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Burnham Independence IN10 Service Instructions Manual

Burnham gas-fired boiler installation, operating and service instructions.

 
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Price - $5.00

Summary of Contents

  • Page 1

    8141049R26-10/08 ® Price - $5.00...

  • Page 2

    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.

  • Page 3

    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.

  • Page 5: Table Of Contents

    (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. Heating Surface: 4.35 sq. ft. per flueway (steam); 5.72 sq. ft. per flueway (water) I.

  • Page 6

    Table 1: Trim and Control Installation in Section Tappings Size Steam Boiler with Tapping (NPT) Probe L.W.C.O. Supply Bush to ¼ ½ Pressure Gauge ½ Gauge Glass Return 3" Nipple & Street Elbow ¾ Safety Relief Valve Bush to ¾ Drain Valve...

  • Page 7: I. Pre-installation

    NOTICE Due to the low water content of the boiler, mis- sizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure.

  • Page 8

    5. For boiler located in an unconfined space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. 6. For boiler located within unconfined space in...

  • Page 9

    (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: Pre- Installation). Install assembled cast iron sections on base assembly: 1.

  • Page 10

    Inspect joints between sections. They were factory sealed. If there are any openings due to shipment or handling, reseal with boiler putty. Install Jacket. See Figure 9. 1. Models IN7-IN12 steam boilers: remove 3 inch diameter knockouts in jacket top panels.

  • Page 11

    9. Install front removable door by engaging upper side edges of panel with side receiving flanges, sliding up and under top panel flange - seating front door fully - then sliding down to engage bottom flange behind lower front tie bar. Install Pilot/Burner Assembly (shipped in Gas Controls Carton).

  • Page 12

    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. Continue to Section III: Semi-Pak Boiler Assembly, Step C.

  • Page 13: Iii. Semi-pak Boiler Assembly

    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 floor. Do not bump boiler jacket against floor.

  • Page 14

    Continue to Section IV. Packaged Boiler Assembly, Paragraph E.

  • Page 15: Iv. Packaged Boiler Assembly

    See Figure 22. 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 certification will become void.

  • Page 16: V. Piping And Trim

    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.

  • Page 20

    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.

  • Page 21

    ALL trapped air must first 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

    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.

  • Page 23

    4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ ANSI Z223.1. Canadian boilers' orifice sizing is indicated on the rating label. High altitude boiler models are identifiable by the third digit in the model number suffix on the rating label: Doe not use matches, candles, open flames or other ignition source to check for leaks.

  • Page 24: Vii. Venting

    Clean chimney if previously used for solid or liquid fuel-burning appliances or fireplaces. DANGER Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe injury or death. Boiler Equipped With Vent Damper 1.

  • Page 25

    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...

  • Page 26: Viii. Electrical

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

  • Page 27

    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. Wire thermostat. Provide Class II circuit between thermostat and boiler.

  • Page 28

    Figure 33: Vent Damper Harness to Limit Figure 34: Vent Damper Schematic Wiring Diagram...

  • Page 29

    THIS PAGE LEFT INTENTIONALLY BLANK...

  • Page 31

    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 flames or excessive heat are present in vestibule.

  • Page 33

    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 flames or excessive heat are present in vestibule.

  • Page 35

    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 flames or excessive heat are present in vestibule.

  • Page 37

    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 flames or excessive heat are present in vestibule.

  • Page 39

    Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. c. Flame Roll-out Switch. Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.

  • Page 41

    Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. c. Flame Roll-out Switch. Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.

  • Page 43

    Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. c. Flame Roll-out Switch. Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.

  • Page 45

    Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. c. Flame Roll-out Switch. Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.

  • Page 47

    Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. c. Flame Roll-out Switch. Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.

  • Page 49

    Control is a multiple use device. If blocked vent switch is activated do not attempt to place boiler in operation. Correct source of blockage and reset blocked vent switch. c. Flame Roll-out Switch. Automatically interrupts boiler operation when flames or excessive heat are present in vestibule.

  • Page 50: Ix. System Start-up

    5. For natural gas fired boiler, temporarily turn off all other gas-fired appliances. 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.

