Burnham Independence IN10 User Manual

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Page 1

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Page 2

The New York City Department of Buildings has approved the Independence® Series boiler: Approval No. MEA 154-93-E Vol. III.

The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the Independence® Series boiler. See the Massachusetts

Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

CAUTION

If, during normal operation, it is necessary to add water to this boiler more frequently than once a month,

consult a qualied service technician to check your system for leaks. A leaky system will increase the volume of make-up water supplied to the boiler which can signicantly shorten the life of the boiler. Entrained in make-up water are dissolved minerals and oxygen. When the fresh, cool make-up water is heated in the boiler the minerals fall out as sediment and the oxygen escapes as a gas. Both can result in reduced boiler life. The

accumulation of sediment can eventually isolate the water from contacting the cast iron. When this happens

the cast iron in that area gets extremely hot and may eventually crack. The presence of free oxygen in the

boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the cast iron through from the inside. Since neither of these failure types are a result of a casting defect the warranty does not apply. Clearly, it is in everyone's best interest to prevent this type of failure. The maintenance of system integrity is the best method to achieve this.

NOTICE

This boiler has a limited warranty, a copy of which is printed on the back of this manual.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete.

Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

Page 3

CAUTION

Probe type low water cutoff devices require annual inspection and maintenance! Although these devices are

solid state in their operation, the probe is exposed to possible contamination in the boiler water and subject

to fouling. Refer to Low Water Cutoff Service Instructions for complete, step-by-step inspection and cleaning instructions.

WARNING

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up

operation, or service. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency.

This boiler must be properly vented. This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air. The interior of the venting system must be inspected and cleaned before the start of the heating season

and should be inspected periodically throughout the heating season for any obstructions. A clean and

unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efciency.

Installation is not complete unless a safety (relief) valve is installed. See the Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler contains very hot water or steam under high pressure. Do not unscrew any pipe ttings nor

attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the pressure and temperature of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or

liquids. All cover plates, enclosures and guards must be in place at all times.

Page 4

Figure 1: Dimensional Drawing

Page 5

Dimensional Data

Approx.

Boiler

Model

Shipping

Weight

'A' 'B' 'C' 'D' 'E' 'F' 'G'

Lbs.

IN3 350 14-1/2 IN4 420 17-3/4 34-3/4 5 8-7/8 5" x 15 ft. 6.5 10.0 5.0 IN5 485 21

IN6 USA

IN6

Canada

IN7 620 27-1/2 13-3/4

IN8 USA

IN8

Canada

IN10 USA

IN10

Canada

IN11 885 40-1/2 20-1/4 16.3 25.4 12.7

IN12 955 43-3/4 21-7/8 1" 17.7 27.6 13.8 (1) 15' chimney height is from bottom of Draft Hood opening to top of Chimney. (2) Gas connection size on IN10-IN11 Continuous Ignition (Standing Pilot) is 1 NPT. (3) Steam boiler's "steamable water volume": water volume from NWL (normal water level) to low water cutoff level.

555 24-1/4 12-1/8 9.3 14.4 7.2

690 30-3/4 15-3/8 12.1 18.8 9.4

815 37-1/4

Dimensions (in inches) Recommended

Min. Round

Chimney Size

(Diameter x Height)

(1)

33-3/4 4

35-3/4 6 5-1/4

36-3/4 7

37-3/4

45 38-3/4 45-1/2

40-1/4

8 8" x 15 ft.IN9 760 34 17 13.5 21.0 10.5

9 9" x 15 ft.

4-3/4

7-1/2

7-1/4 4" x 15 ft.

10-1/2

18-5/8

6" x 15 ft.

7" x 15 ft.

Gas

Conn.

(NPT)

Water Volume (Gal.)

Steam

Boiler

5.1 7.8 3.9

1/2"

3/4"

(2)

7.9 12.2 6.1

10.7 16.6 8.3

14.9 23.2 11.6

Water Boiler

(3)

Heating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water)

Table of Contents

I. Pre-Installation .....................................7

II. Knockdown Boiler Assembly ................

III. Semi-Pak Boiler Assembly ..................

IV. Packaged Boiler Assembly ..................

V. Piping and Trim .................................

VI. Gas Piping ..........................................

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

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

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

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

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

XII. Appendix

Low Water Cut Oﬀ (LWCO) ...............

Page 6

Figure 2: Section Tappings

Table 1: Trim and Control Installation in Section Tappings

Tapping

A 2 Supply Supply Supply Supply

B ½

C ½ Gauge Glass

D 2 Return Return

E ¾

F 2

G 2

H ¾

J ¾ Not Applicable Not Applicable Not Applicable Tankless Heater

K ¾ Low Water Cutoff Plug Plug Plug

L 1

M 1¼

N 1¼

P ¾

Size

(NPT)

Steam Boiler with

Probe L.W.C.O.

Bush to ¼

Pressure Gauge

3" Nipple & Street Elbow

Safety Relief Valve

Bush to ¾ Drain Valve

and/or Optional Return

Optional Supply (IN3-6)

Required Supply (IN7-12

Bush to ¼ &

Syphon Limit

Factory Plugged

Surface Blow-Off

Factory Plugged

Alliance Return

Factory Plugged

Alliance Supply

Factory Plugged

Alliance Limit

Steam Boiler with

Float L.W.C.O.

Plug Plug Plug

Nipple & ½ Union

Gauge, L.W.C.O. Street

Elbow, Syphon & Limit

3" Nipple & Street Elbow

Safety Relief Valve

Bush to ¾ Drain Valve

and/or Optional Return

Optional Supply (IN3-6)

Required Supply (IN7-12

Bush to ¼

Pressure Gauge

Factory Plugged

Surface Blow-Off

Factory Plugged

Alliance Return

Factory Plugged

Alliance Supply

Factory Plugged

Alliance Limit

Water Boiler

Plug Lower Tapping Bush

to ¼ Upper Tapping

Press./Temp. Gauge

Bush to 1½, 3" Npl, Elbow,

2" Npl, Circ. Flange,

Gasket, Circulator Return

3" Nipple & Street Elbow

Safety Relief Valve

Bush to ¾ Drain Valve and/or

Optional Gravity Return

Plug (IN3-12)

Optional Gravity Supply

Well

Limit

Factory Plugged Factory Plugged

Water Boiler with

Tankless Heater

Plug Lower Tapping Bush to

¼ Upper Tapping

Press./Temp. Gauge

Bush to 1½, 3" Npl, Elbow,

2" Npl, Circ. Flange,

Gasket, Circulator Return

3" Nipple & Street Elbow

Safety Relief Valve

Bush to ¾ Drain Valve and/or

Optional Gravity Return

Optional Gravity Supply

Plug (IN3-12)

Limit

Well

Page 7

I. Pre-Installation

WARNING

If you do not follow these instructions exactly, a re or explosion may result causing property

damage or personal injury.

DANGER

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.

NOTICE

Due to the low water content of the boiler, missizing of the boiler with regard to the heating

system load will result in excessive boiler cycling and accelerated component failure. Burnham

DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system.

A. Inspect shipment carefully for any signs of damage. 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/ CSA B149.1 Installation Codes. Where required by the authority having jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, 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

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/CSA B149.1 Installation Code.

WARNING

Adequate combustion and ventilation air must be provided to assure proper combustion.

The following guideline is based on the

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

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.

National Fuel

Page 8

Figure 3: Clearance to Combustible Materials

5. For boiler located in an

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

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.

unconned space in a

unconned space in

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.

Page 9

II. Knocked-Down Boiler Assembly

WARNING

Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency.

A. Install Base-Burner-Manifold Assembly

1. Base-Burner-Manifold is shipped assembled from factory (Gas Valve and Pilot/Burner Assembly is shipped in the "Gas Controls Carton").

2. Unpack base assembly and place in location where boiler is to be installed (Refer to Section I: PreInstallation).

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.

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.

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.

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 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.

Page 10

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

Page 11

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, or 14.

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)

Page 12

I. Install Blocked Vent Switch with sheet metal screws.

1. Models IN3 - IN9. Install on rear ange of canopy.

See Figure 15.

Figure 15: Blocked Vent Switch Installation,

IN3 through IN9

2. Models IN10 - IN12. Install on right side of draft hood. See Figure 16. Reset switch must face away from draft hood relief opening.

3. Attach black 18-2 harness to Blocked Vent Switch terminals. Use end with two fully insulated disconnects.

4. Secure harness to right side jacket panel with clamp.

Figure 16: Blocked Vent Switch Installation,

IN10 through IN12

5. Insert harness through ¾ inch hole in right side jacket panel. Secure with strain relief bushing

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.

Page 13

III. Semi-Pak Boiler Assembly

WARNING

Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency.

A. Remove Crate

1. Remove all hold down screws and brackets.

2. Slide boiler to rear of skid and carefully remove from crate skid onto 2 inch thick piece of wood and

then onto 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:

1. EZ–Connect Carton (either steam or water) includes trim, controls, wiring and wiring instructions for installation.

2. Separate Trim Carton (steam or water) and Control Carton (steam or water). Only wiring requiring special connections is provided. For wiring requirements, refer to Section VIII: Electrical and appropriate wiring diagram.

