Burnham INDEPENDENCE IN10 CANADA Installation and maintenance instructions

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2
The 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 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. 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.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels, or to important information concerning product life.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
CAUTION
If, during normal operation, it is necessary to add water to this boiler more frequently than once a month,
consult a qualied service technician to check your system for leaks. A leaky system will increase the volume
of make-up water supplied to the boiler which can signicantly shorten the life of the boiler. Entrained in
make-up water are dissolved minerals and oxygen. 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. The presence of free oxygen in the
boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the cast
iron through from the inside. Since neither of these failure types are a result of a casting defect the warranty
does not apply. Clearly, it is in everyone's best interest to prevent this type of failure. The maintenance of
system integrity is the best method to achieve this.
NOTICE
This 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 to see that all controls are correctly installed and are
operating properly when the installation is complete.
Surfacerustoncastironsectionsmaybeattributedtothemanufacturingprocessaswellascondensation
during storage. Surface rust is normal and does not affect the performance or longevity of a 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. Refer to Low Water Cutoff Service Instructions for complete, step-by-step inspection and cleaning
instructions.
WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efciency.
Installation is not complete unless a safety (relief) valve is installed. See the Piping and Trim Section of
this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water or steam under high pressure. Do not unscrew any pipe ttings nor
attempt to disconnect any components of this boiler without positively assuring the water is cool and has
no pressure. Always wear protective clothing and equipment when installing, starting up or servicing
this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine
the pressure and temperature of the boiler. This boiler contains components which become very hot
when the boiler is operating. Do not touch any components unless they are cool.
Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
Failuretofollowallinstructionsintheproperordercancausepersonalinjuryordeath. Readallinstructions,
including all those contained in component manufacturers manuals which are provided with the boiler
before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.
All cover plates, enclosures and guards must be in place at all times.

4
Figure 1: Dimensional Drawing

5
Dimensional Data
Heating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water)
Table of Contents
I. Pre-Installation.....................................7
II. Knockdown Boiler Assembly................9
III. Semi-Pak Boiler Assembly..................13
IV. Packaged Boiler Assembly ..................15
V. Piping and Trim .................................16
VI. Gas Piping..........................................22
VII. Venting............................................... 24
VIII. Electrical............................................. 26
IX. System Start-up .................................. 50
X. Service Instructions ............................ 62
XI. Repair Parts........................................ 69
XII. Appendix
Low Water Cut Off (LWCO)............... 90
Boiler
Model
Approx.
Shipping
Weight
Lbs.
Dimensions (in inches) Recommended
Min. Round
Chimney Size
(Diameter x Height)
(1)
Gas
Conn.
(NPT)
Water Volume (Gal.)
'A' 'B' 'C' 'D' 'E' 'F' 'G' Steam
Boiler Water Boiler (3)
IN3 350 14-1/2
40
33-3/4 4
40-1/4
4-3/4 7-1/4 4" x 15 ft.
1/2"
5.1 7.8 3.9
IN4 420 17-3/4 34-3/4 58-7/8 5" x 15 ft. 6.5 10.0 5.0
IN5 485 21 35-3/4 65-1/4 10-1/2 6" x 15 ft. 7.9 12.2 6.1
IN6 USA
555 24-1/4 12-1/8 9.3 14.4 7.2
IN6
Canada 36-3/4 7
7-1/2
7" x 15 ft.
IN7 620 27-1/2 13-3/4
3/4"
10.7 16.6 8.3
IN8 USA
690 30-3/4 15-3/8 12.1 18.8 9.4
IN8
Canada 37-3/4
8 8" x 15 ft.IN9 760 34 17 13.5 21.0 10.5
IN10
USA 815 37-1/4
45 38-3/4 45-1/2
18-5/8 3/4"
(2)
14.9 23.2 11.6
IN10
Canada 99" x 15 ft.
IN11 885 40-1/2 20-1/4 16.3 25.4 12.7
IN12 955 43-3/4 21-7/8 1" 17.7 27.6 13.8
(1) 15' chimney height is from bottom of Draft Hood opening to top of Chimney.
(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.

