Main Valve opens and ignites Main Burners.*

e. After Thermostat is satised Gas Valve is de-

energized, extinguishing pilot and main ame.

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.

b. 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.

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Sensor: senses pilot ame and causes Gas Valve

to interrupt main burner and pilot burner gas

ow should pilot burner ame extinguish.

For Hot Surface to Pilot Trouble Shooting Guide, see

Page 75.

* • SV9500 and SV9600 Gas Valves:

The igniter and pilot gas valve will stay

energized until either the pilot lights or the call for heat ends.

• SV9501 and SV9601 Gas Valves: If the pilot fails to light after a 90 second trial for

Figure 47: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Tankless Heater

T. Water Boiler with Continuous Ignition (Standing Pilot)

and Tankless Heater. See Figure 47.

1. Normal Operation a. Thermostat calls for heat or low limit senses

water temperature below set point.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve(s) is energized allowing main gas ow

and ignition of Main Burners.

d. After Thermostat or low limit is satised Gas

Valve(s) is de-energized, extinguishing main

ame. Vent Damper (if used) closes.

Safety Shutdown

2. 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.

b. Blocked Vent Switch. Automatically interrupts

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Thermocouple: senses pilot ame and causes gas

valve to turn off main burner and pilot burner gas

ow should pilot burner ame extinguish.

Figure 48: Wiring Diagrams, Water, Intermittent Ignition (EI), Tankless Heater

U. Water Boiler with Intermittent Ignition (EI) and

Tankless Heater. See Figure 48.

1. Normal Operation a. Thermostat calls for heat or low limit senses

water temperature below set point.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Ignition Module is energized. Pilot Valve opens

and Igniter is energized to ignite Pilot Burner.

d. Sensor proves presence of pilot ame. Main

Valve(s) opens and ignites Main Burners.

e. After Thermostat or low limit is satised Ignition

Module is de-energized, extinguishing pilot and

main ame. 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.

b. Blocked Vent Switch. Automatically interrupts

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Igniter/Sensor: senses pilot ame and causes

ignition module to turn off main burner and pilot

burner gas ow should pilot burner ame

extinguish. Five to six minutes after shutdown, Ignition Module restarts ignition sequence.

For Electronic Ignition Trouble Shooting Guide, see

Page 74.

Figure 49: Wiring Diagrams, Water, Intermittent Ignition (HSP), Tankless Heater

V. Water Boiler with Intermittent Ignition (HSP) and

Tankless Heater. See Figure 49.

Normal Operation

1. a. Thermostat calls for heat or low limit senses

water temperature below set point.

b. Vent Damper (if used) opens as stated in Vent

Damper Sequence of Operation.

c. Gas Valve is energized. Igniter is energized and

Pilot Valve opens to ignite Pilot Burner.

d. Sensor proves presence of pilot ame and Gas

Valve de-energizes igniter. Main Valve opens and ignites Main Burners.*

e. After Thermostat is satised Gas Valve is de-

energized, extinguishing pilot and main ame.

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.

b. 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.

c. Flame Roll-out Switch. Automatically interrupts

boiler operation when ames or excessive heat

are present in vestibule. Control is single use

device. If ame roll-out switch is activated do

not attempt to place boiler in operation. Correct

source of blockage and replace ame roll-out

switch.

d. Sensor: senses pilot ame and causes Gas Valve

to interrupt main burner and pilot burner gas

ow should pilot burner ame extinguish.

For Hot Surface to Pilot Trouble Shooting Guide, see

Page 75.

* • SV9500 and SV9600 Gas Valves:

The igniter and pilot gas valve will stay

energized until either the pilot lights or the call for heat ends.

• SV9501 and SV9601 Gas Valves: If the pilot fails to light after a 90 second trial for

IX. System Start-up

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A. Safe lighting and other performance criteria were met

with the gas manifold and control assembly provided on

boiler when boiler underwent tests specied in

American National Standard for Gas-Fired LowPressure 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 orices.

C. Fill boiler with water:

1. Steam: ll to normal water line. See Figure 1.

2. Water: ll heating system to approximately 12 PSI.

Vent air from system.

D. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot) from gas supplier.

