Burnham Independence Operating And Service Instructions
Burnham Independence Operating And Service Instructions

Burnham Independence Operating And Service Instructions

Gas - fired boiler

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Price - $3.00

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Summary of Contents for Burnham Independence

  • Page 1 ® 8141049R23.5-4/07 Price - $3.00...
  • Page 2 The City of New York requires either a Licensed Master Plumber or a Fire Suppression Piping Contractor 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.
  • Page 3 f i l l i t . r i l l i t i l t t i...
  • Page 5: Table Of Contents

    Dimensional Data ) . l " 4 . t f " 5 . t f " 2 " 6 . t f ¼ " 7 . t f " 4 " 8 . t f ¼ " 4 " 9 .
  • Page 6 Figure 2: Section Tappings Table 1: Trim and Control Installation in Section Tappings ¼ ½ & ½ ½ ¼ ¼ & ½ " 3 ½ " 3 " 2 " 2 " 3 & " 3 & " 3 & "...
  • Page 7: Pre-Installation

    I. Pre-Installation 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.
  • Page 8 Figure 3: Clearance to Combustible Materials c. Caulking or sealants applied in joints around equipment in space. Duct cross-sectional area window and door frames, between sole plates shall be same as opening free area. and floors, between wall-ceiling joints, between Alternate method for boiler located within confined wall panels, at plumbing and electrical space.
  • Page 9: Knockdown Boiler Assembly

    II. Knocked-Down Boiler Assembly 4. Loosen nuts on tie rods until only finger 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 f i l follows: Install Base-Burner-Manifold Assembly...
  • Page 10 3. Attach canopy using ¼" carriage bolts, nuts, and Install Canopy. washers provided. 1. Install ½" thick x 1" wide ceramic fiber gasket. See Figure 7. Inspect joints between sections. They were factory sealed. If there are any openings due to shipment or handling, reseal with boiler putty.
  • 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. Models IN10 - IN12. Install on right side of draft hood. See Figure 17. Reset switch must face away from draft hood relief opening. Figure 1: Pilot and Gas Piping, Intermittent Ignition (HSP) (IN3 Through IN9) Figure 17: Blocked Vent Switch Installation, IN10 through IN12 Install Blocked Vent Switch with sheet metal screws.
  • Page 13: Semi-Pak Boiler Assembly

    III. Semi-Pak Boiler Assembly b. Level the L404A pressure limit by carefully bending the syphon until the limit's leveling indicator hangs freely with its pointer directly over the index mark inside the back of the case. See Figure 18A. f i l Remove Crate 1.
  • Page 14 h. Install gauge glass and protective rods in fittings. Remove center knockout in rear of Junction Box and insert black plastic snap bushing in i. Attach "Lowest Permissible Water Level" Plate hole. with sheet metal screws in location indicated in Figure 9.
  • Page 15 Screw well into Tapping "H" (¾ NPT). See e. Water with tankless heater only (EZWT and WCT). Secure R8225D relay to Junction Box. Figure 1 and 2. Install bulb in well as far as See Figure 1. possible, then tighten set screw. 4.
  • Page 16: Packaged Boiler Assembly

    IV. Packaged Boiler Assembly Install Jacket Front Panel. Install Draft Hood. Models IN3 through IN9. 1. Locate and open "Rear Draft Hood Carton". 2. Position Draft Hood on Canopy Rear Flange. See f i l Figure 21. Top canopy flange must fully engage "U"-shaped draft hood flange for proper installation Remove crate and move boiler to permanent position and operation.
  • Page 17: Piping And Trim

    V. Piping and Trim 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, fittings, and oxygen permeable materials in distribution system. Eliminate oxygen contamination by repairing system leaks, repairing fittings, using nonpermeable materials in distribution system, and eliminating open tanks in system, or isolating boiler from system with heat...
  • Page 21 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"...
  • Page 22 G. If a long term pressure test of the hydronic system is boiler, ALL trapped air must first be removed from the required, the boiler should first be isolated to avoid a boiler. pressure loss due to the escape of air trapped in the A loss of pressure during such a test, with no visible boiler.
  • Page 23: Gas Piping