6
Figure 2: Section Tappings
Table 1: Trim and Control Installation in Section Tappings
Tapping Size
(NPT) Steam Boiler with Probe L.W.C.O. Steam Boiler with Float L.W.C.O. Water Boiler Water Boiler with Tankless Heater
A2 Supply Supply Supply Supply
B ½ Bush to ¼
Pressure Gauge Plug Plug Plug
C ½ Gauge Glass Nipple & ½ Union Gauge, L.W.C.O. Street
Elbow, Syphon & Limit
Plug Lower Tapping Bush
to ¼ Upper Tapping
Press./Temp. Gauge
Plug Lower Tapping Bush to
¼ Upper Tapping
Press./Temp. Gauge
D2Return Return Bush to 1½, 3" Npl, Elbow, 2" Npl, Circ. Flange,
Gasket, Circulator Return
Bush to 1½, 3" Npl, Elbow,
2" Npl, Circ. Flange,
Gasket, Circulator Return
E ¾ 3" Nipple & Street Elbow
Safety Relief Valve 3" Nipple & Street Elbow Safety Relief Valve 3" Nipple & Street Elbow Safety Relief Valve 3" Nipple & Street Elbow Safety Relief Valve
F2Bush to ¾ Drain Valve
and/or Optional Return Bush to ¾ Drain Valve and/or Optional Return Bush to ¾ Drain Valve and/or Optional Gravity Return Bush to ¾ Drain Valve and/or Optional Gravity Return
G2Optional Supply (IN3-6)
Required Supply (IN7-12 Optional Supply (IN3-6) Required Supply (IN7-12 Plug (IN3-12) Optional Gravity Supply Plug (IN3-12) Optional Gravity Supply
H ¾ Bush to ¼ &
Syphon Limit Bush to ¼ Pressure Gauge Well Limit Well Limit
J ¾ Not Applicable Not Applicable Not Applicable Tankless Heater
K ¾ Low Water Cutoff Plug Plug Plug
L1Factory Plugged
Surface Blow-Off Factory Plugged Surface Blow-Off Factory Plugged Factory Plugged
M1¼ Factory Plugged
Alliance Return Factory Plugged Alliance Return Factory Plugged Factory Plugged
N 1¼ Factory Plugged
Alliance Supply Factory Plugged Alliance Supply Factory Plugged Factory Plugged
P¾Factory Plugged
Alliance Limit Factory Plugged Alliance Limit Factory Plugged Factory Plugged

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. No claims for
variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
B. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to the National
Fuel Gas Code, NFPA 54/ANSI Z223.1 and/or CAN/
CSA B149.1 Installation Codes. Where required by the
authority having jurisdiction, the installation must
conform to the Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME
No. CSD-1.
C. Appliance is design certied for installation on
combustible ooring. Boiler must not be installed on
carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local re
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.
E. Install boiler on level oor as close to chimney as
possible. For basementinstallation provide a solid base,
such as concrete, steel or masonry if oor is not level or
if water may be encountered on oor around boiler.
F. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, control
replacement, etc.).
G. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes, or
the National Fuel Gas Code, NFPA 54/ANSI Z223.1,
Section 5.3, Air for Combustion and Ventilation; or
CAN/CSA B149.1 Installation Code.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and
b. Weather-stripping has been added on openable
windows and doors, and
c. Caulking or sealants applied in joints around
window and door frames, between sole plates
and oors, between wall-ceiling joints, between
wall panels, at plumbing and electrical
penetrations, and at other openings.
WARNING
If you do not follow these instructions exactly,
a re or explosion may result causing property
damage or personal injury.
DANGER
Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
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. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler
to the system.

8
Figure 3: Clearance to Combustible Materials
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.
6. For boiler located within unconned space in
building of unusually tight construction or within
conned space, provide outdoor air through two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 3
inches. Size each opening per following:
a. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 Btu per hour
input of all equipment in space.
b. Vertical ducts. Minimum free area of 1 square
inch per 4,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1 square
inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
Alternate method for boiler located within conned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcient volume such that combined volume of all
spaces meet criteria for unconned space. Size each
opening for minimum free area of 1 square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be xed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
H. Do not install boiler where gasoline or other ammable
vapors or liquids, or sources of hydrocarbons (i.e.
bleaches, cleaners, chemicals, sprays, paint removers,
fabric softeners, etc.) are used or stored.