2. Adjust limit: a. Steam: With an L404A1354 - set cut-out

pressure (MAIN scale) on the pressure limit for (2) PSI and differential pressure (DIFF. scale) below (2) PSI.

With an L404A1651 or an L404F1367 - 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 18A or 18B. 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 50.

Figure 51: Gas Valve Pressure Tap,

Honeywell Gas Valves

Figure 52: 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 51 or 52.

5. For natural gas red boiler, temporarily turn off all

other gas-red appliances.

Figure 50: Front Door Removal

E. Follow Lighting or Operating Instructions.

1. To place boiler in operation. See Figure 53, 54, 55, 56 or 57. 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 ame, see Table 8.

The green LED indicates the status of the system, see Table 9. See Figure 58 for LED locations.

Figure 53: Lighting Instructions, Continuous Ignition System, VR8200 and VR8300 Gas Valves

Figure 54: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas Valve

Figure 55: Operating Instruction, Intermittent Ignition System, SV9500, SV9600, VR8204 and VR8304

(except IN12) Gas Valves

Figure 56: Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas Valves

Figure 57: Operating Instructions, Intermittent Ignition System (HSP), SV9501 and SV9601

Table 7: Ignition Module Terminal Cross-Reference

Ignition Module

Terminal Designation

MV 1

MV/PV 2

PV 3

GND 4

24V (GND) 5

24V 6

SPARK 9

TABLE 8: Yellow LED Flame Codes

Yellow LED

Flash Code

Heartbeat Normal Flame Signal N/A

OFF

Flash Code Descriptions

Wiring Ladder Diagram

Terminal Number

Indicates

Weak Flame Signal -

System will operate reliably but ame signal is

less than desired.

Note: This indication may ash temporarily during or shortly after lightoff on some

applications.

Marginal Flame Signal (less than 1.1 µA) -

System may not operate reliably over time.

Service call recommended.

Note: This indication may ash temporarily during or shortly after lightoff on some

applications.

No Flame or Flame Signal -

below minimum threshold for system operation.

Figure 58: LED Locations

Recommended

Service Action

Perform routine maintenance to

assure optimum

ame signal.

Check gas supply, pilot burner, ame

sense wiring,

contamination of

ame rod, burner

ground connection.

N/A

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- The ash code number signies that the LED ashes X times at 2Hz, remains

off for two seconds, and then repeats sequence.

Table 9: Green LED Status Codes

Green LED

Flash Code

(X + Y)

Flash Fast

Heartbeat Normal operation N/A None

Flash Code Descriptions:

OFF No “Call for Heat” N/A None

Startup - Flame sense calibration

5 minute Retry Delay-

Pilot ame not detected

during trial for ignition

Recycle- Flame failed

during run

Flame sensed out of sequence

Flame sense leakage to ground

Low secondary voltage supply- (below 15.5 Vac)

5 minute Retry Delay-

6 + 2

On every third retry on

same “Call for Heat”

On every 6th ame

6 + 3

failure during run on the same “Call for Heat”

Flame sensed out of

6 + 4

sequence- longer than 10 seconds

Soft lockout due to error

detected during self check sequences

- Flash Fast: rapid blinking

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then

repeats the sequence.

- X + Y ash codes signify that the LED ashes X times at 2Hz, remains off for two seconds, ashes Y times at 2

Hz, remains off for three seconds, and then repeats the sequence.

Indicates Next System Action Recommended Service Action

N/A None

If system fails to light on next trial

for ignition check gas supply, pilot Initiate new trial for ignition after retry delay completed.

Initiate new trial for ignition. Flash code will remain through the ignition

trial until ame is proved.

If situation self corrects within 10 seconds, control returns to normal sequence. If ame out of sequence remains 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 ignition after retry delay completed.

5 minute retry delay, then initiate new

trial for ignition.

Control waits until ame 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.

burner, spark and ame sense wir-

ing, ame 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, ame sense wiring, ame

rod contamination, burner ground

connection.

Check for pilot ame. Replace gas

valve if pilot ame present. If no

pilot ame, cycle “Call for Heat.” If

error repeats, replace control.

Check ame sense lead wire for

damage or shorting. Check that

ame rod is in proper position.

Check ame 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 ame sense wiring, ame rod

contamination or out of position,

burner ground connection.