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 18.

b. The L404F pressure limit employs a snap action

switch and does not require leveling. See Figure

18.

c. 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.

d. Install Low Water Cutoff Probe into Tapping "K"

(¾ NPT). HANDLE PROBE WITH CARE.

e. Attach Low Water cutoff Control to Probe by

following instructions packed with control.

f. Install gauge glass ttings into Tappings "C"

(½ NPT). See Figures 1 and 2. Lower tting has

small drain valve.

g. Install gauge glass and protective rods in ttings.

h. Attach "Lowest Permissible Water Level" Plate

with sheet metal screws in location indicated in Figure 9.

i. 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. The L404F pressure limit employs a snap action

switch and does not require leveling. See Figure

18.

d. 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.

e. Attach "Lowest Permissible Water Level" Plate

with sheet metal screws in location indicated in Figure 9.

f. Attach "Frequent Water Addition" Label above

the "Lowest Permissible Water Level" Plate.

Figure 18: L404F Pressure Limit Control

Page 14

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.

c. Fork connector on yellow wire of gas valve

harness must be removed and wire stripped before making wire connections. Refer to Section VIII for wiring.

d. Steam Boilers only. Secure the R8222

Thermostat Isolation Relay to upper left corner of jacket vestibule panel with sheet metal screws provided. See Figure 20.

e. Water with tankless heater only (EZWT and

WCT). Secure R8225D relay to Junction Box.

See Figure 1.

4. Water Boiler

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.

Figure 19B: Junction Box and Transformer

Assembly

Figure 19A: Junction Box and Mounting Bracket

Assembly

Figure 20: Thermostat Isolation Relay Attachment

Page 15

IV. Packaged Boiler Assembly

WARNING

Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency.

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 45. 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 Figure 18.

2. Snap the electrical conduit from the adjacent junction box into the hole in the control.

3. Open the control's clear cover and attach the two (2) wires in the conduit to the two (2) unused screw terminals.

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

WARNING

Do not alter boiler draft hood or place any obstruction or non-approved damper in the breeching or vent system. Flue gas spillage can

occur. ETL/ETLC certication will become void.

Page 16

V. Piping and Trim

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

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

Safety (relief) valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement.

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.

WARNING

NOTICE

Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh water supply to the boiler upstream of a water softener.

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham's Standard Warranty does not cover problems caused by oxygen

contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

Before using copper for steam piping, consider the following characteristics of copper piping:

1) high coefcient of thermal expansion can induce mechanical stresses and cause expansion/

contraction noises if not accounted for in the piping system design and installation,

2) high heat transfer rate (heat loss) of uninsulated copper piping must be included in the normal

piping and pickup factors used to size the boiler,

3) soldering or brazing pastes and uxes that end up in the system can cause poor heat transfer,

surging, an unsteady water line and wet steam if not thoroughly removed during the boil out procedure and,

4) galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water chemistries if dielectric unions are not used.

Page 17

NOTICE

Figure 24: Steam Boiler Piping (Minimum)

Failure to pipe boiler as specied in this manual may result in excessive system noise, water line uctuations and water carry over.

Page 18

Figure 25: Recommended Water Piping for Circulator Zoned Heating System

Page 19

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

Page 20

Figure 26: Recommended Piping for Combination

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.

WARNING

Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at xtures.

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.

Page 21

G. If a long term pressure test of the hydronic system is

required, the boiler should rst be isolated to avoid a

pressure loss due to the escape of air trapped in the boiler.

To perform a long term pressure test including the

boiler, ALL trapped air must rst be removed from the

boiler.

A loss of pressure during such a test, with no visible

water leakage, is an indication that the boiler contained trapped air.

Page 22

VI. Gas Piping

WARNING

Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is

absolutely leak free and of the proper size and

type for the connected load. An additional gas pressure regulator may be needed. Consult gas supplier.

A. Size gas Piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure 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

Boiler

Model

Number

IN3 62 24¾ ½

Rated Capacity

[cubic feet per hour]

Natural LP/Propane

Gas

Connection

Size

For materials or conditions other than those listed

above, refer to the National Fuel Gas Code, NFPA 54/ ANSI Z223.1 and/or CAN/CSA B149.1. Installation Codes, or size system using standard engineering methods acceptable to authority having jurisdiction.

WARNING

Failure to use proper thread compounds on all

gas connectors may result in leaks of ammable

gas.

WARNING

Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping.

B. Connect boiler gas valve to gas supply system.

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/CSA B149.1 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.

IN4 105 42 ½ IN5 140 56 ½ IN6 175 70 ½ IN7 210 84 ¾ IN8 245 98 ¾ IN9 280 112 ¾

IN10 315 126 ¾*

IN11 349 139½ ¾*

IN12 385 154 1

* Gas connection size is 1" on IN10 and IN11 Continuous Ignition (Standing Pilot)

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. Corrections for the specic gravity of natural gas

can be found in Table 5.

Figure 29: Recommended Gas Piping

Page 23

4. All above ground gas piping upstream from manual 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

Doe not use matches, candles, open ames or other ignition source to check for leaks.

DANGER

Table 3: Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less

Length\

[Feet]

10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950

30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530

70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 118 220 460 90 40 84 160 320 53 110 205 430

100 38 79 150 305 50 103 195 400

½ ¾ 1 1¼ ½ ¾ 1 1¼

0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop

Table 5: Specic Gravity Correction Factors for

Natural Gas

Table 4: Fitting Equivalent Lengths

Nominal Pipe Size

Fitting

½ ¾ 1 1¼

45° Ell 0.7 1.0 1.2 1.6 90° Ell 1.6 2.1 2.6 3.5

Tee

(As Elbow)

3.1 4.1 5.2 6.9

Specic

Gravity

0.50 1.10 1.30 1.07

0.55 1.04 1.40 1.04

0.60 1.00 1.50 1.00

0.65 0.96 1.60 0.97

0.70 0.93 1.70 0.94

0.75 0.90

0.80 0.87

Correction

Factor

Specic

Gravity

Correction

Factor

NOTICE

USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially oriced

to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/

ANSI Z223.1. Canadian boilers' orice sizing is indicated on the rating label. High altitude boiler models are identiable by the third digit in the model number sufx on the rating label:

_IN_ _ _ - _ _ 2 less than 2000 ft. elevation

_IN_ _ _ - _ _ 4 2000 to 4500 ft. elevation (Canada)

_IN_ _ _ - _ _ 5 2000 to 5000 ft. elevation (USA)

Page 24

VII. Venting

WARNING

This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation instructions of this manual.

Do not operate appliance where gasoline or other ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used, stored and/or present in the air.

A. Install vent system in accordance with local building

codes; or local authority having jurisdiction; or National Fuel Gas Code, ANSI Z223.1/NFPA 54, Part 7, Venting of Equipment and/or CAN/CSA B149.1 Installation Codes. Install any of the following for this Independence Series Category I, draft hood equipped appliance:

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.

DANGER

Inspect existing chimney before installing boiler.

Failure to clean or replace perforated pipe or tile lining will cause severe injury or death.

C. Boiler Equipped With Vent Damper

1. Open Vent Damper Carton and remove Installation Instructions. Read Installation Instructions thoroughly before proceeding.

Do not use one vent damper to control two heating appliances.

Provide adequate clearance for servicing 6" minimum clearance between damper and combustible construction.

DO NOT force the vent damper over the rolled bead on the draft hood collar. The vent damper should rest on the rolled bead.

Please refer to the specications,

installation instructions and trouble

shooting guide packed in the vent damper

carton for complete detailed installation instructions.

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) 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. USA - 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.

CAUTION

NOTICE

Page 25

D. Install Vent Connector from draft hood or vent

damper to chimney. See Figure 30.

1. Do not connect into same leg of chimney serving an

open replace.

2. Vent pipe to chimney must not be smaller than outlet on draft hood or vent damper. Type B is recommended, but single-wall vent pipe may be used. Arrange venting system so boiler is served by vent damper device.

3. Where two or more appliances vent into a common vent, the area of the common vent should be at least equal to the area of the largest vent plus 50% of the area in the additional vent(s). Do not connect the vent of this appliance into any portion of mechanical draft systems operating under positive pressure.

4. Horizontal run should be as short as possible. The maximum length of an uninsulated horizontal run must not exceed 75% of the height of the chimney.

5. Vent pipe should have the greatest possible initial rise above draft hood consistent with headroom available and required clearance from adjacent combustible building structure. Vent pipe should be installed above bottom of chimney to prevent blockage.

6. Vent pipe should slope upward from draft hood to chimney not less than one inch in four feet. No portion of vent pipe should run downward or have dips or sags. Vent pipe must be securely supported.

7. Vent pipe must be inserted into but not beyond inside wall of chimney liner. Seal tight between vent pipe and chimney.

E. If an Existing Boiler is Removed:

When an existing boiler is removed from a common

venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.

At the time of removal of an existing boiler, the

following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation:

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other

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

Page 26

VIII. Electrical

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of

electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock

once power is turned off.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.

Each boiler must be protected with a properly fused disconnect.

Never jump out or make inoperative any safety or operating controls.

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.