9
Figure 4: Base Gasket Installation
II. Knocked-Down Boiler Assembly
WARNING
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualied service agency.
A. Install Base-Burner-Manifold Assembly
1. Base-Burner-Manifold is shipped assembled from
factory (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).
B. Install assembled cast iron sections on base assembly:
1. Install (4) 5/16" x ¼" self-tapping screws through
(4) holes in upper base ange with screw heads on
underside of ange. Note: Screws are located in
ber gasket parts bag.
2. Install ceramic ber gasket. See Figure 4.
3. Position boiler above base with lugs cast in boiler
sections centered over screws protruding from top of
base. Lower boiler onto base taking care not to
disturb ceramic ber gasket. Secure with 5/16"
locknuts and washers provided. See Figure 5.
Figure 5: Section Assembly Attachment
4. Loosen nuts on tie rods until only nger 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
follows:
a. Place rubber gasket over heater coil and against
heater plate. Align holes in plate and gasket.
b. Install water heater coil through opening into top
nipple ports of boiler and fasten with 3/8" hex
head machine screws and at washers.
Note: If tankless heater is not installed, heater
opening cover plate must remain in place.
C. Test boiler for leaks before connecting to system and
installing controls, trim and jacket.
1. Attach pressure gauge (capable of indicating 30 psi)
on boiler.
2. Attach ll valve and piping to return tapping and
purge valve to supply tapping. See Figure 6.
Figure 6: Hydrostatic Pressure Test
3. Install plugs in remaining tappings.
4. Fill boiler completely with water by venting air
through purge valve. Close purge valve and apply
water pressure of at least 10 psi but not exceeding
30 psi gauge pressure.
5. Examine boiler carefully inside and outside for leaks
or damage due to shipment or handling.

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.
3. Attach canopy using ¼" carriage bolts, nuts, and
washers provided.
E. Inspect joints between sections. They were factory
sealed. If there are any openings due to shipment or
handling, reseal with boiler putty.
F. Install Jacket. See Figure 9.
1. Models IN7-IN12 steam boilers: remove 3 inch
diameter knockouts in jacket top panels.
2. Raise rear panel under rear ange of canopy and rest
on oor. Position rear panel and secure to jacket side
panels with sheet metal screws. For Models IN10-
IN12, secure jacket upper rear panels to side panels
with sheet metal screws.
3. Secure bothjacket side panels to base with sheet
metal screws.
4. Position front tie bar and secure to jacket side panels
with sheet metal screws.
5. Positionvestibule panel and secure to side panels
with sheet metal screws.
6. Attach Rating Label and Vent Damper Instruction
Label at designated locations on vestibule panel.
7. Install top panels by placing over and around outside
of side and rear panels. Seat fully and secure with
sheet metal screws.
8. Install black plastic rings into 1-3/32 inch diameter
holes located below upper louvers of front
removable door.

11
Figure 11: Pilot and Gas Piping, Continuous
Ignition (Standing Pilot) (IN3 through IN9 Only)
Figure 13: Pilot and Gas Piping, Intermittent Ignition
(EI) (IN3 through IN11 Only)
Figure 12: Pilot and Gas Piping, Continuous Ignition
(Standing Pilot) (IN10 through IN12 Only)
Figure 14: Pilot and Gas Piping, Intermittent Ignition
(EI) (IN12 Only)
9. Install front removable door by engaging upper side
edges of panel with side receiving anges, sliding
up and under top panel ange - seating front door
fully - then sliding down to engage bottom ange
behind lower front tie bar.
G. Install Pilot/Burner Assembly (shipped in Gas
Controls Carton). See Figure 10.
Figure 10: Combustion Chamber
1. Remove jacket front removable door.
a. Remove burner access panel located above
burners.
b. Install Pilot/Burner Assembly where noted on
gas manifold.
i. Insert rear of burner in burner tray slot.
ii. Position burner over the orice.
NOTE: The burner to the right may need to
be lifted from the orice to install pilot/
burner assembly. Reinstall lifted burner
over the orice.
c. Reinstall burner access panel.
H. Install Gas Valve on main gas burner assembly (if not
factory assembled). See Figure 11, 12, 13, or 14.
1. Connect gas valve to manifold.
2. Connect pilot tubing from pilot burner to gas valve
pilot tapping.
3. Continuous Ignition (standing pilot): connect
thermocouple to gas valve.

12
Figure 16: Blocked Vent Switch Installation,
IN10 through IN12
Figure 15: Blocked Vent Switch Installation,
IN3 through IN9
I. Install Blocked Vent Switch with sheet metal screws.
1. Models IN3 - IN9. Install on rear ange of canopy.
See Figure 15.
2. Models IN10 - IN12. Install on right side of draft
hood. See Figure 16. Reset switch must face away
from draft hood relief opening.
3. Attach black 18-2 harness to Blocked Vent Switch
terminals. Use end with two fully insulated
disconnects.
4. Secure harness to right side jacket panel with clamp.
5. Insert harness through ¾ inch hole in right side
jacket panel. Secure with strain relief bushing
J. Intermittent Ignition (EI): Install Ignition Module.
1. Mount ignition module mounting bracket to inside
of right side panel using (2) #6 x ¾" sheet metal
screws provided.
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.
K. Continue to Section III: Semi-Pak Boiler Assembly,
Step C.

13
III. Semi-Pak Boiler Assembly
WARNING
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualied 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 thickpiece of wood and
then onto oor. Do not bump boiler jacket against
oor.
3. Do not drop boiler at any time.
B. Move Boiler To Permanent Position. Refer to Section
I: Pre-Installation.
C. Identify Trim and Controls
FIRST - Determine controls ordered with boiler and
refer to appropriate section(s) following:
There are two ordering methods for trim and controls:
1. EZ–Connect Carton (either steam or water) includes
trim, controls, wiring and wiring instructions for
installation.
2. Separate Trim Carton (steam or water) and Control
Carton (steam or water). Only wiring requiring
special connections is provided. For wiring
requirements, refer to Section VIII: Electrical and
appropriate wiring diagram.
D. Install Trim and Controls
Refer to appropriate paragraphs (following) for trim
and controls to be installed.
1. Steam Boiler with Probe Low Water Cutoff
a. Install pressure limit control into Tapping "H"
with siphon, ¾" x ¼" hex bushing, ¾" elbow and
¾" x 3" nipple provided. See Figures 1 and 2.
DO NOT TWIST CONTROL. Use wrench on
hex tting located at bottom of control. See
Figure 18.
b. The L404F pressure limit employs a snap action
switch and does not require leveling. See Figure
18.
c. Install pressure gauge into Tapping "B" (½ NPT
bushed to ¼ NPT). See Figures 1 and 2. Tighten
with wrench applied to square shank on back of
gauge. DO NOT APPLY PRESSURE ON
GAUGE CASE since this may destroy
calibration of gauge.
d. Install Low Water Cutoff Probe into Tapping "K"
(¾ NPT). HANDLE PROBE WITH CARE.
e. Attach Low Water cutoff Control to Probe by
following instructions packed with control.
f. Install gauge glass ttings into Tappings "C"
(½ NPT). See Figures 1 and 2. Lower tting has
small drain valve.
g. Install gauge glass and protective rods in ttings.
h. Attach "Lowest Permissible Water Level" Plate
with sheet metal screws in location indicated in
Figure 9.
i. Attach "Frequent Water Addition" Label above
the "Lowest Permissible Water Level" Plate.
2. Steam Boiler with McDonnell & Miller 67 Float
Low Water Cutoff
a. Install Low Water Cutoff, see instructions packed
with control.
i. Screw brass nipples with union halves into
Tappings "C" (½ NPT). See Figure 1 and 2.
ii. Attach Gauge Glass/Low Water Cutoff
Assembly to union halves.
iii. Afx Blow-Down Card to Jacket Left Side
Panel adjacent to low water cutoff.
iv. Provide blow down discharge piping.
b. Attach street elbow siphon and pressure limit
control to low water cutoff. DO NOT TWIST
CONTROL. Use wrench on hex tting located at
bottom of control.
c. The L404F pressure limit employs a snap action
switch and does not require leveling. See Figure
18.
d. Install pressure gauge into Tapping "H" (¾ NPT
bushed to ¼ NPT). See Figures 1 and 2. Tighten
with wrench applied to square shank on back of
gauge. DO NOT APPLY PRESSURE ON
GAUGE CASE since this may destroy
calibration of gauge.
e. Attach "Lowest Permissible Water Level" Plate
with sheet metal screws in location indicated in
Figure 9.
f. Attach "Frequent Water Addition" Label above
the "Lowest Permissible Water Level" Plate.
Figure 18: L404F Pressure Limit Control

14
Figure 20: Thermostat Isolation Relay Attachment
3. All Steam Boilers and Water 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.
ii. Install mounting bracket to rear of Junction
Box with two (2) blunt sheet metal screws
provided.
iii. Align center and mounting holes of Junction
Box with upper front corner of jacket left
side panel.
iv. Install Junction Box to jacket from inside
vestibule area with two (2) blunt sheet metal
screws provided.
b. Mount transformer on Junction Box. For
Canadian boiler provide strain relief by loosely
securing Transformer to Junction Box with wire
tie inserted through Transformer plate and a
Junction Box mounting hole. See Figure 19B.
c. Fork connector on yellow wire of gas valve
harness must be removed and wire stripped
before making wire connections. Refer to
Section VIII for wiring.
d. Steam Boilers only. Secure the R8222
Thermostat Isolation Relay to upperleft corner of
jacket vestibule panel with sheet metal screws
provided. See Figure 20.
e. Water with tankless heater only (EZWT and
WCT). Secure R8225D relay to Junction Box.
See Figure 1.
4. Water Boiler
a. Install Temperature/Pressure Gauge into upper
Tapping "C" (½ NPT bushed to ¼ NPT). See
Figure 1 and 2. Tighten by wrench applied to
square shank on back of gauge. DO NOT
APPLY PRESSURE ON GAUGE CASE since
this may destroy calibration of gauge.
Figure 19B: Junction Box and Transformer
Assembly
Figure 19A: Junction Box and Mounting Bracket
Assembly
b. Install hot water temperature limit and/or
combination control. Remove well from control.
Screw well into Tapping "H" (¾ NPT). See
Figure 1 and 2. Install bulb in well as far as
possible, then tighten set screw.
c. On boilers equipped with a circulator without
tankless heater in areas where condensation of
ue gases is encountered in boiler ueways, a
reverse-acting circulator control should be
installed in supply as close as possible to boiler
in order to avoid condensation.
E. Continue to Section IV. Packaged Boiler Assembly,
Paragraph E.

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.
B. Remove Jacket Front Panel. See Figure 45.
C. Remove poly bag from vestibule area.
D. On Steam Boilers with probe low water cutoff the
L404 pressure limit/control has been packed in the
vestibule area.
1. Screw the pressure limit/control onto the syphon.
DO NOT TWIST CONTROL. Use wrench on hex
tting at bottom of control. See Figure 18.
2. Snap the electrical conduit from the adjacent
junction box into the hole in the control.
3. Open the control's clear cover and attach the two (2)
wires in the conduit to the two (2) unused screw
terminals.
IV. Packaged Boiler Assembly
Figure 21: Draft Hood Attachment
E. Install Jacket Front Panel.
F. Install Draft Hood. Models IN3 through IN9.
1. Locate and open "Rear Draft Hood Carton".
2. Position Draft Hood on Canopy Rear Flange. See
Figure 21. Top canopy ange must fully engage
"U"-shaped draft hood ange for proper installation
and operation. Care must be taken to assure that
draft hood is level.
3. Secure Rear Draft Hood to Canopy with wing nuts
provided. See Figure 22.
WARNING
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualied service agency.
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 certication will become void.

