Burnham Independence IN10 User Manual

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10Figure 9: Jacket AssemblyFigure 7: Canopy Gasket InstallationFigure 8: Canopy InstallationD. Install Canopy.1. Install ½" thick x 1" wid

11Figure 11: Pilot and Gas Piping, Continuous Ignition (Standing Pilot) (IN3 through IN9 Only)Figure 13: Pilot and Gas Piping, Intermittent Ignition (

12Figure 16: Blocked Vent Switch Installation, IN10 through IN12Figure 15: Blocked Vent Switch Installation, IN3 through IN9I. Install Blocked Vent S

13III. Semi-Pak Boiler AssemblyWARNINGInstallation of this boiler should be undertaken only by trained and skilled personnel from a qual

14Figure 20: Thermostat Isolation Relay Attachment3. All Steam Boilers and Water Boilers except "EZW" and "WC" Controls Cartonsa.

15Figure 22: Securing Draft Hood to CanopyA. Remove crate and move boiler to permanent position as detailed in Section III: Semi-Pak Boiler Assembly.

16V. Piping and TrimA. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Sources of oxygen contamination

17Figure 24: Steam Boiler Piping (Minimum)NOTICEFailure to pipe boiler as specied in this manual may result in excessive system noise, water line uc

18Figure 25: Recommended Water Piping for Circulator Zoned Heating System

19Figure 25A: Recommended Water Piping for Zone Valve Zoned Heating System

2The 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 requir

20Figure 27: Recommended Piping forIndirect Water HeaterFigure 28: Tankless Heater PipingFigure 26: Recommended Piping for Combination Heating and Coo

21G. 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 o

22VI. Gas PipingWARNINGFailure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always

23Table 4: Fitting Equivalent LengthsTable 5: Specic Gravity Correction Factors for Natural Gas4. All above ground gas piping upstrea

24VII. VentingA. Install vent system in accordance with local building codes; or local authority having jurisdiction; or National Fuel Gas Code, ANS

253. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the

26A. General. Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements t

27Table 6: Thermostat Heat Anticipator Settings Set heat anticipator to match system requirements. See Table 6. In general, setting heat anticipator

28Figure 34: Vent Damper Schematic Wiring DiagramFigure 33: Vent Damper Harness to Limit

29THIS PAGE LEFT INTENTIONALLY BLANK

3CAUTIONProbe type low water cutoff devices require annual inspection and maintenance! Although these devices are solid state in their operation, the

30Figure 35: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low Water Cutoff

31b. Low Water Cutoff (LWCO): Automatically interrupts main burner operation when surface of boiler water falls to lowest permissible operating level

32Figure 36: Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low Water Cutoff

33level. Normal operation resumes when water returns to normal level.c. Blocked Vent Switch. Automatically interrupts main burner operation when exce

34Figure 37: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Float Low Water Cutoff

35J. Steam Boiler with Continuous Ignition (Standing Pilot) and Float Low Water Cutoff. See Figure 37.1. Normal Operationa. Thermostat calls for h

36Figure 38: Wiring Diagrams, Steam, Intermittent Ignition (EI), Float Low Water Cutoff

37K. Steam Boiler with Intermittent Ignition (EI) and Float Low Water Cutoff. See Figure 38.1. Normal Operationa. Thermostat calls for heat. Therm

38Figure 39: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Intermittent Circulation

39L. Water Boiler with Continuous Ignition (Standing Pilot) and Intermittent Circulation. See Figure 39.1. Normal Operationa. Thermostat calls for

4Figure 1: Dimensional Drawing

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

41M. Water Boiler with Intermittent Ignition (EI) and Intermittent Circulation. See Figure 40.1. Normal Operationa. Thermostat calls for heat.b. V

42Figure 41: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Gravity Circulation

43N. Water Boiler with Continuous Ignition (Standing Pilot) and Gravity Circulation. See Figure 41.1. Normal Operationa. Thermostat calls for heat

44Figure 42: Wiring Diagrams, Water, Intermittent Ignition (EI), Gravity Circulation

45O. Water Boiler with Intermittent Ignition (EI) and Gravity Circulation. See Figure 42.1. Normal Operationa. Thermostat calls for heat. Thermost

46Figure 43: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Tankless Heater

47P. Water Boiler with Continuous Ignition (Standing Pilot) and Tankless Heater. See Figure 43.1. Normal Operationa. Thermostat calls for heat or

48Figure 44: Wiring Diagrams, Water, Intermittent Ignition (EI), Tankless Heater

49Q. Water Boiler with Intermittent Ignition (EI) and Tankless Heater. See Figure 44.1. Normal Operationa. Thermostat calls for heat or low limit

5Dimensional DataHeating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water)Table of Contents I. Pre-Installation ...

