Burnham INDEPENDENCE Instructions d'exploitation

1Price - $3.00INSTALLATION, OPERATINGANDSERVICE INSTRUCTIONSINDEPENDENCE SERIESGAS BOILER8141049R7-2/00For service or repairs to boiler, call you

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

11Figure 11: Pilot and Gas Piping, ContinuousIgnition (Standing Pilot) (IN3 through IN9 Only)Figure 13: Pilot and Gas Piping, IntermittentIgnition (EI

12Figure 17: Blocked Vent Switch Installation,IN10 through IN12Figure 16: Blocked Vent Switch Installation,IN3 through IN9I. Install Blocked Vent Swit

13III. Semi-Pak Boiler AssemblyA. Remove Crate1. Remove all hold down screws and brackets.2. Slide boiler to rear of skid and carefully remove fromcr

14Figure 20: Thermostat Isolation Relay Attachmentiii. Align center and mounting holes of JunctionBox with upper front corner of jacket left sidepanel

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

16V. Piping and TrimA. Design and install boiler and system piping to preventoxygen contamination of boiler water. Sources ofoxygen contamination ar

17Figure 24: Steam Boiler Piping (Minimum)NOTICEFailure to pipe boiler as specified in this manual may result in excessive system noise, water lineflu

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

19Figure 25A: Water Boiler Piping for Zone Valve Zoned Systems

2The following terms are used throughout this manual to bring attention to the presence of hazards of various risklevels, or to important information

20Figure 27: Required Bypass PipingFigure 28: Tankless Heater PipingFigure 26: Recommended Piping for CombinationHeating and Cooling (Refrigeration) S

21VI. Gas PipingA. Size gas Piping. Design system to provide adequategas supply to boiler. Consider these factors:1. Allowable pressure drop from poi

22Table 4: Fitting Equivalent LengthsTable 5: Specific Gravity Correction FactorsFittingNominal Pipe Size½¾11¼45° Ell 0.7 1 1.2 1.690° Ell 1.6 2.1 2.6

23VII. VentingA. Install vent system in accordance with local buildingcodes; or local authority having jurisdiction; orNational Fuel Gas Code, ANSI Z

241. Seal any unused openings in the common ventingsystem.2. Visually inspect the venting system for proper sizeand horizontal pitch and determine the

25A. General. Install wiring and ground boiler in accordancewith requirements of authority having jurisdiction, or inabsence of such requirements the

26Table 6: Thermostat Heat Anticipator SettingsSet heat anticipator to match system requirements. SeeTable 6. In general, setting heat anticipator too

27Figure 34: Vent Damper Schematic Wiring DiagramFigure 33: Vent Damper Harness to Limit

28Figure 35: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low Water Cutoff

29b. Low Water Cutoff (LWCO): Automaticallyinterrupts main burner operation when surface ofboiler water falls to lowest permissible operatinglevel. No

3NOTICEThis 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

30Figure 36: Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low Water Cutoff

31boiler water falls to lowest permissible operatinglevel. Normal operation resumes when waterreturns to normal level.c. Blocked Vent Switch. Automati

32Figure 37: Wiring Diagrams, Steam, Intermittent Ignition (HSP), Probe Low Water Cutoff

33J. Steam Boiler with Intermittent Ignition (HSP) and ProbeLow Water Cutoff. See Figure 37.1. Normal Operationa. Thermostat calls for heat. Thermost

34Figure 38: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Float Low Water Cutoff

35K. Steam Boiler with Continuous Ignition (Standing Pilot)and Float Low Water Cutoff. See Figure 38.1. Normal Operationa. Thermostat calls for heat.

36Figure 39: Wiring Diagrams, Steam, Intermittent Ignition (EI), Float Low Water Cutoff

37L. Steam Boiler with Intermittent Ignition (EI) and FloatLow Water Cutoff. See Figure 39.1. Normal Operationa. Thermostat calls for heat. Thermosta

38Figure 40: Wiring Diagrams, Steam, Intermittent Ignition (HSP), Float Low Water Cutoff

39M. Steam Boiler with Intermittent Ignition (HSP) and FloatLow Water Cutoff. See Figure 40.1. Normal Operationa. Thermostat calls for heat. Thermost

4Figure 1: Dimensional Drawing

40Figure 41: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Intermittent Circulation

41N. Water Boiler with Continuous Ignition (Standing Pilot)and Intermittent Circulation. See Figure 41.1. Normal Operationa. Thermostat calls for hea

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

43O. Water Boiler with Intermittent Ignition (EI) andIntermittent Circulation. See Figure 42.1. Normal Operationa. Thermostat calls for heat.b. Vent

44Figure 43: Wiring Diagrams, Water, Intermittent Ignition (HSP), Intermittent Circulation

45P. Water Boiler with Intermittent Ignition (HSP) andIntermittent Circulation. See Figure 43.1. Normal Operationa. Thermostat calls for heat.b. Vent

46Figure 44: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Gravity Circulation

47Q. Water Boiler with Continuous Ignition (Standing Pilot)and Gravity Circulation. See Figure 44.1. Normal Operationa. Thermostat calls for heat. Th

48Figure 45: Wiring Diagrams, Water, Intermittent Ignition (EI), Gravity Circulation

49R. Water Boiler with Intermittent Ignition (EI) and GravityCirculation. See Figure 45.1. Normal Operationa. Thermostat calls for heat. Thermostat I

5Table of ContentsI. Pre-Installation ... 7II. Knockdown Boiler Assembly ... 9III. Semi-Pak Boiler As

50Figure 46: Wiring Diagrams, Water, Intermittent Ignition (HSP), Gravity Circulation