16
V. Piping and Trim
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. Eliminate
oxygen contamination by repairing system leaks,
repairing ttings, using nonpermeable materials in
distribution system, and eliminating open tanks in
system, or isolating boiler from system with heat
exchanger.
B. Install Safety (Relief) Valve in Tapping "E" (¾ NPT).
See Figure 23. Use ¾ NPT x 3" nipple and ¾ NPT
elbow provided. Safety (Relief) Valve must be installed
with spindle in vertical position.
Figure 23: Trim Installation
WARNING
Safety (relief) valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut-off
valves, plugs or caps. Consult Local Codes for
proper discharge piping arrangement.
C. Install Drain Valve in Tapping "F" (2 NPT bushed to
¾ NPT). See Figure 23.
D. Connect supply and return piping to heating system.
Maintain minimum ½ inch clearance from combustible
materials.
1. For STEAM HEATING see Figure 24. Consult
I=B=R Installation and Piping Guides.
2. For HOT WATER HEATING with Circulator
(forced) see Figure 25 and 25A. ConsultI=B=R
Installation and Piping Guides.
3. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled
medium piped in parallel with heating boiler using
appropriate valves to prevent the chilled medium
from entering the boiler. See Figure 26. Also
consult I=B=R Installation and Piping Guides.
4. If boiler is connected to heating coils located in air
handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
ow control valves to prevent gravity circulation of
boiler water during cooling system operation.
WARNING
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
NOTICE
Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh water
supply to the boiler upstream of a water softener.
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.
Before using copper for steam piping, consider the following characteristics of copper piping:
1) high coefcient of thermal expansion can induce mechanical stresses and cause expansion/
contraction noises if not accounted for in the piping system design and installation,
2) high heat transfer rate (heat loss) of uninsulated copper piping must be included in the normal
piping and pickup factors used to size the boiler,
3) soldering or brazing pastes and uxes that end up in the system can cause poor heat transfer,
surging, an unsteady water line and wet steam if not thoroughly removed during the boil out
procedure and,
4) galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water
chemistries if dielectric unions are not used.

17
Figure 24: Steam Boiler Piping (Minimum)
NOTICE
Failure to pipe boiler as specied in this manual may result in excessive system noise, water line uctuations and water carry over.

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

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

20
Figure 27: Recommended Piping for
Indirect Water Heater Figure 28: Tankless Heater Piping
Figure 26: Recommended Piping for Combination
Heating and Cooling (Refrigeration) Systems
E. 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" (1¼ NPT). Install zone
circulator and strainer in supply piping. Install
check valve to prevent gravity circulation of
boiler water.
b. Limit. See Figure 23. Install temperature limit
control (Honeywell L4006A or equal) in Tapping
"P" (¾ NPT). See Figure 2. Set at 180°F to
prevent steam production during non-space
heating periods.
5. Use boiler bypass if boiler is operated in system
which has a large volume or excessive radiation
where low boiler water temperatures may be
encountered (i.e. converted gravity circulation
system, etc.).
a. Bypass should be same size as supply and return
lines with valves located in bypass and supply
outlet as illustrated in Figures 25 and 25A in
order to regulate water ow to maintain higher
boiler water temperatures.
b.Set bypass and boiler supply valves to a half
throttle position to start.
c. After installation is complete, operate boiler
according to Section IX: System Start-up.
6. A hot water boiler installed above radiation level
must be provided with a low water cutoff device as
part of installation.
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. Appendix for further details) .
7. If a tankless heater coil is used, connect water lines
to ¾ NPT tappings in coil plate.
2. Water without tankless heater. Install in same
manner as space heating zone.
F. Tankless Heater (if used). See Figure 28.
1. Install automatic tempering or mixing valve to
prevent delivery of scalding hot water to xtures.
Higher temperature water for dishwashers and
automatic washers is possible by piping hot water
from heater prior to entering mixing valve. Install
per manufacturer's instructions.
WARNING
Install automatic mixing valve at tankless heater
outlet to avoid risk of burns or scalding due to
excessively hot water at xtures.
2. Install ow regulator. Match regulator rating to
tankless heater rating. Install in cold water inlet
below and minimum 3 feet downstream of tankless
heater inlet.
3. Install water softener in areas of hard water, this will
reduce mineral deposits which could hinder heat
transfer and delivery of hot water.