Check gas supply, pilot burner, ame

sense wiring, contamination of ame

rod, burner ground connection.

Check for pilot ame. Replace gas

valve if pilot ame present. If no

pilot ame, cycle “Call for Heat.” If

error repeats, replace control.

Reset by cycling “Call for Heat.” If

error repeats, replace the control

Figure 59: Pilot Burner Flame, Honeywell Q350

Figure 62: Pilot Burner Flame, Honeywell Q3480

Figure 60: Pilot Burner Flame, Honeywell Q327

Figure 61: Pilot Burner Flame, Honeywell Q348

Figure 63: 40mm Main Burner Flame

Figure 64: 1" Main Burner Flame

F. Checkpilotburnerameandmainburnerames

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through observation port.

1. Check pilot ame.

a. Continuous Ignition (Standing Pilot), Models

IN3 through IN7. See Figure 59. Pilot burner

produces a single ame. Flame should be steady,

medium hard blue enveloping 3/8 to ½ inch of thermocouple.

b. Continuous Ignition (Standing Pilot), Models

IN8 through IN12. See Figure 60. Pilot burner

produces three (3) ames. Center ame should

be steady, medium hard blue enveloping 3/8 to ½ inch of thermocouple.

c. Electronic Ignition (EI), Models IN3 through

IN12. See Figure 61. Pilot should be lit only after completing Step 3. Pilot burner produces

three (3) ames. Center ame should be steady,

medium hard blue enveloping 3/8 to ½ inch of sensing probe.

2. With boiler operating, open drain and slowly drain boiler.

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. Rell 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.

d. Hot Surface to Pilot Ignition (HSP), Models IN3

through IN9. See Figure 62. Pilot should be lit only after completing Step 3. Pilot burner

produces three (3) ames. Center ame should

be steady, medium hard blue enveloping 3/8 to ½ inch of sensing probe.

2. Adjust thermostat to highest setting.

3. Check main burner ames. See Figure 63 or 64. Flame should have clearly dened 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 should 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".

3. Hot Surface to Pilot Ignition (HSP): disconnect igniter/sensor (3 wire quick connect) from gas valve.

I. Check low water cutoff (steam only).

1. Adjust thermostat to highest setting.

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.

K. Adjust gas input rate to boiler. Natural Gas.

1. Adjust thermostat to highest setting.

2. Check manifold gas pressure. 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 or HSP Ignition

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 if unattainable, highest pressure without forcing adjustment screw

Table 10: Input Rate

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03 06 021 042 006 23 65 311 522 365 43 35 601 212 925 63 05 001 002 005 83 74 59 981 474 04 54 09 081 054 24 34 68 271 034 44 14 28 461 014 64 93 87 751 193 84 73 57 051 573 05 63 27 441 063 25 53 96 831 643 45 33 76 331 333 65 23 46 921 123 85 13 26 421 013 06 03 06 021 003 26 92 85 611 092 46 92 65 211 182 66 92 45 901 372 86 82 35 601 562 07 62 15 301 752 27 52 05 001 052 47 42 84 79 342 67 42 74 59 732 87 32 64 29 132 08 22 54 09 522

3. Clock gas meter for at least 30 seconds. Use Table

10 to determine gas ow rate in Cubic Feet per

Hour.

4. Determine Input Rate. Multiply gas ow rate by gas

heating value.

5. Compare measured input rate to input rate stated on Rating Label.

a. Boiler must not be overred. Reduce input rate

(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.

by decreasing manifold pressure. Do not reduce

more than 0.3 inch w.c. If boiler is still overred,

contact your Governale distributor or Regional

Ofce for replacement Gas Orice.

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 orices. Drill one (1) drill size

larger (drill size is stamped on orice, or see

Key No. 4D in repair parts section).

iii. Reinstall gas orices and main burners.

Measure input rate.

6. Recheck Main Burner Flame.

7. Return other gas-red appliances to previous

conditions of use.

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 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 qualied

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 53, 54, 55, 56 or 57.

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.