51S. Water Boiler with Intermittent Ignition (HSP) andGravity Circulation. See Figure 46.1. Normal Operationa. Thermostat calls for heat. Thermostat

52Figure 47: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Tankless Heater

53T. Water Boiler with Continuous Ignition (Standing Pilot)and Tankless Heater. See Figure 47.1. Normal Operationa. Thermostat calls for heat or low

54Figure 48: Wiring Diagrams, Water, Intermittent Ignition (EI), Tankless Heater

55U. Water Boiler with Intermittent Ignition (EI) and TanklessHeater. See Figure 48.1. Normal Operationa. Thermostat calls for heat or low limit sens

56Figure 49: Wiring Diagrams, Water, Intermittent Ignition (HSP), Tankless Heater

57V. Water Boiler with Intermittent Ignition (HSP) andTankless Heater. See Figure 49.1. Normal Operationa. Thermostat calls for heat or low limit sen

58IX. System Start-upFigure 52: Gas Valve Pressure Tap, RobertshawGas ValveFigure 51: Gas Valve Pressure Tap, Honeywell GasValvesFigure 50: Front D

59Figure 53: Lighting Instructions, Continuous Ignition System, VR8200 and VR8300 Gas Valves81460177

6Figure 2: Section TappingsTappingSize(NPT)Steam Boiler with ProbeL.W.C.O.Steam Boiler withFloat L.W.C.O.Water BoilerWater Boiler with TanklessHeater

60Figure 54: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas Valve81460179

61Figure 55: Operating Instruction, Intermittent Ignition System, SV9500, SV9600, VR8204 and VR8304(except IN12) Gas Valves81460147

62Figure 56: Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas Valves81460192

63Figure 57: Operating Instructions, Intermittent Ignition System (HSP), SV9501 and SV9601"FOR YOUR SAFETY"BEFORE OPERATING result in a

64Figure 63: 1" Main Burner FlameFigure 58: Pilot Burner Flame, Honeywell Q350Figure 60: Pilot Burner Flame, Honeywell Q348Figure 59: Pilot Burn

65d. Intermittent Ignition (HSP), Models IN3 throughIN9. See Figure 61. Pilot should be lit only aftercompleting Step 3. Pilot burner produces thre

66ii. Remove gas orifices. Drill one (1) drill sizelarger (drill size is stamped on orifice, or seeKey No. 4D in repair parts section).iii. Reinstall

67a. Run 1 NPT pipe from Surface Blow-Off Tapping"L" to open drain. Do not install shut-off valve orother restriction. See Figure 2.b. Fill

68testing with Hydrion paper which is used in thesame manner as litmus paper, except it givesspecific readings. A color chart on the side of thesmall

69X. Service InstructionsA. General. Inspection and service should be conductedannually, except as noted. Turn off electrical power andgas supply whi

7I. Pre-InstallationA. Inspect shipment carefully for any signs of damage. Allequipment is carefully manufactured, inspected andpacked. Our responsib

70Remove all obstrutions. Replace all deteriorated partsand support properly. Seal all joints.E. Clean Boiler Flueways.1. Shut down gas boiler in acco

71 F. Remove Burners for cleaning, changing orifice plugs, orrepairs.1. Turn off electric service to boiler.2. Turn off gas supply to boiler.3. Remove

72Honeywell Electronic Ignition Trouble Shooting Guide

73Honeywell Hot Surface to Pilot Trouble Shooting Guide

74VIII. Repair PartsAll Independence Series Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you requireassista

75Service ScheduleDate Service Performed

76KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN121. Section Assembly1ALeft End Section (less tankless heater)717100021111

77KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN122. Canopy and Draft Hood2A Canopy Assembly61110031 --- --- --- --- ---

78KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN123. Base Assembly3A Base Tray718600391 1 --- --- --- --- --- --- --- ---

79KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN123. Base Assembly (Continued)3B2 Base Rear Insulation72060035 1 --- --- -

8Figure 3: Clearance to Combustible Materialsc. Caulking or sealants applied in joints aroundwindow and door frames, between sole platesand floors, be

80KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN123. Base Assembly (Continued)3F Burner Access Panel718600361 1 --- --- --

81Key No. Description Part No.QuantityIN3 IN4 IN5 IN 6 IN 7 IN 8 IN 9 IN10 IN11 IN124. Manifold and Main Burners (1 Inch M ain Burners Only)4AMain Bur

82KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN94. Manifold and Main Burners (40MM MAIN BURNERS ONLY)4A Main Burner 8236135 1 2 3 4 5

83KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN94. Manifold and Main Burners (40MM MAIN BURNERS ONLY) ContinuedNatural Gas, Sea Level

84KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN125. Pilot Burner and Gas Valve, Continous Ignition (Standing Pilot), Natu

85KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN125. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas5A

86KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN95. Pilot Burner and Gas Valve, Intermittent Ignition (HSP), Natural Gas5APilot Burner,

87

88KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Jacket Assembly1 Left Side Panel60410013 1 1 1 1 1 1 1 --- --- ---604100

89KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Jacket Assembly (Continued)5A Upper Left Rear Panel (not shown) 60410105

9Figure 4: Base Gasket Installation II. Knocked-Down Boiler AssemblyA. Install Base-Burner-Manifold Assembly1. Base-Burner-Manifold is shipped assemb

90KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Steam Trim7ASafety Valve, ¾ NPT, 15 psi,Conbraco 13-511-0881660530111111

91

92KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12Water Trim7ASafety Relief Valve, ¾ NPT, 30 psi,Conbraco 10-407-058166036

93

94KeyNo.Description Part No.QuantityIN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN1212. Transformer (Steam and Gravity Water Only)12AJunction Box, 4-11/16&q

95

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