Page 27

Set heat anticipator to match system requirements. See

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

Ignition System

System Type

Heat Anticipator Setting (1)

Continuous (Standing Pilot) Intermittent (EI)

Steam with Probe

(McDonnell & Miller PS-802 or

Hydrolevel CGB-400)

Low Water Cutoff

Steam with Float

(McDonnell & Miller 67)

Low Water Cutoff

Water (Intermittent Circulation) Figure 39, Page 38 Figure 40, Page 40 0.3

Water (Gravity Circulation) Figure 41, Page 42 Figure 42, Page 44 0.3

Water with Tankless Heater Figure 43, Page 46 Figure 44, Page 48 0.6

(1) If system tends to overheat above thermostat's temperature setting, reduce heat anticipator setting by 0.1 or 0.2 amps. If system tends to shortcycle without reaching desired room temperature, increase heat anticipator setting by 0.1 or 0.2 amps.

Figure 35, Page 30 Figure 36, Page 32 0.8

Figure 37, Page 34 Figure 38, Page 36 0.8

Page 28

Figure 33: Vent Damper Harness to Limit

Figure 34: Vent Damper Schematic Wiring Diagram

Page 29

THIS PAGE LEFT INTENTIONALLY BLANK

Page 30

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

Page 31

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.

Page 32

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

Page 33

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 65. For LED Status Codes, see Tables 8 and 9 on pages 55 and 56.

Page 34

Figure 37: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Float Low Water Cutoff

Page 35

J. Steam Boiler with Continuous Ignition (Standing Pilot)

and Float 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(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.

Page 36

Figure 38: Wiring Diagrams, Steam, Intermittent Ignition (EI), Float Low Water Cutoff

Page 37

K. Steam Boiler with Intermittent Ignition (EI) 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. 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 65. For LED Status Codes, see Tables 8 and 9 on pages 55 and 56.

Page 38

Figure 39: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Intermittent Circulation

Page 39

L. Water Boiler with Continuous Ignition (Standing Pilot)

and Intermittent Circulation. See Figure 39.

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.

Page 40

Figure 40: Wiring Diagrams, Water, Intermittent Ignition (EI), Intermittent Circulation

Page 41

M. Water Boiler with Intermittent Ignition (EI) and

Intermittent Circulation. See Figure 40.

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 65. For LED Status Codes, see Tables 8 and 9 on pages 55 and 56.

Page 42

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

Page 43

N. Water Boiler with Continuous Ignition (Standing Pilot)

and Gravity Circulation. See Figure 41.

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.

Page 44

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

Page 45

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

Circulation. See Figure 42.

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

Relay is energized, closing contacts.

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 65. For LED Status Codes, see Tables 8 and 9 on pages 55 and 56.

Page 46

Figure 43: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Tankless Heater

Page 47

P. Water Boiler with Continuous Ignition (Standing Pilot)

and Tankless Heater. See Figure 43.

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

water temperature below set point.

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.

Page 48

Figure 44: Wiring Diagrams, Water, Intermittent Ignition (EI), Tankless Heater

Page 49

Q. Water Boiler with Intermittent Ignition (EI) and

Tankless Heater. See Figure 44.

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

water temperature below set point.

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 65. For LED Status Codes, see Tables 8 and 9 on pages 55 and 56.

Page 50

IX. System Start-up

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

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 18. b. Water without tankless heater: set at 200°F. c. Water with tankless heater: set limit at 220°F and

operating control to 200°F.

3. Remove front removable panel. See Figure 45.

Figure 46: Gas Valve Pressure Tap,

Honeywell Gas Valves

Figure 47: Gas Valve Pressure Tap,

Robertshaw Gas Valve

4. Connect manometer to gas valve pressure tapping (for IN12 connect to gas valve with pilot control). See Figure 46 or 47.

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

other gas-red appliances.

E. Follow Lighting or Operating Instructions.

1. To place boiler in operation. See Figure 48, 49, 50 or 51. Sequence of Operation is outlined with wiring diagrams in Section VIII: Electrical.

2. Electronic Ignition Modules with LED indicators. Table 7 cross-references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams. The yellow

LED indicates the status of the ame, see Table 8.

The green LED indicates the status of the system, see Table 9. See Figure 52 for LED locations.

Figure 45: Front Door Removal

Page 51

Figure 48: Lighting Instructions, Continuous Ignition System, VR8200 and VR8300 Gas Valves

Page 52

Figure 49: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas Valve

Page 53

Figure 50: Operating Instruction, Intermittent Ignition System, VR8204 and VR8304

(except IN12) Gas Valves

Page 54

Figure 51: Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas Valves

Page 55

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 52: 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.

Page 56

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-

6 + 2

6 + 3

6 + 4

- 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

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

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 DelayOn every third retry on same “Call for Heat”

On every 6th ame

failure during run on the

same “Call for Heat”

Flame sensed out of

sequence- longer than 10 seconds

Soft lockout due to error detected during self check sequences

repeats the sequence.

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

Page 57

Figure 53: Pilot Burner Flame, Honeywell Q350

Figure 54: Pilot Burner Flame, Honeywell Q327

Figure 56: 40mm Main Burner Flame

Figure 57: 1" Main Burner Flame

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

through observation port.

1. Check pilot ame.

a. Continuous Ignition (Standing Pilot), Models

IN3 through IN7. See Figure 53. 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 54. 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 55. 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.

Figure 55: Pilot Burner Flame, Honeywell Q348

CAUTION

Avoid operating this boiler in an environment

where saw dust, loose insulation bers, dry wall

dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation.

Page 58

2. Adjust thermostat to highest setting.

3. Check main burner ames. See Figure 56 or 57. 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".

I. Check low water cutoff (steam only).

1. Adjust thermostat to highest setting.

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

CAUTION

Do not drain below gauge glass.

3. Main burners will extinguish when water level drops below low water cutoff. Water should still be visible in gauge glass. Verify limit, thermostat or other controls have not shut off boiler.

4. Adjust thermostat to lowest setting. 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.

WARNING

Failure to properly adjust gas input rate will result

in over ring or under ring of the appliance.

Improper and unsafe boiler operation may result.

3. Water: Observe temperature gauge. When temperature exceeds limit set point main burners should extinguish.

4. Adjust limit to setting above observed reading. Main burners should reignite.

5. Adjust thermostat to lowest setting. Adjust limit to desired setting.

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 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 (turn adjustment screw counterclockwise to decrease manifold pressure, or clockwise to increase manifold pressure).

iii. Turn on gas valve not having pilot control.

Adjust gas valve pressure regulator to obtain required manifold pressure. Manifold pressure may not change during initial turns of adjustment screw.

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

10 to determine gas 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

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).

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.

Page 59

Table 10: Input Rate

Seconds

for One

Revolution

30 60 120 240 600 32 56 113 225 563 34 53 106 212 529 36 50 100 200 500 38 47 95 189 474 40 45 90 180 450 42 43 86 172 430 44 41 82 164 410 46 39 78 157 391

48 37 75 150 375 50 36 72 144 360 52 35 69 138 346

54 33 67 133 333 56 32 64 129 321

58 31 62 124 310 60 30 60 120 300 62 29 58 116 290

64 29 56 112 281 66 29 54 109 273

68 28 53 106 265 70 26 51 103 257 72 25 50 100 250 74 24 48 97 243 76 24 47 95 237 78 23 46 92 231 80 22 45 90 225

One-Half

Cu. Ft.

Size of Gas Meter Dial

One

Cu. Ft.

Two

Cu. Ft.

Five

Cu. Ft.

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 48, 49, 50, or 51.

c. Operate boiler with steam in entire system for

several days to bring system oil and dirt back to boiler.

d. Drain condensate from drain valve in wet return.

Operate boiler until condensate runs clean.

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

APPLIANCE. See Figure 48, 49, 50, or 51. b. Fill boiler to normal waterline. c. Remove safety valve. d. Pour recommended boil-out compound into

boiler through safety valve opening. e. Reinstall safety valve in Tapping "E" with

spindle in vertical position. See Figures 1 and 2. f. Follow Lighting or Operating Instructions to

place boiler in operation. See Figure 48, 49, 50,

or 51.

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 48, 49, 50, or 51. Drain boiler and system piping. h. Remove drain valve. Thoroughly wash boiler

water passages with high pressure spray through

drain valve tapping. 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 48, 49, 50,

or 51. 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.

Page 60

h. Follow instructions TO TURN OFF GAS TO

APPLIANCE. See Figure 48, 49, 50, or 51. 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 48, 49, 50,

or 51. 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 48, 49, 50, or 51.

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 48, 49, 50, or 51.

e. Operate boiler for at least 30 minutes after

condensate begins to run hot. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 48, 49, 50, or 51.

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 48, 49, 50,

or 51. 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 48, 49, 50, or 51. Open all radiator valves. Reinstall all supply main air valves. Open gate valve in Hartford Loop.

l. Allow boiler to cool until crown sheet is no

longer too hot to touch. Close drain valves at boiler and in return main. Fill boiler slowly to normal waterline.

m. Follow Lighting or Operating Instructions to

place boiler in operation. See Figure 48, 49, 50, or 51. Allow boiler to steam for 10 minutes. Drain one quart of water from lower Gauge

Glass 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.

Page 61

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.

Page 62

X. Service Instructions

DANGER

This boiler uses ammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify,

remove or tamper with any control device.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.