    VI. Gas Piping jurisdiction specifies a gravity factor be applied. For specific gravity greater than 0.70, apply gravity factor from Table 5. If exact specific gravity is not shown choose next higher value. For materials or conditions other than those listed above, refer to the National Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or CAN/CGA B149 Installation Codes, or size system using standard...
  • Page 24 4. All above ground gas piping upstream from manual ½ psig or less, isolate boiler from gas supply piping gas valve must be electrically continuous and by closing boiler's individual manual shut-off valve. bonded to a grounding electrode. Do not use gas 2.
  • Page 25: Venting

    7, Venting of Equipment and/or CAN/CGA B149 Installation Codes, Part 5, Venting Systems and Air Supply for Appliances. 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.
  • Page 26 3. Insofar as is practical, close all building doors and Install Vent Connector from draft hood or vent windows and all doors between the space in which damper to chimney. See Figure 30. the appliances remaining connected to the common 1.
  • Page 27: Electrical

    VIII. Electrical . f f 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. Wire Vent Damper (if used). 1.
  • Page 28 Set heat anticipator to match system requirements. See 1. A separate electrical circuit must be run from the Table 6. In general, setting heat anticipator too low will main electrical service with an over-current device/ cause boiler to short cycle without bringing heated disconnect in the circuit.
  • Page 29 Figure 33: Vent Damper Harness to Limit Figure 34: Vent Damper Schematic Wiring Diagram...
  • Page 31 b. Low Water Cutoff (LWCO): Automatically Steam Boiler with Continuous Ignition (Standing Pilot) interrupts main burner operation when surface of and Probe Low Water Cutoff. See Figure 35. boiler water falls to lowest permissible operating 1. Normal Operation level. Normal operation resumes when water a.
  • Page 33 boiler water falls to lowest permissible operating Steam Boiler with Intermittent Ignition (EI) and Probe level. Normal operation resumes when water Low Water Cutoff. See Figure 36. returns to normal level. 1. Normal Operation c. Blocked Vent Switch. Automatically interrupts a.
  • Page 35 system blockage occurs. Control is a multiple Steam Boiler with Intermittent Ignition (HSP) and use device. If blocked vent switch is activated do Probe Low Water Cutoff. See Figure 37. not attempt to place boiler in operation. Correct 1. Normal Operation source of blockage and reset blocked vent a.
  • Page 37 b. Low Water Cutoff (LWCO): Automatically Steam Boiler with Continuous Ignition (Standing Pilot) interrupts main burner operation when surface of and Float Low Water Cutoff. See Figure 38. boiler water falls to lowest permissible operating 1. Normal Operation level. Normal operation resumes when water a.
  • Page 39 boiler water falls to lowest permissible operating Steam Boiler with Intermittent Ignition (EI) and Float level. Normal operation resumes when water Low Water Cutoff. See Figure 39. returns to normal level. 1. Normal Operation c. Blocked Vent Switch. Automatically interrupts a.
  • Page 41 system blockage occurs. Control is a multiple Steam Boiler with Intermittent Ignition (HSP) and Float use device. If blocked vent switch is activated do Low Water Cutoff. See Figure 40. not attempt to place boiler in operation. Correct 1. Normal Operation source of blockage and reset blocked vent a.
  • Page 43 b. Blocked Vent Switch. Automatically interrupts Water Boiler with Continuous Ignition (Standing Pilot) main burner operation when excessive vent and Intermittent Circulation. See Figure 41. system blockage occurs. Control is a multiple 1. Normal Operation use device. If blocked vent switch is activated do a.
  • Page 45 b. Blocked Vent Switch. Automatically interrupts Water Boiler with Intermittent Ignition (EI) and main burner operation when excessive vent Intermittent Circulation. See Figure 42. system blockage occurs. Control is a multiple 1. Normal Operation use device. If blocked vent switch is activated do a.
  • Page 47 source of blockage and reset blocked vent Water Boiler with Intermittent Ignition (HSP) and switch. Intermittent Circulation. See Figure 43. c. Flame Roll-out Switch. Automatically interrupts 1. Normal Operation boiler operation when flames or excessive heat a. Thermostat calls for heat. are present in vestibule.
  • Page 49 temperature falls below set point. Water Boiler with Continuous Ignition (Standing Pilot) and Gravity Circulation. See Figure 44. b. Blocked Vent Switch. Automatically interrupts main burner operation when excessive vent 1. Normal Operation system blockage occurs. Control is a multiple a.
  • Page 51 b. Blocked Vent Switch. Automatically interrupts Water Boiler with Intermittent Ignition (EI) and Gravity Circulation. See Figure 45. main burner operation when excessive vent system blockage occurs. Control is a multiple 1. Normal Operation use device. If blocked vent switch is activated do a.
  • Page 53 source of blockage and reset blocked vent Water Boiler with Intermittent Ignition (HSP) and switch. Gravity Circulation. See Figure 46. c. Flame Roll-out Switch. Automatically interrupts 1. Normal Operation boiler operation when flames or excessive heat a. Thermostat calls for heat. Thermostat Isolation are present in vestibule.
  • Page 55 b. Blocked Vent Switch. Automatically interrupts Water Boiler with Continuous Ignition (Standing Pilot) main burner operation when excessive vent and Tankless Heater. See Figure 47. system blockage occurs. Control is a multiple 1. Normal Operation use device. If blocked vent switch is activated do a.
  • Page 57 b. Blocked Vent Switch. Automatically interrupts Water Boiler with Intermittent Ignition (EI) and main burner operation when excessive vent Tankless Heater. See Figure 48. system blockage occurs. Control is a multiple 1. Normal Operation use device. If blocked vent switch is activated do a.
  • Page 59 source of blockage and reset blocked vent Water Boiler with Intermittent Ignition (HSP) and switch. Tankless Heater. See Figure 49. c. Flame Roll-out Switch. Automatically interrupts 1. Normal Operation boiler operation when flames or excessive heat a. Thermostat calls for heat or low limit senses are present in vestibule.
  • Page 60: System Start-Up

    IX. System Start-up Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on boiler when boiler underwent tests specified in American National Standard for Gas-Fired Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13. Check Main Burners.
  • Page 61 Figure 3: Lighting Instructions, Continuous Ignition System, VR8200 and VR8300 Gas Valves...
  • Page 62 Figure 4: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas Valve...
  • Page 63 Figure : Operating Instruction, Intermittent Ignition System, SV900, SV900, VR8204 and VR8304 (except IN12) Gas Valves...
  • Page 64 Figure : Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas Valves...
  • Page 65 Figure 7: Operating Instructions, Intermittent Ignition System (HSP), SV901 and SV901...
  • Page 66 Table 7: Ignition Module Terminal Cross-Reference Ignition Module Wiring Ladder Diagram Terminal Designation Terminal Number MV/PV 24V (GND) SPARK Figure 8: LED Locations TABLE 8: Yellow LED Flame Codes Yellow LED Recommended Indicates Flash Code Service Action Heartbeat Normal Flame Signal Weak Flame Signal - System will operate reliably but flame signal is Perform routine...
  • Page 67 Table 9: Green LED Status Codes Green LED Flash Code Indicates Next System Action Recommended Service Action (X + Y) No “Call for Heat” None Startup - Flame sense Flash Fast None calibration Heartbeat Normal operation None If system fails to light on next trial for ignition check gas supply, pilot 5 minute Retry Delay- Initiate new trial for ignition after retry...
  • Page 68 Figure 9: Pilot Burner Flame, Honeywell Q30 Figure 2: Pilot Burner Flame, Honeywell Q3480 Figure 0: Pilot Burner Flame, Honeywell Q327 Figure 3: 40mm Main Burner Flame Figure 4: 1" Main Burner Flame Figure 1: Pilot Burner Flame, Honeywell Q348...
  • Page 69 2. With boiler operating, open drain and slowly drain Check pilot burner flame and main burner flames boiler. through observation port. 1. Check pilot flame. a. Continuous Ignition (Standing Pilot), Models IN3 through IN7. See Figure 59. Pilot burner produces a single flame. Flame should be steady, medium hard blue enveloping 3/8 to ½...
  • Page 70 b. Increase input rate if less than 98% of Rating Table 10: Input Rate Label input. Increase manifold gas pressure no more than 0.3 inch w.c. If measured input rate is still less than 98% of rated input: Remove Main Burners per procedure in Section X: Service Instructions.
  • Page 71 f. Follow Lighting or Operating Instructions to between 7 and 11. Add recommended water place boiler in operation. See Figure 53, 54, 55, treatment chemicals, if necessary, to bring the pH 56 or 57. Check controls operation per within the specified range. Paragraphs F to J.
  • Page 72 n. Drain second quart sample from lower Gauge h. Allow boiler water to reach operating Glass fitting. If sample is not clear, repeat cycle temperature, if possible. of draining boiler and return main and refilling i. Continue to Circulate the water for a few hours. boiler until sample is clear.
  • Page 73: Service Instructions

