Instruction/ maintenance manual of the product IN10 Burnham
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8141049R26-10/08 Price - $5.00 , r e l i o b n o n o i t a m r o f n i g n i k e e s n e h W . r o t c a r t n o c g n i t a e h r u o y l l a c , r e l i o b o t s r i a p e r r o e c i v r e s r o F .
2 The New Y ork City Department of Buildings has approved the Independence® Series boiler: Approval No. MEA 154-93-E V ol. III. The City of New Y ork 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 .
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.
4 Figure 1: Dimensional Drawing.
5 Dimensional Data Heating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water) T able of Contents I. P re-I nstallation ..................................... 7 II. Knockdown Boiler Assembly ................ 9 III. Semi-P ak Boiler Assembly .
6 Figure 2: Section T appings T able 1: T rim and Control Installation in Section T appings T apping Size (NPT) Steam Boiler with Probe L.W .C.O. Steam Boiler with Float L.
7 I. Pre-Installation 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.
8 Figure 3: Clearance to Combustible Materials 5. For boiler located in an unconned space in a building of other than unusually tight construction , adequate combustion and ventilation air is normally provided by fresh air inltration through cracks around windows and doors.
9 Figure 4: Base Gasket Installation II. Knocked-Down Boiler Assembly W ARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency .
10 Figure 9: Jacket Assembly Figure 7: Canopy Gasket Installation Figure 8: Canopy Installation D. Install Canopy . 1. Install ½" thick x 1" wide ceramic ber gasket. See Figure 7. 2. Position canopy on ceramic ber gasket. See Figure 8.
1 1 Figure 1 1: Pilot and Gas Piping, Continuous Ignition (Standing Pilot) (IN3 through IN9 Only) Figure 13: Pilot and Gas Piping, Intermittent Ignition (EI) (IN3 through IN1 1 Only) Figure 12: Pilot .
12 Figure 16: Blocked V ent Switch Installation, IN10 through IN12 Figure 15: Blocked V ent Switch Installation, IN3 through IN9 I. Install Blocked V ent Switch with sheet metal screws. 1. Models IN3 - IN9. Install on rear ange of canopy . See Figure 15.
13 III. Semi-Pak Boiler Assembly W ARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied 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 .
14 Figure 20: Thermostat Isolation Relay Attachment 3. All Steam Boilers and W ater 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.
15 Figure 22: Securing Draft Hood to Canopy A. Remove crate and move boiler to permanent position as detailed in Section III: Semi-Pak Boiler Assembly .
16 V . Piping and T rim 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.
17 Figure 24: Steam Boiler Piping (Minimum) NOTICE Failure to pipe boiler as specied in this manual may result in excessive system noise, water line uctuations and water carry over .
18 Figure 25: Recommended W ater Piping for Circulator Zoned Heating System.
19 Figure 25A: Recommended W ater Piping for Zone V alve Zoned Heating System.
20 Figure 27: Recommended Piping for Indirect W ater Heater Figure 28: T ankless Heater Piping Figure 26: Recommended Piping for Combination Heating and Cooling (Refrigeration) Systems E. Alliance Indirect W ater Heater (if used). Refer to Alliance Installation, Operating and Service Instructions for additional information.
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 . T o perform a long term pressure test including the boiler , ALL trapped air must rst be removed from the boiler .
22 VI. Gas Piping W ARNING 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.
23 T able 4: Fitting Equivalent Lengths T able 5: Specic Gravity Correction Factors for Natural Gas 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.
24 VII. V enting A. Install vent system in accordance with local building codes; or local authority having jurisdiction; or National Fuel Gas Code , ANSI Z223.1/NFP A 54, Part 7, V enting 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.
25 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. T urn on clothes dryers and any appliance not connected to the common venting system.
26 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/NFP A 70 and/or CSA C22.1 Electrical Code. B. Wir e V ent Damper (if used).
27 T able 6: Thermostat Heat Anticipator Settings Set heat anticipator to match system requirements. See T able 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.
28 Figure 34: V ent Damper Schematic Wiring Diagram Figure 33: V ent Damper Harness to Limit.
29 THIS P AGE LEFT INTENTIONALL Y BLANK.
30 Figure 35: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low W ater Cutoff.
31 b . Low W ater Cutoff (L WCO): 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 V ent Switch. Automatically interrupts main burner operation when excessive vent system blockage occurs.
32 Figure 36: Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low W ater Cutoff.
33 level. Normal operation resumes when water returns to normal level. c . Blocked V ent 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.
34 Figure 37: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Float Low W ater Cutoff.
35 J. Steam Boiler with Continuous Ignition (Standing Pilot) and Float Low W ater Cutoff. See Figure 37. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation.
36 Figure 38: Wiring Diagrams, Steam, Intermittent Ignition (EI), Float Low W ater Cutoff.
37 K. Steam Boiler with Intermittent Ignition (EI) and Float Low W ater Cutoff. See Figure 38. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation.
38 Figure 39: Wiring Diagrams, W ater , Continuous Ignition (Standing Pilot), Intermittent Circulation.
39 L. W ater Boiler with Continuous Ignition (Standing Pilot) and Intermittent Circulation. See Figure 39. 1. Normal Operation a. Thermostat calls for heat. b. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation. c . Gas V alve(s) is energized allowing main gas ow and ignition of Main Burners.
40 Figure 40: Wiring Diagrams, W ater , Intermittent Ignition (EI), Intermittent Circulation.
41 M. W ater Boiler with Intermittent Ignition (EI) and Intermittent Circulation. See Figure 40. 1. Normal Operation a. Thermostat calls for heat. b. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation. c . Ignition Module is energized.
42 Figure 41: Wiring Diagrams, W ater , Continuous Ignition (Standing Pilot), Gravity Circulation.
43 N. W ater 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. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation.
44 Figure 42: Wiring Diagrams, W ater , Intermittent Ignition (EI), Gravity Circulation.
45 O. W ater 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. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation.
46 Figure 43: Wiring Diagrams, W ater , Continuous Ignition (Standing Pilot), T ankless Heater.
47 P . W ater Boiler with Continuous Ignition (Standing Pilot) and T ankless Heater . See Figure 43. 1. Normal Operation a. Thermostat calls for heat or low limit senses water temperature below set point. b. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation.
48 Figure 44: Wiring Diagrams, W ater , Intermittent Ignition (EI), T ankless Heater.
49 Q. W ater Boiler with Intermittent Ignition (EI) and T ankless Heater . See Figure 44. 1. Normal Operation a. Thermostat calls for heat or low limit senses water temperature below set point. b. V ent Damper (if used) opens as stated in V ent Damper Sequence of Operation.
50 IX. System Start-up Figure 47: Gas V alve Pressure T ap, Robertshaw Gas V alve Figure 46: Gas V alve Pressure T ap, Honeywell Gas V alves Figure 45: Front Door Removal W ARNING Completely read, understand and follow all instructions in this manual before attempting start up.
51 Figure 48: Lighting Instructions, Continuous Ignition System, VR8200 and VR8300 Gas V alves.
52 Figure 49: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas V alve.
53 Figure 50: Operating Instruction, Intermittent Ignition System, VR8204 and VR8304 (except IN12) Gas V alves.
54 Figure 51: Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas V alves.
55 T able 7: Ignition Module T erminal Cross-Reference Ignition Module T erminal Designation Wiring Ladder Diagram T erminal Number MV 1 MV/PV 2 PV 3 GND 4 24V (GND) 5 24V 6 SP ARK 9 Figure 52: LED Lo.
56 Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal ope.
57 Figure 57: 1" Main Burner Flame Figure 53: Pilot Burner Flame, Honeywell Q350 Figure 55: Pilot Burner Flame, Honeywell Q348 Figure 54: Pilot Burner Flame, Honeywell Q327 Figure 56: 40mm Main Burner Flame F . Checkpilotburnerameandmainburnerames through observation port.
58 2. Adjust thermostat to highest setting. 3. Check main burner ames. See Figure 56 or 57. Flame should have clearly dened inner cones with no yellow tipping. Orange-yellow streaks caused by dust should not be confused with true yellow tipping.
59 T able 10: Input Rate 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.
60 h. Follow instructions T O 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.
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 V alve using extreme care to avoid damaging it. b . Partially ll boiler . Pour recommended compound into boiler through safety relief valve opening.
62 X. Service Instructions A. General. Inspection and service should be conducted annually , except as noted. T urn off electrical power and gas supply while conducting service or maintenance. Follow instructions T O TURN OFF GAS TO APPLIANCE. See Figures 48, 49, 50 or 51.
63 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 .
64 CAUTION When necessary to remove burners, be sure to reinstall them in the original manner by engaging the orice and locating hole in the rear of the burner tray . Burners must be aligned with the burner manifold. F . Remove Burners for cleaning, changing orice plugs, or repairs.
65 M. Excessive Make-Up W ater CAUTION IF , DURING NORMAL OPERA TION, IT IS NECESSAR Y TO ADD MORE W A TER THAN INDICA TED BELOW , CONSUL T A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS. Model No. Gallons Per Month Gallons Per Y ear IN3 0.
66 Honeywell Electronic Ignition T rouble Shooting Guide.
67 Honeywell Hot Surface to Pilot T rouble Shooting Guide.
68 Important Produc t Safety Information Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts t hat contain refracto ry ceramic fibers (RCF).