2. Boil-out boiler. a. Follow instructions TO TURN OFF GAS TO

APPLIANCE. See Figure 53, 54, 55, 56 or 57. b. Fill boiler to normal waterline. 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 53, 54, 55, 56 or 57. Check controls operation per

Paragraphs F to J. Boil water for at least 5 hours.

g. Follow instructions TO TURN OFF GAS TO

APPLIANCE. See Figure 53, 54, 55, 56 or 57. Drain boiler and system piping.

h. Remove drain valve. Thoroughly wash boiler

water passages with high pressure spray through drain valve tapping.

i. Reinstall drain valve in Tapping "F". See

Figures 1 and 2.

3. Second Boil-out for Stubborn Cases. If all oil and grease is not removed a second boilout using surface blow-off is necessary.

a. Run 1 NPT 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 53, 54, 55,

56 or 57. Boil water for approximately 5 hours

without producing steam.

g. Open boiler ll 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. h. Follow instructions TO TURN OFF GAS TO

APPLIANCE. See Figure 53, 54, 55, 56 or 57.

Drain boiler and system piping. i. Remove drain valve. Thoroughly wash boiler

water passages with high pressure spray through

drain valve tapping. j. Fill boiler to normal waterline. If water in gauge

glass is not clear, repeat procedure starting at

step b. k. 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.

c. Reinstall safety valve in Tapping "E" with

spindle in vertical position. See Figures 1 and 2.

d. Follow Lighting or Operating Instructions to

place boiler in operation. See Figure 53, 54, 55,

56 or 57. e. Boil water or heat water to 180°F. 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 specied range.

5. If unsteady water line, foaming or priming persist: a. Follow Lighting or Operating Instructions to

place boiler in operation. See Figure 53, 54, 55, 56 or 57.

b. Install gate valve (shut-off valve) in Hartford

Loop. Install drain valves in return main and at boiler. See Figure 23.

c. Connect hoses from drain valves to oor drain.

Close gate valve in Hartford Loop. Open drain valve in return main.

d. Fill boiler to normal water line. Follow Lighting

or Operating Instructions to place boiler in operation. See Figure 53, 54, 55, 56 or 57.

e. Operate boiler for at least 30 minutes after

condensate begins to run hot. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 53, 54, 55, 56 or 57.

f. Close all radiator valves. Remove all supply

main air valves. Plug openings in supply main.

g. Drain approximately 5 gallons of boiler water

into container. Mix in recommended boil-out compound.

h. 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.

i. Follow Lighting or Operating Instructions to

place boiler in operation. See Figure 53, 54, 55, 56 or 57. Slowly feed water to boiler. Water will rise slowly into supply main and back through

return main. Adjust ow 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 53, 54, 55, 56 or 57. 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 53, 54, 55, 56 or 57. Allow boiler to steam for 10 minutes. Drain one quart of water from lower Gauge

Glass tting.

n. Drain second quart sample from lower Gauge

Glass tting. If sample is not clear, repeat cycle of draining boiler and return main and relling

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

relled 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

specic 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 specied 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 qualied

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 manner.

a. Remove Safety Relief Valve using extreme care

to avoid damaging it.

b. Partially ll boiler. Pour recommended

compound into boiler through safety relief valve opening.

c. Replace Safety Relief Valve. d. Fill entire system with water. e. Start ring equipment. f. Circulate the water through the entire system. g. Vent the system, including the radiation.

h. Allow boiler water to reach operating

temperature, if possible.

i. Continue to Circulate the water for a few hours. j. Stop the ring equipment. k. Drain the system in a manner and to a location

that hot water can be discharged with safety.

l. 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. Rell 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

relled 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

specic readings. A color chart on the side of the

within the specied 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 red

boiler to such an extent that it appears that the boiler is leaking. This condensation can be expected to stop after the boiler is hot.

O. 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 if damper is in full open position.

P. Review User's Information Manual and system

operation with owner or operator.

Q. Post instructions near boiler for reference by owner

and service personnel. Maintain instructions in legible condition.

X. Service Instructions

REGNAD

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REGNAD

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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 53, 54, 55, 56 or 57.

B. Maintenance of Low Water Cutoff

1. McDonnell & 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.

d. Unscrew probe from Tapping 'K'. Inspect for

scale and sediment buildup.

e. Remove light deposits with damp cloth soaked

with vinegar.

f. Remove stubborn deposits using diluted

phosphoric acid (H2PO4) 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.