    X. Service Instructions General. Inspection and service should be conducted e. Remove light deposits with damp cloth soaked with vinegar. annually, except as noted. Turn off electrical power and gas supply while conducting service or maintenance. f. Remove stubborn deposits using diluted Follow instructions TO TURN OFF GAS TO phosphoric acid (H ) solution, 3 parts water...
  • Page 74 Figure : Boiler Flueway Cleaning 5. tightness of joints. Remove all accumulations of Inspect connecting lines to boiler for soot with wire brush and vacuum accumulation of mud and scale. Clean as necessary. Remove all obstructions. Replace all deteriorated parts ii.
  • Page 75 Install Burners by reversing procedures used to remove burner. Main burners must be in slots in rear of burner tray and seated on main burner orifices. Reconnect pilot gas supply, and thermocouple lead (continuous ignition) or igniter/sensor/ground. See Table 11 for Pilot Burner location. Table 11: Pilot Burner Location Remove Burners for cleaning, changing orifice plugs, or repairs.
  • Page 77 Honeywell Hot Surface to Pilot Trouble Shooting Guide...
  • Page 78 Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. After this product is fired, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health.
  • Page 79: 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 80 " 0 ½ " " 7 ¾ " " 3 ½ " " 9 ¾ " ½ " " 9 " 8 " 5...
  • Page 81 , t l ¼ " 1 " 4 ¼ ¼...
  • Page 83 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 84 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 85 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 86 Manifold and 40mm Main Burners ° 1 ° 8 ° 1 ° 1...
  • Page 87 i t l ) . t f i r f i r i t l ) . t f i r i t l ) . t f i r f i r i t l ) . t f i r f i r i t l ) .
  • Page 88 , ) t f i r f i r t t i " 8 ¼ " 8 " 0 " 8 " 0 , ) t f i r f i r t t i " 8 ¼ " 8 "...
  • Page 89 , ) I f i r t t i " 8 ¼ " 8 " 0 " 8 " 0 , " , ) I f i r t t i " 8 ¼ " 8 " 0 " 8 "...
  • Page 90 f i r f i r ) " " 4 " 4 " 4 " 0 " 4 " 0 f i r f i r ) " " 4 " 4 " 4 " 0 " 4 " 0...
  • Page 91 THIS PAGE LEFT BLANK INTENTIONALLY...
  • Page 95 ¾ ¾ ¾ " 3 , f f & l l i , f f , f f & l l i , t i ¼ ° 0 ¾ ¼ ¼ ° 0 ¾...
  • Page 97 ¾ ¾ ¾ " 3 & & ½ ½ " " 8 " 8 , t i , t i , t i , l l ¾...
  • Page 98 Quantity Description Part No. IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 Transformer/J-Box Adapter Plate Junction Box, 4-11/16" x 4-11/16" x 2-1/8" 81361761 Transformer/J-Box Adapter Plate 7011001 Sheet Metal Screw, #8 x 1/2, Type B, 80860019 Phillips Head, Blunt O/CL Bushing, Heyco OCB-875 8136066 J-Box Attachment Bracket...
  • Page 99 THIS PAGE LEFT BLANK INTENTIONALLY...
  • Page 101 " 6 " 6 " 8 o l l o l l " 4 " 5 " 6 " 7 " 8 " 9...
  • Page 102: Low Water Cut Off (Lwco)

    XII. Low Water Cut Off (LWCO) f i t . f f When manufacturers recommend an annual inspection of the probe. A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is How to Wire installed below the top of the hot water boiler (i.e.
  • Page 103 U.S. Boiler the owner should write to U.S. Boiler Co., Inc., Burnham Hydronics, Co., Inc. and installed in a single or two-family residence and do not at P.O.
  • Page 104: Limited Warranty

    U.S. Boiler Co., Inc. warrants its residential cast iron steam boilers c.) Boiler components must not have been damaged in labeled Independence, Independence PV and V-8 Series to be free of handling during shipment or installation. defects in material and workmanship when shipped and to remain free of 7.

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