50IX. System Start-upFigure 47: Gas Valve Pressure Tap,Robertshaw Gas ValveFigure 46: Gas Valve Pressure Tap,Honeywell Gas ValvesFigure 45: Front D

51Figure 48: Lighting Instructions, Continuous Ignition System, VR8200 and VR8300 Gas Valves

52Figure 49: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas Valve

53Figure 50: Operating Instruction, Intermittent Ignition System, VR8204 and VR8304 (except IN12) Gas Valves

54Figure 51: Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas Valves

55Table 7: Ignition Module Terminal Cross-ReferenceIgnition ModuleTerminal DesignationWiring Ladder Diagram Terminal NumberMV 1MV/PV 2PV 3GND 424V (G

56Green LED Flash Code(X + Y)aIndicates Next System Action Recommended Service ActionOFF No “Call for Heat” N/A NoneFlash FastStartup - Flame sense ca

57Figure 57: 1" Main Burner FlameFigure 53: Pilot Burner Flame, Honeywell Q350Figure 55: Pilot Burner Flame, Honeywell Q348Figure 54: Pilot Burn

582. 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

59Table 10: Input RateL. Adjust gas input rate to boiler. LP/Propane.1. Set thermostat to highest setting.2. Adjust tank regulator for gas valve in

6Figure 2: Section TappingsTable 1: Trim and Control Installation in Section TappingsTappingSize (NPT)Steam Boiler with Probe L.W.C.O.Steam Boiler wi

60h. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 48, 49, 50, or 51. Drain boiler and system piping.i. Remove drain valve. Thoroughl

611. 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

62X. Service InstructionsA. General. Inspection and service should be conducted annually, except as noted. Turn off electrical power and gas supply

635. tightness of joints. Remove all accumulations of soot with wire brush and vacuum Remove all obstructions. Replace all deteriorated parts and su

64CAUTIONWhen necessary to remove burners, be sure to reinstall them in the original manner by engaging the orice and locating hole in the

65M. Excessive Make-Up WaterCAUTIONIF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW, CONSULT A QUALIF

66Honeywell Electronic Ignition Trouble Shooting Guide

67Honeywell Hot Surface to Pilot Trouble Shooting Guide

68Important Product Safety InformationRefractory Ceramic Fiber ProductWarning:The Repair Parts list designates parts that contain refractory ceramic f

69XI. Repair PartsAll Independence® Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assis-tance in

7I. Pre-InstallationA. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our respon

70Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN121. Section Assembly 1ALeft End Section (less tankless heater) 7171000

71Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN122. Canopy and Draft Hood Canopy/Draft Hood Parts2A Canopy Assembly61110

72Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN123. Base Assembly3A Base Tray718600391 1 --- --- --- --- --- --- --- ---

73Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN123. Base Assembly (Continued)3B2 Base Rear Insulation72060035 1 --- ---

74Manifold and 1" Main BurnersKey No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN123. Base Assembly (Continued)3F Burner

75Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN124. Manifold and Main Burners (1 Inch Main Burners Only)4A Main Burner 8

76Manifold and 40mm Main BurnersKey No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN94. Manifold and Main Burners (40MM MAIN BURNERS ONLY)4A

77Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN94. Manifold and Main Burners (40MM MAIN BURNERS ONLY) ContinuedNatural Gas, High Alti

78Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN125. Pilot Burner and Gas Valve, Continuous Ignition (Standing Pilot), N

79Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN125. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas

8Figure 3: Clearance to Combustible Materials5. For boiler located in an unconned space in a building of other than unusually tight construction, ad

80

81Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Jacket Assembly1 Left Side Panel60410013 1 1 1 1 1 1 1 --- --- ---60410

82Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Jacket Assembly (Continued) - Refer to Figure on Page 805A Upper Left R

83Key No.Description Part No. QuantitySteam Trim7A Safety Valve, 3/4 NPT, 15 psi, Conbraco 13-511-08 81660530 17B Elbow, 3/4 NPT 806601502 27C Nipple,

84

85Key No.Description Part No. IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Water Trim7ASafety Relief Valve, 3/4 NPT, 30 psi, Conbraco 10-407-0581660363 1

86Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Transformer/J-Box Adapter Plate1 Junction Box, 4-11/16" x 4-11/16&

87THIS PAGE LEFT BLANK INTENTIONALLY

88

89Key No.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN1212. Transformer (Steam and Gravity Water Only)12A Junction Box, 4-11/1

9Figure 4: Base Gasket Installation II. Knocked-Down Boiler AssemblyWARNINGInstallation of this boiler should be undertaken only by trained

90 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

91if the residential grade water boiler is used or operated over its ratedcapacity, is subjected to unauthorized modification, or is damagedas a resul

92By this Warranty Statement the U.S. Boiler™ Company, Inc. of Lancaster,Pennsylvania issues limited warranties subject to the terms and conditionssta