  • 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 : Ignition Module Terminal Cross-Reference Ignition Module Wiring Ladder Diagram Terminal Designation MV/PV 24V (GND) SPARK TABLE 8: Yellow LED Flame Codes Yellow LED Flash Code Heartbeat Flash Code Descriptions - Heartbeat: Constant ½ second bright, ½ second dim cycles. - The flash code number signifies that the LED flashes 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 Indicates (X + Y) No “Call for Heat” Startup - Flame sense Flash Fast calibration Heartbeat Normal operation 5 minute Retry Delay- Pilot flame not detected during trial for ignition Recycle- Flame failed during run Flame sensed out of...

  • Page 57

    CAUTION Avoid operating this boiler in an environment where saw dust, loose insulation fibers, 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...

  • Page 58

    Rating Label. a. Boiler must not be overfired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still overfired, contact your Governale distributor or Regional Office for replacement Gas Orifice. b. Increase input rate if less than 98% of Rating Label input.

  • Page 59

    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.

  • Page 60

    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".

  • Page 61

    Boiler is now ready to be put into service. CONDENSATION — Following a cold start, condensation (sweating) may occur in a gas fired 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.

  • Page 62: X. Service Instructions

    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.

  • Page 63

    Remove all obstructions. Replace all deteriorated parts and support properly. Seal all joints. 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.

  • Page 64

    12 & 13 * Burners numbered left to right as viewed from front of boiler. 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.

  • Page 65

    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.

  • 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.

  • Page 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, 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.

  • Page 70

    Description 1. Section Assembly Left End Section (less tankless heater) 717100022 Left End Section (with tankless heater) 717100042 Center Section Right End Section Tie Rod, 3/8-16 x 10" Tie Rod, 3/8-16 x 12-1/2" Tie Rod, 3/8-16 x 17" Tie Rod, 3/8-16 x 20-3/4" Tie Rod, 3/8-16 x 23"...

  • Page 71

    Description 2. Canopy and Draft Hood Canopy/Draft Hood Parts Canopy Assembly Rear Draft Hood Carton Assembly Canopy/Draft Hood Carton Assembly (complete) Carriage Bolt, ¼ -20 x 1" Flat Washer, ¼" Hex Nut, ¼ -20 Gasket Wingnut, ¼ -20 All Components for use in both USA or Canada, unless marked with * for USA Only or ** for Canada Only Part No.

  • Page 72

    Description 3. Base Assembly Base Tray Base Wrapper Base End Insulation Part No. 718600391 718600491 718600591 718600691 718600791 718600891 718600991 718601091 718601191 718601291 718600311 718600411 718600511 718600611 718600711 718600811 718600911 718601011 718601111 718601211 720601 Quantity IN10 IN11 IN12...

  • Page 73

    Description 3. Base Assembly (Continued) Base Rear Insulation Base Front Panel Assembly Burner Tray (1 Inch Main Burners) Burner Tray (40mm Main Burners) Base Leg Assembly Base Leg [Included in Key No. 3E] Nylon Glide [Included in Key No. 3E] Part No.

  • Page 74

    Description 3. Base Assembly (Continued) Burner Access Panel Left End Jacket Attachment Bracket Right End Jacket Attachment Bracket Base Sealant 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 Washer, 5/16, USS Hex Lock Nut, 5/16 -18 Screw, Sheet Metal, #8 x 1/2"...

  • Page 75

    Description 4. Manifold and Main Burners (1 Inch Main Burners Only) Main Burner 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) Manifold Main Burner Orifice, #45 Pink Natural...

  • Page 76

    Description 4. Manifold and Main Burners (40MM MAIN BURNERS ONLY) Main Burner Intermittent Ignition Only Main Burner with 41° Pilot Bracket 24-Volt Continuous Ignition (Standing Pilot) Natural Gas Main Burner with 48° Pilot Bracket Main Burner with 41° Pilot Bracket 24-Volt Continuous Ignition (Standing Pilot) LP Gas Main Burner with 41°...