69 XI. Repair Parts All Independence® Repair Parts may be obtained through your local Burnham Wholesale distributor . Should you require assis- tance in locating a Burnham Distributor in your area, o.
70 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 1. Section Assembly 1A Left End Section (less tankless heater) 7 1710002 2 1 1 1 1 1 1 1 1 1 1 Left End Section (w.
71 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 2. Canopy and Draft Hood Canopy/Draft Hood Parts 2A Canopy Assembly 61 1 1003 1 --- --- --- --- --- --- --- --- --.
72 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 3. Base Assembly 3A Base T ray 71860 0391 1 --- --- --- --- --- --- --- --- --- 71860 0491 --- 1 --- --- --- --- -.
73 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 3. Base Assembly (Continued) 3B2 Base Rear Insulation 72060035 1 --- --- --- --- --- --- --- --- --- 72060045 --- .
74 Manifold and 1" Main Burners Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 3. Base Assembly (Continued) 3F Burner Access Panel 71860 0361 1 --- --- --- ---.
75 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN1 0 IN1 1 I N12 4. Manifold and Main Burners (1 Inch Main Burners Only) 4A Main Burner 8236099 2 4 6 8 1 1 13 15 17 20 22 4B Main.
76 Manifold and 40mm Main Burners Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 4. Manifold and Main Burners (40MM MAIN BURNERS ONL Y) 4A Main Burner 8236135 1 2 3456 7 Intermitten.
77 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 4. Manifold and Main Burners (40MM MAIN BURNERS ONL Y) Continued Natural Gas, High Altitude (2000-5000 Ft.) USA Only 4D Main Burner Orice #39 822727 2 3 --- --- --- --- --- Main Burner Orice #38 822720 --- --- 456 7 8 LP Gas, High Altitude (2000-5000 Ft.
78 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 5. Pilot Burner and Gas V alve, Continuous Ignition (Standing Pilot), Natural Gas 5A Pilot Burner , Honeywell Q350.
79 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 5. Pilot Burner and Gas V alve, Intermittent Ignition (EI), Natural Gas 5A Pilot Burner , Honeywell Q348A1002 8236072 1 1 1 1 1 1 1 1 1 1 5B Pilot Orice, Honeywell 388146NE Included with 5A 1 1 1 1 1 1 1 1 1 1 5C Compression Nut/Fitting, 1/4" OD x 1/4 C.
80.
81 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 Jacket Assembly 1 Left Side Panel 60410013 1 1 1 1 1 1 1 --- --- --- 60410023 --- --- --- --- --- --- --- 1 1 1 2 .
82 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 I N10 IN1 1 IN12 Jacket Assembly (Continued) - Refer to Figure on Page 80 5A Upper Left Rear Panel (not shown) 604101 051 --- --- -.
83 Key No. Description Part No. Quantity Steam T rim 7A Safety V alve, 3/4 NPT , 15 psi, Conbraco 13-51 1-08 81660530 1 7B Elbow , 3/4 NPT 806601502 2 7C Nipple, 3/4 NPT x 3" 806600002 2 8A Low W ater Cutoff, McDonnell & Miller PS-802-24 (Probe Included) 80160720 1 Low W ater Cutoff, Hydrolevel CG400-2090 (Less Probe - See Key No.
84.
85 Key No. Description Part No. IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN 1 1 IN12 W ater T rim 7A Safety Relief V alve, 3/4 NPT , 30 psi, Conbraco 10-407-05 81660363 1 1 1 1 1 1 1 1 1 1 7B Elbow , 3/4 NPT .
86 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN1 1 IN12 T ransformer/J-Box Adapter Plate 1 Junction Box, 4-1 1/16" x 4-1 1/16" x 2-1/8" 81361761 1 1 1 1 1 1.
87 THIS P AGE LEFT BLANK INTENTIONALL Y.
88.
89 Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN1 1 IN12 12. T ransformer (Steam and Gravity Water Only) 12A Junction Box, 4-1 1/16" x 4-1 1/16" x 2-1/8" Ref.
90 A 24 V AC L WCO is used primarily for gas red boilers where a 24 volt control circuit exists within the boiler . However , a 24 V AC L WCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.
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 ser.
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.
An important point after buying a device Burnham IN10 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Burnham IN10 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Burnham IN10 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Burnham IN10 you will learn all the available features of the product, as well as information on its operation. The information that you get Burnham IN10 will certainly help you make a decision on the purchase.
If you already are a holder of Burnham IN10, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Burnham IN10.
However, one of the most important roles played by the user manual is to help in solving problems with Burnham IN10. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Burnham IN10 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