If any controls are replaced, they must be replaced with identical models. Read, understand and follow all the instructions and warnings contained in all the sections of this

manual. If any electrical wires are disconnected during service, clearly label the wires and assure that the wires

are reconnected properly. Never jump out or bypass any safety or operating control or component of this boiler. Read, understand and follow all the instructions and warnings contained in ALL of the component

instruction manuals. Assure that all safety and operating controls and components are operating properly before placing

the boiler back in service.

A. General. Inspection and service should be conducted

annually, except as noted. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figures 48, 49, 50 or 51.

B. Maintenance of Low Water Cutoff

1. McDonnell & Miller PS-802 or Hydrolevel CycleGard CG400 Probe Style Only.

a. Drain boiler to point below Tapping 'K'. See

Figure 2. b. Disconnect wire(s) connecting control and probe. c. Remove control from probe.

DANGER

Assure that the boiler is at zero pressure before removing the LWCO probe. Do not rely on the pressure gauge to indicate that the boiler is at zero pressure. Open the safety valve to relieve all internal pressure prior to proceeding. Safety valve discharge piping must be piped such that the potential for burns is eliminated.

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

scale and sediment buildup.

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.

Page 63

Figure 58: Boiler Flueway Cleaning

i. Inspect connecting lines to boiler for

accumulation of mud and scale. Clean as necessary.

ii. Examine wiring for brittle or worn

insulation and clean electrical contact.

iii. Inspect solder joints on bellows and 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 45.

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 58.

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.

Page 64

CAUTION

When necessary to remove burners, be sure to reinstall them in the original manner by engaging

the orice and locating hole in the rear of the burner tray. Burners must be aligned with the

burner manifold.

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

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 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 58.

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 59.

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

Pilot Located Between Burners*

Boiler Size

1 inch 40mm

IN3 1 & 2 1 & 2 IN4 2 & 3 2 & 3 IN5 3 & 4 2 & 3 IN6 4 & 5 3 & 4 IN7 6 & 7 3 & 4 IN8 7 & 8 4 & 5

IN9 8 & 9 4 & 5 IN10 9 & 10 --IN11 11 & 12 --IN12 12 & 13 ---

* Burners numbered left to right as viewed from front of boiler.

I. Lubrication. Manufacturers Instruction should be

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

1. Type of lubricant to be used.

2. Frequency of lubrication.

3. Points to lubricate.

J. Check operation. Follow 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.

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.

Figure 59: Honeywell Q348 Spark Gap

Page 65

M. Excessive Make-Up Water

CAUTION

IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN

INDICATED BELOW, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM

FOR LEAKS.

Model No.

IN3 0.1 1 IN4 0.1 1 IN5 0.2 2 IN6 0.2 2 IN7 0.2 3 IN8 0.2 3

IN9 0.3 3 IN10 0.3 4 IN11 0.3 4 IN12 0.4 4

Gallons Per

Month

Gallons Per

Year

A leaky system will increase the volume of make-up

water supplied to the boiler, which can signicantly

shorten the life of the boiler. Entrained in make-up water are dissolved minerals, salts, and oxygen. When the fresh, cool make-up water is heated in the boiler, the minerals fall out as sediment, the salts coat the inside of the boiler, and the oxygen escapes as a gas. The accumulation of sediment eventually isolates the water from contacting the cast iron. When this happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen or chloride slats in the boiler corrodes the cast iron from the inside. More make-up water and higher concentrations of contaminants damage the boiler sooner. Our warranty does not cover corrosion and sediment-related damage. Clearly it is in everyone's best interest to prevent this type of failure. You can do your part by ensuring that your system is leak-free, keeping leakage to less than 2 percent of the total water volume each month.

Page 66

Honeywell Electronic Ignition Trouble Shooting Guide

Page 67

Honeywell Hot Surface to Pilot Trouble Shooting Guide

Page 68

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a

result of servicing or repair, these substances become airborne and, if inhaled,

may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures: Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

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

approved respirator

2. Long sleeved, loose fitting 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 airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United

States and Canada.

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 difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

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

immediate medical attention.

Page 69

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.

SERVICE RECORD

DATE SERVICE PERFORMED

Page 70

Key No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

1. Section Assembly

Left End Section (less tankless heater) 717100022 1 1 1 1 1 1 1 1 1 1

Left End Section (with tankless heater) 717100042 1 1 1 1 1 1 1 1 1 1 1B Center Section 717100031 1 2 3 4 5 6 7 8 9 10 1C Right End Section 717100011 1 1 1 1 1 1 1 1 1 1

Tie Rod, 3/8-16 x 10" 80861071 2 --- --- --- --- --- --- --- --- ---

Tie Rod, 3/8-16 x 12-1/2" 80861010 --- 2 --- --- --- --- --- --- --- ---

Tie Rod, 3/8-16 x 17" 80861011 --- --- 2 --- --- --- --- --- --- ---

Tie Rod, 3/8-16 x 20-3/4" 80861012 --- --- --- 2 --- --- --- --- --- ---

Tie Rod, 3/8-16 x 23" 80861049 --- --- --- --- 2 --- --- --- --- --1D

Tie Rod, 3/8-16 x 27-1/2" 80861014 --- --- --- --- --- 2 --- --- --- ---

Tie Rod, 3/8-16 x 29" 80861034 --- --- --- --- --- --- 2 --- --- ---

Tie Rod, 3/8-16 x 32-3/4" 80861035 --- --- --- --- --- --- --- 2 --- ---

Tie Rod, 3/8-16 x 36-1/2" 80861036 --- --- --- --- --- --- --- --- 2 ---

Tie Rod, 3/8-16 x 39" 80861020 --- --- --- --- --- --- --- --- --- 2 1E Washer, 3/8" 80860600 4 4 4 4 4 4 4 4 4 4 1F Nut, 3/8-16 80860400 4 4 4 4 4 4 4 4 4 4 1G Slip Nipple, 5" 7066003 2 3 4 5 6 7 8 9 10 11 1H Slip Nipple, 22B 806600375 2 3 4 5 6 7 8 9 10 11

Page 71

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

2. Canopy and Draft Hood Canopy/Draft Hood Parts

6111003 1 --- --- --- --- --- --- --- --- --6111004 --- 1 --- --- --- --- --- --- --- --6111005 --- --- 1 --- --- --- --- --- --- ---

2A Canopy Assembly

2B Rear Draft Hood Carton Assembly

Canopy/Draft Hood Carton Assembly

(complete)

2D Carriage Bolt, ¼ -20 x 1" 80860115 4 4 4 4 4 4 4 4 4 4 2E Flat Washer, ¼" 80860603 4 4 4 4 4 4 4 4 4 4

2F Hex Nut, ¼ -20 80860407 4 4 4 4 4 4 4 4 4 4 2G Gasket 6206001 1 1 1 1 1 1 1 1 1 1 2H Wingnut, ¼ -20 80860900 2 2 2 2 2 2 2 --- --- ---

All Components for use in both USA or Canada, unless marked with * for USA Only or ** for Canada Only

6111006 --- --- --- 1 --- --- --- --- --- --6111007 --- --- --- --- 1 --- --- --- --- --6111008 --- --- --- --- --- 1 --- --- --- ---

6111009 --- --- --- --- --- --- 1 --- --- --61110033 1 --- --- --- --- --- --- --- --- --61110043 --- 1 --- --- --- --- --- --- --- --61110053 --- --- 1 --- --- --- --- --- --- --61110063 --- --- --- 1* --- --- --- --- --- --61110064 --- --- --- 1** --- --- --- --- --- --61110073 --- --- --- --- 1 --- --- --- --- --61110083 --- --- --- --- --- 1* --- --- --- --61110084 --- --- --- --- --- 1** --- --- --- --61110093 --- --- --- --- --- --- 1 --- --- --61110102 --- --- --- --- --- --- --- 1* --- ---

611101021 --- --- --- --- --- --- --- 1** --- ---

61110112 --- --- --- --- --- --- --- --- 1 --61110122 --- --- --- --- --- --- --- --- --- 1

Page 72

Key No.

3. Base Assembly

Description Part No.

Quantity

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

718600391 1 --- --- --- --- --- --- --- --- --718600491 --- 1 --- --- --- --- --- --- --- --718600591 --- --- 1 --- --- --- --- --- --- --718600691 --- --- --- 1 --- --- --- --- --- ---

3A Base Tray

3B Base Wrapper

3B1 Base End Insulation 720601 2 2 2 2 2 2 2 2 2 2

718600791 --- --- --- --- 1 --- --- --- --- --718600891 --- --- --- --- --- 1 --- --- --- --718600991 --- --- --- --- --- --- 1 --- --- --718601091 --- --- --- --- --- --- --- 1 --- --718601191 --- --- --- --- --- --- --- --- 1 --718601291 --- --- --- --- --- --- --- --- --- 1 718600311 1 --- --- --- --- --- --- --- --- --718600411 --- 1 --- --- --- --- --- --- --- --718600511 --- --- 1 --- --- --- --- --- --- --718600611 --- --- --- 1 --- --- --- --- --- --718600711 --- --- --- --- 1 --- --- --- --- --718600811 --- --- --- --- --- 1 --- --- --- --718600911 --- --- --- --- --- --- 1 --- --- --718601011 --- --- --- --- --- --- --- 1 --- --718601111 --- --- --- --- --- --- --- --- 1 --718601211 --- --- --- --- --- --- --- --- --- 1

Page 73

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

3. Base Assembly (Continued)

72060035 1 --- --- --- --- --- --- --- --- --72060045 --- 1 --- --- --- --- --- --- --- --72060055 --- --- 1 --- --- --- --- --- --- --72060065 --- --- --- 1 --- --- --- --- --- ---

3B2 Base Rear Insulation

3C Base Front Panel Assembly

Burner Tray (1 Inch Main Burners)

Burner Tray (40mm Main Burners)

3E Base Leg Assembly 6186001 4 4 4 4 4 4 4 4 6 6 3E1 Base Leg [Included in Key No. 3E] 71860021 4 4 4 4 4 4 4 4 6 6 3E2 Nylon Glide [Included in Key No. 3E] 8186006 4 4 4 4 4 4 4 4 6 6

72060075 --- --- --- --- 1 --- --- --- --- --72060085 --- --- --- --- --- 1 --- --- --- --72060095 --- --- --- --- --- --- 1 --- --- --72060105 --- --- --- --- --- --- --- 1 --- --72060115 --- --- --- --- --- --- --- --- 1 ---

72060126 --- --- --- --- --- --- --- --- --- 1 618600341 1 --- --- --- --- --- --- --- --- --618600441 --- 1 --- --- --- --- --- --- --- --618600541 --- --- 1 --- --- --- --- --- --- --618600641 --- --- --- 1 --- --- --- --- --- --618600741 --- --- --- --- 1 --- --- --- --- --618600841 --- --- --- --- --- 1 --- --- --- --618600941 --- --- --- --- --- --- 1 --- --- --618601041 --- --- --- --- --- --- --- 1 --- --618601141 --- --- --- --- --- --- --- --- 1 --618601241 --- --- --- --- --- --- --- --- --- 1 718600305 1 --- --- --- --- --- --- --- --- --718600405 --- 1 --- --- --- --- --- --- --- --718600505 --- --- 1 --- --- --- --- --- --- --718600605 --- --- --- 1 --- --- --- --- --- --718600705 --- --- --- --- 1 --- --- --- --- --718600805 --- --- --- --- --- 1 --- --- --- --718600905 --- --- --- --- --- --- 1 --- --- --718601005 --- --- --- --- --- --- --- 1 --- --718601105 --- --- --- --- --- --- --- --- 1 --718601205 --- --- --- --- --- --- --- --- --- 1

71806037 1 --- --- --- --- --- --- --- --- ---

71806047 --- 1 --- --- --- --- --- --- --- ---

71806057 --- --- 1 --- --- --- --- --- --- ---

71806067 --- --- --- 1 --- --- --- --- --- ---

71806077 --- --- --- --- 1 --- --- --- --- --718600806 --- --- --- --- --- 1 --- --- --- --718600906 --- --- --- --- --- --- 1 --- --- ---

Page 74

Key No.

Description Part No.

3. Base Assembly (Continued)

Quantity

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

718600361 1 --- --- --- --- --- --- --- --- --718600461 --- 1 --- --- --- --- --- --- --- --718600561 --- --- 1 --- --- --- --- --- --- --718600661 --- --- --- 1 --- --- --- --- --- ---

3F Burner Access Panel

3G Left End Jacket Attachment Bracket 7046011 1 1 1 1 1 1 1 1 1 1 3H Right End Jacket Attachment Bracket 7046012 1 1 1 1 1 1 1 1 1 1

3J Base Sealant 6206002 1 1 1 1 1 1 1 1 1 1

Screw, Self Tapping, Type F, Phillips

Pan Head, 1/4 -20 x 1/2", Plated Screw, Self Tapping, Type F, Hex

Head, 5/16 -18 x 1-1/4", Plated

3M Washer, 5/16, USS 80860601 4 4 4 4 4 4 4 4 4 4 3N Hex Lock Nut, 5/16 -18 80860464 4 4 4 4 4 4 4 4 4 4 3P Screw, Sheet Metal, #8 x 1/2" 80860000 2 2 2 2 2 2 2 2 2 2

718600761 --- --- --- --- 1 --- --- --- --- --718600861 --- --- --- --- --- 1 --- --- --- --718600961 --- --- --- --- --- --- 1 --- --- --718601061 --- --- --- --- --- --- --- 1 --- --718601161 --- --- --- --- --- --- --- --- 1 --718601261 --- --- --- --- --- --- --- --- --- 1

80860700 16 16 16 16 17 17 17 17 21 21

80860717 4 4 4 4 4 4 4 4 4 4

Manifold and 1" Main Burners

Page 75

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

4. Manifold and Main Burners (1 Inch Main Burners Only)

4A Main Burner 8236099 2 4 6 8 11 13 15 17 20 22

Main Burner with Pilot Bracket (Continuous Ignition) (Q350 Pilot)

Main Burner with Pilot Bracket

(Continuous Ignition) (Q327 Pilot) Main Burner with Pilot Bracket

(Intermittent Ignition) (Q348 Pilot)

8236097 1 1 1 1 1 --- --- --- --- ---

8236098 --- --- --- --- --- 1 1 1 1 1

8236098 1 1 1 1 1 1 1 1 1 1

82260033 1 --- --- --- --- --- --- --- --- --82260043 --- 1 --- --- --- --- --- --- --- --82260053 --- --- 1 --- --- --- --- --- --- --82260063 --- --- --- 1 --- --- --- --- --- ---

4C Manifold

Natural

Gas

Only

LP Only

Note: Orice Sizes shown for normal altitude (0-2000 feet). For High Altitude consult factory.

Main Burner Orice, #45 Pink 822711 3 5 7 9 --- --- --- --- --- ---

Main Burner Orice, #47 White 822710 --- --- --- --- 12 14 16 18 21 23

Main burner Orice, #55 Green 822708 3 --- --- --- --- --- --- --- --- ---

Main Burner Orice, 1.25 mm, Purple 822705 --- 5 7 9 --- --- --- --- --- ---

Main Burner Orice, 3/64", Blue 822704 --- --- --- --- 12 14 16 --- --- ---

Screw, Machine, Slotted Round Head,

10-32 x 3/16" Screw, Self Tapping, Phillips Pan

Head, 1/4 -20 x 1/2"

82260073 --- --- --- --- 1 --- --- --- --- --82260083 --- --- --- --- --- 1 --- --- --- --82260093 --- --- --- --- --- --- 1 --- --- --82260103 --- --- --- --- --- --- --- 1 --- --82260113 --- --- --- --- --- --- --- --- 1 --82260123 --- --- --- --- --- --- --- --- --- 1

80860800 2 2 2 2 2 2 2 2 2 2

80860700 4 4 4 4 4 4 4 4 4 4

Page 76

Manifold and 40mm Main Burners

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9

Quantity

4. Manifold and Main Burners (40MM MAIN BURNERS ONLY)

4A Main Burner 8236135 1 2 3 4 5 6 7

Intermittent Ignition Only

4B Main Burner with 41° Pilot Bracket 8236136 1 1 1 1 1 1 1

24-Volt Continuous Ignition (Standing Pilot) Natural Gas

Main Burner with 48° Pilot Bracket 8236143 1 1 1 1 --- --- ---

Main Burner with 41° Pilot Bracket 8236136 --- --- --- --- 1 1 1

24-Volt Continuous Ignition (Standing Pilot) LP Gas

4B Main Burner with 41° Pilot Bracket 823136 1 1 1 1 1 1 1

82260038 1 --- --- --- --- --- --82260048 --- 1 --- --- --- --- --82260058 --- --- 1 --- --- --- ---

Manifold

82260068 --- --- --- 1 --- --- --82260078 --- --- --- --- 1 --- ---

82260088 --- --- --- --- --- 1 --82260098 --- --- --- --- --- --- 1

Page 77

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9

Quantity

4. Manifold and Main Burners (40MM MAIN BURNERS ONLY) Continued

Natural Gas, High Altitude (2000-5000 Ft.) USA Only

Main Burner Orice #39 822727 2 3 --- --- --- --- ---

Main Burner Orice #38 822720 --- --- 4 5 6 7 8

LP Gas, High Altitude (2000-5000 Ft.) USA Only

4D Main Burner Orice #53 822722 2 3 4 5 6 7 8

Natural Gas, High Altitude (5000-9000 Ft.) USA Only

Main Burner Orice #41 822729 2 3 --- --- --- --- ---

Main Burner Orice #42 822728 --- --- 4 5 6 7 8

LP Gas, High Altitude (5000-9000 Ft.) USA Only

Main Burner Orice #54 822734 2 --- --- --- --- --- ---

Main Burner Orice #53 822722 --- 3 4 5 6 7 8

Natural Gas, High Altitude (2000-4500 Ft.) Canada Only

Main Burner Orice #37 822719 2 --- --- --- --- --- ---

Main Burner Orice #36 822771 --- 3 4 5 6 7 8

LP Gas, High Altitude (2000-4500 Ft.) Canada Only

4D Main Burner Orice #52 822721 2 3 4 5 6 7 8

Screw, Machine, Slotted Round Head,

#10-32 x 3/16" Screw, Self Tapping, Phillips Pan Head,

1/4 - 20 x 1/2"

Injection Shield Assembly

80860800 2 2 2 2 2 2 2

80860700 4 4 4 4 4 4 4

718600362 1 --- --- --- --- --- --718600462 --- 1 --- --- --- --- --718600562 --- --- 1 --- --- --- --718600662 --- --- --- 1 --- --- --718600762 --- --- --- --- 1 --- --718600862 --- --- --- --- --- 1 --718600962 --- --- --- --- --- --- 1

Page 78

Key No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

5. Pilot Burner and Gas Valve, Continuous Ignition (Standing Pilot), Natural Gas

Pilot Burner, Honeywell Q350A1321 8236065 1 1 1 1 1 --- --- --- --- ---

Pilot Burner, Honeywell Q327A1006 8236022 --- --- --- --- 1** 1 1 1 1 1 Pilot Orice, Honeywell 390686-22

Pilot Orice, Honeywell 388146AG --- --- --- --- --- 1 1 1 1 1 Compression Nut/Fitting, 1/4" OD x 1/4

C.C. (Included with 5A) Pilot Tubing, 1/4" OD x 30" 8236122 1 1 1 1 1 --- --- --- --- ---

Pilot Tubing, 1/4" OD x 40" 8236123 --- --- --- --- --- 1 1 1 1 1 Gas Valve, Honeywell VR8200C3005 81660143 1 1 1 1 --- --- --- --- --- --Gas Valve, Honeywell VR8200C6065 100333-01 1** 1** 1** 1** --- --- --- --- --- --Gas Valve, Honeywell VR8300C4027 81660154 --- --- --- --- 1 1 1 --- --- ---

Gas Valve, Honeywell VR8300C4266 100334-01 --- --- --- --- 1** 1** 1** --- --- ---

Gas Valve, Robertshaw

7000ERHC-S7C Gas Valve, ITT K3A451 81660080 --- --- --- --- --- --- --- 1 1 1

5F Thermocouple, Honeywell Q309A 8236024 1 1 1 1 1 1 1 1 1 1

Included

with 5A

8236109 2 2 2 2 2 2 2 2 2 2

81660156 --- --- --- --- --- --- --- 1 1 1

1 1 1 1 1 --- --- --- --- ---

5. Pilot Burner and Gas Valve, Continuous Ignition (Standing Pilot), LP/Propane

Pilot Burner, Honeywell Q350A1339 8236066 1 1 1 1 1 --- --- --- --- ---

Pilot Burner, Honeywell Q327A1147 8236023 1** 1** 1** 1** 1** 1 1 --- --- --Pilot Orice, Honeywell 390686-23

Pilot Orice, Honeywell 388146KR --- --- --- --- --- 1 1 --- --- --Compression Nut/Fitting, 1/4" OD x 1/4

C.C. (Included with 5A and 5E) Pilot Tubing, 1/4" OD x 30" 8236122 1 1 1 1 1 --- --- --- --- ---

Pilot Tubing, 1/4" OD x 40" 8236123 --- --- --- --- --- 1 1 --- --- --Gas Valve, Honeywell VR8200C3013 81660144 1 1 1 1 --- --- --- --- --- ---

Gas Valve, Honeywell VR8300C4035 81660163 --- --- --- --- 1 1 1 --- --- ---

5F Thermocouple, Honeywell Q309A 8236024 1 1 1 1 1 1 1 --- --- ---

Note: Gas Valve specications shown for normal altitude (0-2000 feet). For High Altitude consult factory. ** 40mm Burners Only

Included

with 5A

8236109 2 2 2 2 2 2 2 --- --- ---

1 1 1 1 1 --- --- --- --- ---

Page 79

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas

5A Pilot Burner, Honeywell Q348A1002 8236072 1 1 1 1 1 1 1 1 1 1

5B Pilot Orice, Honeywell 388146NE

Compression Nut/Fitting, 1/4" OD x 1/4

C.C. (Included with 5A and 5E) Pilot Tubing, 1/4" OD x 30" 8236122 1 1 1 1 1 --- --- --- --- ---

Pilot Tubing, 1/4" OD x 40" 8236123 --- --- --- --- --- 1 1 1 1 1 Gas Valve, Honeywell VR8204C3007 81660145 1 1 1 1 --- --- --- --- --- ---

Gas Valve, Honeywell VR8304P4306 81660161 --- --- --- --- 1 1 1 1 1 2 Igniter/Sensor Cable, 36", Honeywell

394800-36

5G Ground Wire Assembly 6136054 1 1 1 1 1 1 1 1 1 1

Included

with 5A

8236109 2 2 2 2 2 2 2 2 2 2

8236084 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), LP/Propane

5A Pilot Burner, Honeywell Q348A1010 8236081 1 1 1 1 1 1 1 --- --- ---

5B Pilot Orice, Honeywell 388146KP

Compression Nut/Fitting, 1/4" OD x 1/4

C.C. (Included with 5A and 5E) Pilot Tubing, 1/4" OD x 30" 8236122 1 1 1 1 1 --- --- --- --- ---

Pilot Tubing, 1/4" OD x 40" 8236123 --- --- --- --- --- 1 1 --- --- ---

Included

with 5A

8236109 2 2 2 2 2 2 2 --- --- ---

1 1 1 1 1 1 1 --- --- ---

Gas Valve, Honeywell VR8204C3015 81660146 1 1 1 1 --- --- --- --- --- ---

Gas Valve, Honeywell VR8304P4314 81660160 --- --- --- --- 1 1 1 --- --- --Igniter/Sensor Cable, 36" Honeywell

394800-36

5G Ground Wire Assembly 6136054 1 1 1 1 1 1 1 --- --- ---

Note: Gas Valve specications shown for normal altitude (0-2000 feet). For High Altitude consult factory.

8236084 1 1 1 1 1 1 1 --- --- ---

Page 80

Page 81

Key

No.

Jacket Assembly

Description Part No.

Quantity

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

1 Left Side Panel

2 Right Side Panel

3 Front Removable Panel

60410013 1 1 1 1 1 1 1 --- --- ---

60410023 --- --- --- --- --- --- --- 1 1 1

60410012 1 1 1 1 1 1 1 --- --- ---

60410022 --- --- --- --- --- --- --- 1 1 1

60410033 1 --- --- --- --- --- --- --- --- ---

60410043 --- 1 --- --- --- --- --- --- --- ---

60410053 --- --- 1 --- --- --- --- --- --- ---

60410063 --- --- --- 1 --- --- --- --- --- ---

60410073 --- --- --- --- 1 --- --- --- --- ---

60410083 --- --- --- --- --- 1 --- --- --- ---

60410093 --- --- --- --- --- --- 1 --- --- ---

60410103 --- --- --- --- --- --- --- 1 --- ---

60410113 --- --- --- --- --- --- --- --- 1 ---

60410123 --- --- --- --- --- --- --- --- --- 1

60410034 1 --- --- --- --- --- --- --- --- ---

60410044 --- 1 --- --- --- --- --- --- --- ---

60410054 --- --- 1 --- --- --- --- --- --- ---

4 Vestibule Panel

5 Rear Panel

60410064 --- --- --- 1 --- --- --- --- --- ---

60410074 --- --- --- --- 1 --- --- --- --- ---

60410084 --- --- --- --- --- 1 --- --- --- ---

60410094 --- --- --- --- --- --- 1 --- --- ---

60410104 --- --- --- --- --- --- --- 1 --- ---

60410114 --- --- --- --- --- --- --- --- 1 ---

60410124 --- --- --- --- --- --- --- --- --- 1 60410035 1 --- --- --- --- --- --- --- --- --60410045 --- 1 --- --- --- --- --- --- --- --60410055 --- --- 1 --- --- --- --- --- --- --60410065 --- --- --- 1 --- --- --- --- --- --60410075 --- --- --- --- 1 --- --- --- --- --60410085 --- --- --- --- --- 1 --- --- --- --60410095 --- --- --- --- --- --- 1 --- --- --60410105 --- --- --- --- --- --- --- 1 --- --60410115 --- --- --- --- --- --- --- --- 1 --60410125 --- --- --- --- --- --- --- --- --- 1

Page 82

Key No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

Jacket Assembly (Continued) - Refer to Figure on Page 80

5A Upper Left Rear Panel (not shown) 604101051 --- --- --- --- --- --- --- 1 1 1 5B Upper Right Rear Panel (not shown) 604101052 --- --- --- --- --- --- --- 1 1 1

60410036 1 --- --- --- --- --- --- --- --- --60410046 --- 1 --- --- --- --- --- --- --- --60410056 --- --- 1 --- --- --- --- --- --- --60410066 --- --- --- 1 --- --- --- --- --- ---

6A Front Top Panel

6B Rear Top Panel

7 Lower Front Tie Bar

60410076 --- --- --- --- 1 --- --- --- --- --60410086 --- --- --- --- --- 1 --- --- --- --60410096 --- --- --- --- --- --- 1 --- --- --60410106 --- --- --- --- --- --- --- 1 --- --60410116 --- --- --- --- --- --- --- --- 1 ---

60410126 --- --- --- --- --- --- --- --- --- 1 604100361 1 --- --- --- --- --- --- --- --- --604100461 --- 1 --- --- --- --- --- --- --- --604100561 --- --- 1 --- --- --- --- --- --- --604100661 --- --- --- 1 --- --- --- --- --- --604100761 --- --- --- --- 1 --- --- --- --- --604100861 --- --- --- --- --- 1 --- --- --- --604100961 --- --- --- --- --- --- 1 --- --- --604101061 --- --- --- --- --- --- --- 1 --- --604101161 --- --- --- --- --- --- --- --- 1 --604101261 --- --- --- --- --- --- --- --- --- 1

70410034 1 --- --- --- --- --- --- --- --- ---

70410044 --- 1 --- --- --- --- --- --- --- ---

70410054 --- --- 1 --- --- --- --- --- --- ---

70410064 --- --- --- 1 --- --- --- --- --- ---

70410074 --- --- --- --- 1 --- --- --- --- ---

70410084 --- --- --- --- --- 1 --- --- --- ---

70410094 --- --- --- --- --- --- 1 --- --- ---

70410104 --- --- --- --- --- --- --- 1 --- ---

70410114 --- --- --- --- --- --- --- --- 1 ---

70410124 --- --- --- --- --- --- --- --- --- 1

Page 83

Key

No.

Description Part No. Quantity

Steam Trim

7A Safety Valve, 3/4 NPT, 15 psi, Conbraco 13-511-08 81660530 1 7B Elbow, 3/4 NPT 806601502 2

7C Nipple, 3/4 NPT x 3" 806600002 2

Low Water Cutoff, McDonnell & Miller PS-802-24 (Probe Included) 80160720

Low Water Cutoff, McDonnell & Miller 67-BC-1 (Float Type) 80160517

8B Probe for CG400 80160629 1

Gauge Glass, Extended Shank (with Probe LWCO Only) 8056128

Gauge Glass, Standard Shank (with Float LWCO Only) 8056020

10A Limit, Honeywell L404F1367 80160369 1 10B Syphon, 1/4 NPT x 90° 806603010 1 10C Bushing, 3/4 NPT x 1/4 NPT 806600508 1 10D Syphon, 1/4 NPT x 180° 806603030 1 11A Pressure Gauge 8056010 1 11B Drain Valve, Conbraco 31-612-02 806603012 1 11C Bushing, 2 NPT x 3/4 NPT 806600515 1

1Low Water Cutoff, Hydrolevel CG400-2090 (Less Probe - See Key No. 8B) 80160725

Page 84

Page 85

Key

No.

Description Part No. IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Water Trim

Safety Relief Valve, 3/4 NPT, 30 psi,

Conbraco 10-407-05 7B Elbow, 3/4 NPT 806601520 1 1 1 1 1 1 1 1 1 1 7C Nipple, 3/4 NPT x 3" 806600002 2 2 2 2 2 2 2 2 2 2

Circulator, Bell & Gossett NRF-22 with

Gaskets

Circulator, Grundfos UP 15-42F 8056044

Circulator, Taco 007 8056007

Gasket, Bell & Gossett NRF-22 806602029 8B

Gasket, Taco '00' Series 806602006 8C Flange, 1-1/2 NPT 806602014 2 2 2 2 2 2 2 2 2 2 8D Screw, Cap Hex Head, 7/16 -14 x 1-1/2" 80861301 4 4 4 4 4 4 4 4 4 4 8E Nut, Hex, 7/16 -14 80860406 4 4 4 4 4 4 4 4 4 4

Tankless Heater, A-62 6031201 --- 1 1 1 1 1 1 1 1 1

Tankless Heater, #222 6036007 --- --- 1 1 1 1 1 1 1 1

Tankless Heater, A-51 6031202 --- --- --- 1 1 1 1 1 1 1

Tankless Heater, A-53 6031203 --- --- --- --- 1 1 1 1 1 1

Heater Cover Plate 7036001 1 1 1 1 1 1 1 1 1 1

9B Gasket 8036020 1 1 1 1 1 1 1 1 1 1 9C Washer, 3/8" 80860600 6 6 6 6 6 6 6 6 6 6 9D Screw, Cap Hex Head, 3/8 -16 x 7/8" 80861337 6 6 6 6 6 6 6 6 6 6

Limit, Honeywell L8148E1299

(Intermittent Circulation Only)

Limit, Honeywell L6081A1010

10A

(Tankless Heater Only)

Limit, Honeywell L4006A2015

(Gravity Circulation Only)

Well, Honeywell 123871A

(Tankless Heater Only)

10B

Well, Honeywell 123870A (Intermittent or

Gravity Circulation Only)

Temperature/Pressure Gauge,

11A

ENFM 41042.5210

11B Drain Valve, Conbraco 31-612-02 806603012 1 1 1 1 1 1 1 1 1 1

11C Bushing, 2 NPT x 3/4 NPT 806600515 1 1 1 1 1 1 1 1 1 1

Transformer, 50VA, Honeywell AT150D1019

(Tankless Heater or Gravity Circulation Only)

Relay, DPST, Honeywell R8225D1029

(Tankless Heater Only)

Relay, SPST, Honeywell R8222K1000

(Gravity Circulation Only)

81660363 1 1 1 1 1 1 1 1 1 1

8056174

1 1 1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2 2 2Gasket, Grundfos 510179 806602016

80160607

80160469

80160400U

80160452

80160426

8056169U 1 1 1 1 1 1 1 1 1 1

80160186 1 1 1 1 1 1 1 1 1 1

80160265 1 1 1 1 1 1 1 1 1 1

80160127 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1

Page 86

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

Page 87

THIS PAGE LEFT BLANK INTENTIONALLY

Page 88

Page 89

Key

No.

Description Part No.

IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12

Quantity

12. Transformer (Steam and Gravity Water Only)

12A Junction Box, 4-11/16" x 4-11/16" x 2-1/8" Refer to Table on Page 86 12B Transformer, 50 VA, Honeywell AT150D1019 80160186 1 1 1 1 1 1 1 1 1 1

12C Relay, SPST, Honeywell R8222K1000 80160127 1 1 1 1 1 1 1 1 1 1

13. Flame Rollout Switch

13A Flame Rollout Switch 80160044 1 1 1 1 1 1 1 1 1 1 13B Flame Rollout Switch Bracket 7186018 1 1 1 1 1 1 1 1 1 1

14. Blocked Vent Switch

14 Blocked Vent Switch

6016067 1 1 1 1 1 1 1 --- --- --6111001 --- --- --- --- --- --- --- 1 1 1

15. Ignition Module (Intermittent Ignition Only)

15 Ignition Module, Honeywell S8610M3009 100958-01 1 1 1 1 1 1 1 1 1 1

--- Ignition Module Support Bracket 7016001 1 1 1 1 1 1 1 1 1 1

16. Vent Damper

4" 8116321 1 --- --- --- --- --- --- --- --- --- 5" 8116322 --- 1 --- --- --- --- --- --- --- ---

All components for use in both USA and Canada, unless marked with * for USA Only or ** for Canada Only.

6" 8116323 --- --- 1 1* --- --- --- --- --- --7" 8116324 --- --- --- 1** 1 1* --- --- --- --8" 8116325 --- --- --- --- --- 1** 1 1* --- --9" 8116326 --- --- --- --- --- --- --- 1** 1 1

Page 90

XII. Low Water Cut Off (LWCO)

WARNING

DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.

baseboard on the same oor level as the boiler). In

addition, some jurisdictions require the use of a LWCO with a hot water boiler.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

What Kind

Typically, in residential applications, a probe type

LWCO is used instead of a oat type, due to their

relative costs and the simplicity of piping for a probe LWCO.

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

manufacturers recommend an annual inspection of the probe.

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration can be

universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown below.

LWCO Location

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch connection must have a minimum diameter to

prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located above

the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without draining the heating system. Many probe LWCO

Wiring of Typical LWCO

A 24 VAC LWCO is used primarily for gas red boilers

where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.

How to Test

Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by lling the system.

The boiler should attempt to operate once the water level is above the LWCO.

Page 91

if the residential grade water boiler is used or operated over its rated

capacity, is subjected to unauthorized modification, or is damaged as a result of being otherwise improperly operated or serviced including, but not limited to, damage from any of the following:

operation with insufficient water, allowing the boiler to freeze, subjecting the boiler to flood conditions, and operation with unapproved water or fuel additives which cause deposits or corrosion.

5.Removal and Installation: These warranties do not cover expenses of removal or reinstallation. The owner is responsible for

the cost of removing and reinstalling any defective part and its

replacements and all labor and material connected therewith.

6.Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach

of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties.

7.Limitation of Damages: Under no circumstances shall U.S. Boiler

Co., Inc. be liable for incidental, indirect, special or consequential

damages of any kind whatsoever under these warranties, including, but not limited to, injury or damage to persons or property and damages for loss of use, inconvenience or loss of time. U.S. Boiler Co., Inc. liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the

residential grade water boiler involved. Some states do not allow the exclusion or limitation of incidental or consequential damages, so

the above limitation or exclusion may not apply to you.

8.Limitation of Warranties: These warranties set forth the entire obligation of U.S. Boiler Co., Inc. with respect to any defect in a residential grade water boiler and U.S. Boiler Co., Inc. shall have no express obligations, responsibilities or liabilities of any kind whatso-

ever other than those set forth herein. These warranties are given in lieu of all other express warranties.

ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

PROCEDURE FOR OBTAINING WARRANTY SERVICE

In order to assure prompt warranty service, the owner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply

with this request will not void the owner’s rights under these warranties.

Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If

this action is not possible or does not produce a prompt response,

the owner should write to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079, Lancaster, PA 17604, giving full particulars in

support of the claim.

The owner is required to make available for inspection by U.S.

Boiler Co., Inc. or its representative the parts claimed to be

defective and, if requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S. Boiler Co., Inc. at the above address for

inspection or repair. In addition, the owner agrees to make all

reasonable efforts to settle any disagreement arising in connection

with a claim before resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Subject to the terms and conditions set forth below, U.S. Boiler™

Co., Inc. Lancaster, Pennsylvania hereby extends the following limited

warranties to the original owner of a residential grade water boiler

manufactured and shipped on or after July 1,1991:

ONE YEAR LIMITED WARRANTY

ON RESIDENTIAL GRADE WATER BOILERS

U.S. Boiler Co., Inc. warrants to the original owner that its residential grade water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be

free of defects in material and workmanship under normal usage for a

period of one year from the date of original installation. If any part of

a water boiler is found to be defective in material or workmanship during

this one year period, U.S. Boiler Co., Inc. will, at its option, repair or

replace the defective part.

LIFETIME LIMITED WARRANTY

ON HEAT EXCHANGER

U.S. Boiler Co., Inc. warrants to the original owner that the heat

exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation. If a

claim is made under this warranty during the first ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option, repair or replace the heat exchanger. If a claim is made under this warranty after the expiration of ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option and upon payment of the pro-rated

service charge set forth below, repair or replace the heat exchanger.

The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in

service and will be determined as a percentage of the retail price of the

heat exchanger model involved at the time the warranty claim is made

as follows:

sraeY

ecivreSnI

01-1 11 21 31 41 51 61 71

egrahCecivreS

fo%sa

ecirPliateR

egrahC

5 01 51 02 52 03 53

sraeY

ecivreSnI

81 91 02 12 22 32 42

dna52

evoba

egrahCecivreS

fo%sa

ecirPliateR

04 54 05 55 06 56 07 57

NOTE: If the heat exchanger model involved is no longer available

due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the

Burnham Hydronics Repair Parts Price Sheet where the heat

exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.

ADDITIONAL TERMS AND CONDITIONS

1.Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These warranties are applicable only to water boilers designated as residential grade by U.S. Boiler Co., Inc. and installed in a single or two-family residence and do not apply to steam boilers of any kind or to commercial grade boilers.

2. Components Manufactured by Others: Upon expiration of the one year limited warranty on residential grade water boilers, all boiler components manufactured by others but furnished by U.S. Boiler Co., Inc. (such as oil burner, circulator and controls) will be subject only to the manufacturer’s warranty, if any.

3. Proper Installation: The warranties extended by U.S. Boiler Co.,

Inc. are conditioned upon the installation of the residential grade

water boiler in strict compliance with U.S. Boiler Co., Inc. installation instructions. U.S. Boiler Co., Inc. specifically disclaims liability of any kind caused by or relating to improper installation.

4. Proper Use and Maintenance: The warranties extended by U.S.

Boiler Co., Inc. conditioned upon the use of the residential grade water boiler for its intended purposes and its maintenance

accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable

Limited Warranty

FOR RESIDENTIAL GRADE WATER BOILERS

03/03

Page 92

By this Warranty Statement the U.S. Boiler™ Company, Inc. of Lancaster, Pennsylvania issues limited warranties subject to the terms and conditions stated below. These limited warranties apply to residential cast iron boilers labeled Independence

, Independence® PV, V8H™ and MegaSteam™ Series, these warranties are issued only to the original homeowner at the original place of installation.

U.S. Boiler Company, Inc. warrants its residential cast iron steam boilers labeled Independence, Independence PV, V8H and MegaSteam Series to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of one year from the date of original installation. In the event that any part of such a steam boiler is found to be defective in material or workmanship during the one-year period, then U.S. Boiler Company, Inc. will repair or replace, at its option, the defective part.

U.S. Boiler Company, Inc. warrants the cast iron section assembly of its residential cast iron steam boilers labeled Independence, Independence PV, V8H and MegaSteam Series, to be free of defects in material and workmanship when shipped and to remain free of such defects under normal usage for a period of 10 years from the date of original boiler installation. In the event that such cast iron section assembly is found to be defective in material or workmanship during this period, U.S. Boiler Company, Inc. will repair or replace, at its option, the defective cast iron section assembly.

U.S. Boiler Company, Inc. warrants the cast iron sections of the MegaSteam boiler to resist TEMPERATURE INDUCED CHLORIDE ACTIVATED GRAPHITIC CORROSION for a period of  ve years from the date of original installation. In the event that any cast iron section of a MegaSteam boiler fails due to this corrosion mechanism during this period, U.S. Boiler Company, Inc. will repair or replace, at its option, the failed cast iron section assembly.

U.S. Boiler Company, Inc. warrants the cast iron and steel nipples that join the sections to be free from defects in material and workmanship for the lifetime of the original owner at the time of installation. In the event that such nipples are found to be defective in material or workmanship during this period, U.S. Boiler Company, Inc. will repair or replace at its option, the cast iron section assembly.

1. This warranty does not cover expenses for removal or reinstallation. The homeowner will be responsible for the cost of removing and reinstalling the defective part or its replacement and all labor and material connected therewith. Replacement material will be invoiced to the distributor in the usual manner and will be subject to adjustment upon proof of defect.

2. This warranty, in no way, can be considered as a guarantee of workmanship of an installer connected with the installation of the U.S. Boiler Company, Inc. boiler or as imposing on U.S. Boiler Company, Inc. liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation, which liability is expressly disclaimed.

3. This warranty will not be applicable if the boiler is used or operated over its rated capacity; or installed for uses other than home heating; or is not maintained in accordance with U.S. Boiler Company, Inc. recommendation or accepted good practice as determined by hydronics industry standards.

4. This warranty will not be applicable if the boiler has been damaged as a result of being improperly serviced or operated, including but not limited to the following: operated with insuf cient water, allowed to freeze; subject to  ood conditions; or operated with water conditions and/or fuels or additives which cause unusual deposits or corrosion in or on the heat exchanger.

FIRST YEAR - LIMITED WARRANTY FOR

RESIDENTIAL CAST IRON STEAM BOILERS

Limited Warranty

FOR RESIDENTIAL CAST IRON STEAM BOILERS

SECOND THROUGH 10 YEAR - LIMITED

WARRANTY FOR THE CAST IRON SECTION

ASSEMBLY OF RESIDENTIAL CAST IRON STEAM BOILERS

ADDITIONAL TERMS AND CONDITIONS

5. This warranty applies only to boilers installed within the United States, and Canada.

6. In order for this warranty to be effective: a.) The boiler must have been properly installed in a single or two-family residential dwelling. This warranty does not apply to boilers installed in apartments or to commercial or industrial installation. b.) The boiler must have been assembled in strict compliance with installation instructions furnished with the boiler by U.S. Boiler Company, Inc. c.) Boiler components must not have been damaged in handling during shipment or installation.

7. The foregoing provisions of this warranty shall be effective to the maximum extent permitted by applicable law, and, to the extent that any such provision would otherwise be inconsistent with applicable law, such provision shall be limited in effect to the minimum extent necessary to avoid such unconscionable result or inconsistency with applicable law.

8. The remedy for breach of this warranty is expressly limited to the repair or replacement of any part found to be defective under conditions of normal use; and the remedy for breach of this warranty or for negligence does not extend to liability for incidental, special or consequential damages or losses such as loss of the use of the materials, inconvenience or loss of time. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you.

9. This warranty is in lieu of all others, and any and all express or implied warranties (including, without limitation, any implied warranties of merchantability or  tness for a particular purpose) are expressly limited in duration to the period of the warranty as previously stated herein. Some states do not allow limitation on how long an implied warranty lasts, so the above limitation may not apply to you.

10.Not withstanding any of the above provisions, U.S. Boiler Company, Inc. liability under this warranty shall not exceed the selling price of the product found to be defective.

In order to assure prompt warranty service the homeowner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will not

void the homeowner’s rights under this warranty.

Upon discovery of a condition believed to be related to a defect in material or workmanship covered by this warranty statement, the homeowner should notify the installer who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the homeowner should write to U.S. Boiler Company, Inc., at P.O. Box 3079, Lancaster, PA 17604 giving full particulars in support of the claim.

The homeowner is required to make available for inspection by U.S. Boiler Company, Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Company, Inc., to ship said parts prepaid to Burnham Hydronics at the above address for inspection or repair. In addition, the homeowner agrees to make all reasonable efforts to settle any disagreement arising in connection with his claim before resorting to legal remedies in the courts.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

LIFETIME NIPPLE LEAKAGE WARRANTY

PROCEDURE FOR OBTAINING WARRANTY SERVICE

FIRST THROUGH 5 YEAR - LIMITED WARRANTY AGAINST

WATERSIDE CORROSION IN THE MEGASTEAM SERIES