  • Page 77

    Description 4. Manifold and Main Burners (40MM MAIN BURNERS ONLY) Continued Natural Gas, High Altitude (2000-5000 Ft.) USA Only Main Burner Orifice #39 Main Burner Orifice #38 LP Gas, High Altitude (2000-5000 Ft.) USA Only Main Burner Orifice #53 Natural Gas, High Altitude (5000-9000 Ft.) USA Only Main Burner Orifice #41 Main Burner Orifice #42 LP Gas, High Altitude (5000-9000 Ft.) USA Only...

  • Page 78

    Description 5. Pilot Burner and Gas Valve, Continuous Ignition (Standing Pilot), Natural Gas Pilot Burner, Honeywell Q350A1321 Pilot Burner, Honeywell Q327A1006 Pilot Orifice, Honeywell 390686-22 Pilot Orifice, Honeywell 388146AG Compression Nut/Fitting, 1/4" OD x 1/4 C.C. (Included with 5A) Pilot Tubing, 1/4" OD x 30" Pilot Tubing, 1/4"...

  • Page 79

    Description 5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas Pilot Burner, Honeywell Q348A1002 Pilot Orifice, 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" Pilot Tubing, 1/4" OD x 40" Gas Valve, Honeywell VR8204C3007 Gas Valve, Honeywell VR8304P4306 Igniter/Sensor Cable, 36", Honeywell...

  • Page 81

    Description Jacket Assembly Left Side Panel Right Side Panel Front Removable Panel Vestibule Panel Rear Panel Part No. 60410013 60410023 60410012 60410022 60410033 60410043 60410053 60410063 60410073 60410083 60410093 60410103 60410113 60410123 60410034 60410044 60410054 60410064 60410074 60410084 60410094 60410104 60410114 60410124 60410035...

  • Page 82

    Description Jacket Assembly (Continued) - Refer to Figure on Page 80 Upper Left Rear Panel (not shown) Upper Right Rear Panel (not shown) Front Top Panel Rear Top Panel Lower Front Tie Bar Part No. 604101051 604101052 60410036 60410046 60410056 60410066 60410076 60410086...

  • Page 83

    Steam Trim Safety Valve, 3/4 NPT, 15 psi, Conbraco 13-511-08 Elbow, 3/4 NPT Nipple, 3/4 NPT x 3" Low Water Cutoff, McDonnell & Miller PS-802-24 (Probe Included) Low Water Cutoff, Hydrolevel CG400-2090 (Less Probe - See Key No. 8B) Low Water Cutoff, McDonnell & Miller 67-BC-1 (Float Type) Probe for CG400 Gauge Glass, Extended Shank (with Probe LWCO Only) Gauge Glass, Standard Shank (with Float LWCO Only)

  • Page 85

    Description Water Trim Safety Relief Valve, 3/4 NPT, 30 psi, Conbraco 10-407-05 Elbow, 3/4 NPT Nipple, 3/4 NPT x 3" Circulator, Bell & Gossett NRF-22 with Gaskets Circulator, Grundfos UP 15-42F Circulator, Taco 007 Gasket, Bell & Gossett NRF-22 Gasket, Grundfos 510179 Gasket, Taco '00' Series Flange, 1-1/2 NPT Screw, Cap Hex Head, 7/16 -14 x 1-1/2"...

  • Page 86

    Description Transformer/J-Box Adapter Plate Junction Box, 4-11/16" x 4-11/16" x 2-1/8" 81361761 Transformer/J-Box Adapter Plate Sheet Metal Screw, #8 x 1/2, Type B, Phillips Head, Blunt O/CL Bushing, Heyco OCB-875 J-Box Attachment Bracket Part No. IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 7011001 80860019 8136066...

  • Page 87

    THIS PAGE LEFT BLANK INTENTIONALLY...

  • Page 89

    Description 12. Transformer (Steam and Gravity Water Only) 12A Junction Box, 4-11/16" x 4-11/16" x 2-1/8" 12B Transformer, 50 VA, Honeywell AT150D1019 12C Relay, SPST, Honeywell R8222K1000 1. Flame Rollout Switch 13A Flame Rollout Switch 13B Flame Rollout Switch Bracket 14.

  • Page 90: Low Water Cut Off (lwco)

    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.

  • Page 91

    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.

  • Page 92

    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...

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