Burnham INDEPENDENCE IN3, INDEPENDENCE IN10, INDEPENDENCE IN6, INDEPENDENCE IN4, INDEPENDENCE IN5 Installation & Service Instructions Manual

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8141049R26-10/08 Price - $5.00

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

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

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

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

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

DANGER

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.

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.

NOTICE

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.

Figure 1: Dimensional Drawing

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) ...............

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

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

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.

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.

D. Install Canopy.

1. Install ½" thick x 1" wide ceramic ber gasket. See

Figure 7.

Figure 7: Canopy Gasket Installation

2. Position canopy on ceramic ber gasket. See Figure

3. Attach canopy using ¼" carriage bolts, nuts, and washers provided.

E. Inspect joints between sections. They were factory

sealed. If there are any openings due to shipment or handling, reseal with boiler putty.

F. Install Jacket. See Figure 9.

1. Models IN7-IN12 steam boilers: remove 3 inch diameter knockouts in jacket top panels.

2. Raise rear panel under rear ange of canopy and rest on oor. Position rear panel and secure to jacket side

panels with sheet metal screws. For Models IN10IN12, secure jacket upper rear panels to side panels with sheet metal screws.

3. Secure both jacket side panels to base with sheet metal screws.

4. Position front tie bar and secure to jacket side panels with sheet metal screws.

5. Position vestibule panel and secure to side panels with sheet metal screws.

6. Attach Rating Label and Vent Damper Instruction Label at designated locations on vestibule panel.

7. Install top panels by placing over and around outside of side and rear panels. Seat fully and secure with sheet metal screws.

8. Install black plastic rings into 1-3/32 inch diameter holes located below upper louvers of front removable door.

Figure 8: Canopy Installation

Figure 9: Jacket Assembly

9. Install front removable door by engaging upper side

edges of panel with side receiving anges, sliding up and under top panel ange - seating front door fully - then sliding down to engage bottom ange

behind lower front tie bar.

G. Install Pilot/Burner Assembly (shipped in Gas

Controls Carton). See Figure 10.

Figure 10: Combustion Chamber

1. Remove jacket front removable door. a. Remove burner access panel located above

burners.

b. Install Pilot/Burner Assembly where noted on

gas manifold.

i. Insert rear of burner in burner tray slot. ii. Position burner over the orice.

NOTE: The burner to the right may need to

be lifted from the orice to install pilot/

burner assembly. Reinstall lifted burner

over the orice.

c. Reinstall burner access panel.

H. Install Gas Valve on main gas burner assembly (if not

factory assembled). See Figure 11, 12, 13, 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)

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.

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

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

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.

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

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.

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.

Figure 25: Recommended Water Piping for Circulator Zoned Heating System

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

Figure 26: Recommended Piping for Combination

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.

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

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

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

To perform a long term pressure test including the

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

boiler.

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

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

VI. Gas Piping

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

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

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)

NOTICE

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

D. Install Vent Connector from draft hood or vent

damper to chimney. See Figure 30.

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

open replace.

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

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

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

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

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

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

E. If an Existing Boiler is Removed:

When an existing boiler is removed from a common

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

At the time of removal of an existing boiler, the

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

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

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

deciencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range-hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close

replace dampers.

4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the

ame of a match or candle, or smoke from a

cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return

doors, windows, exhaust fans, replace dampers and

any other gas-burning appliance to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, NFPA 54/ANSI Z223.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 in the National Fuel Gas Code, NFPA 54/ ANSI Z223.1.

Figure 30: Typical Vent Installation

VIII. Electrical

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.

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

Figure 33: Vent Damper Harness to Limit

Figure 34: Vent Damper Schematic Wiring Diagram

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