2. McDonnell & Miller 67 Float Style Only. a. Weekly (or more frequently if necessary). Open

blow-off valve to ush sediment chamber. Follow instructions on Blow-Down Card afxed to Jacket adjacent to low water cutoff.

b. Annually. Dismantle to extent necessary to

remove obstructions and insure proper function of working parts.

Figure 65: 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 oat.

Check oat for evidence of collapse. Check

mercury bulb (where applicable) for mercury separation or discoloration. Do not attempt to repair mechanisms in eld. 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 oat mechanisms.

C. Water Feeder and Additional Low Water Cutoff.

Refer to manufacturer's instructions.

D. Vent System. Check annually for:

1. obstructions

2. accumulations of soot

3. deterioration of vent pipe or vent accessories due to condensation or other reasons

4. 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.

E. Clean Boiler Flueways.

1. Shut down gas boiler in accordance with lighting/ operating instructions attached to inside of Front Removable Door. See Figure 50.

2. Remove Burner Access Panel and Burners. See Paragraph F. Clean Burners if necessary.

3. Remove Jacket Top Panels.

4. Remove Canopy from top of boiler.

5. Thoroughly clean the ueways with ue brush. See

Figure 65.

6. Clean boiler heating surface accessible from combustion chamber with straight handle wire brush. Reinstall burners and connect gas train. See Paragraphs F & 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.

NOITUAC

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F. Remove Burners for cleaning, changing orice plugs,

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or repairs.

1. Turn off electric service to boiler.

2. Turn off gas supply to boiler.

3. Remove jacket front panel.

4. Disconnect pilot tubing at gas valve.

5. Disconnect thermocouple tubing at gas valve (Continuous Ignition only). Disconnect igniter/ sensor cable and ground wire at ignition module Intermittent Ignition (EI) only. Disconnect Igniter/ Sensor (3 wire quick connect) from gas valve

Intermittent Ignition (HSP) only. Disconnect ame

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 orice.

Pull burner from combustion chamber. See Figure

10. Pilot main burner can only be removed by lifting at 45° angle after adjacent 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 65.

G. Remove Pilot Assembly for Servicing. Remove

machine screw(s) holding pilot burner to pilot bracket,

after rst 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 Q348 intermittent (EI) pilot, see Figure 66.

l. Use a round wire gauge to check spark gap.

2. Spark gap should be 0.125" for optimum performance.

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 orices.

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

I. Lubrication. Manufacturers Instruction should be

followed on all parts installed on boiler requiring lubrication. This includes:

l. Type of lubricant to be used.

2. Frequency of lubrication.

3. Points to lubricate.

J. Check operation. Follow Steps 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.

Figure 66: Honeywell Q348 Spark Gap

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 is 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.

Honeywell Hot Surface to Pilot Trouble Shooting Guide

Warning:

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This product contains refractory ceramic bers (RCF). RCF has been classied as a possible human carcinogen. After this product is red, RCF may, when exposed to extremely high temperature (>1800F), change into a known human

carcinogen. When disturbed as a result of servicing or repair, RCF becomes

airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace previously red RCF (combustion chamber insulation, target walls, canopy gasket, ue cover gasket, etc.) or attempt any service or

repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved

respirator

2. Long sleeved, loose tting clothing

3. Gloves

4. 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 air tight plastic bag.

First Aid Procedures:

• If 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 difculty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing

difculties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

SERVICE RECORD

DATE SERVICE PERFORMED

XI. Repair Parts

All Independence® Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.

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Key

No.

Transformer/J-Box Adapter Plate

1 Junction Box, 4-11/16" x 4-11/16" x 2-1/8" 81361761 1 1 1 1 1 1 1 1 1 1 2 Transformer/J-Box Adapter Plate 7011001 1 1 1 1 1 1 1 1 1 1 3 Sheet Metal Screw, #8 x 1/2, Type B,

Phillips Head, Blunt 4 O/CL Bushing, Heyco OCB-875 8136066 1 1 1 1 1 1 1 1 1 1 5 J-Box Attachment Bracket 7131001 1 1 1 1 1 1 1 1 1 1

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

80860019 2 2 2 2 2 2 2 2 2 2

Quantity

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100

Burnham Independence Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual