Burnham Independence Training manual

8141049R23.5-4/07 Price - $3.00
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RELIOBDERIF-SAG

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 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.
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.
REGNAD
noitautissuodrazahyltnenimminasetacidnI
,htaednitluserlliw,dediovatonfi,hcihw
ytreporplaitnatsbusroyrujnisuoires
.egamad
NOITUAC
noitautissuodrazahyllaitnetopasetacidnI
nitluseryam,dediovatonfi,hcihw
ytreporproyrujnironimroetaredom
.egamad
GNINRAW
noitautissuodrazahyllaitnetopasetacidnI
,htaednitluserdluoc,dediovatonfi,hcihw
ytreporplaitnatsbusroyrujnisuoires
.egamad
ECITON
,noitallatsninosnoitcurtsnilaicepssetacidnI
erahcihwecnanetniamro,noitarepo
yrujnilanosrepotdetalertontubtnatropmi
.sdrazah
NOITUAC
ecnonahtyltneuqerferomreliobsihtotretawddaotyrassecensiti,noitarepolamrongnirud,fI
metsysykaelA.skaelrofmetsysruoykcehcotnaicinhcetecivresdeifilauqatlusnoc,htnoma
netrohsyltnacifingisnachcihwreliobehtotdeilppusretawpu-ekamfoemulovehtesaercnilliw
ehtnehW.negyxodnaslarenimdevlossideraretawpu-ekamnideniartnE.reliobehtfoefileht
ehtdnatnemidessatuollafslarenimehtreliobehtnidetaehsiretawpu-ekamlooc,hserf
tnemidesfonoitalumuccaehT.efilreliobdecudernitlusernachtoB.sagasasepacsenegyxo
noritsacehtsneppahsihtnehW.noritsacehtgnitcatnocmorfretawehtetalosiyllautnevenac
ehtninegyxoeerffoecneserpehT.kcarcyllautneveyamdnatohylemertxestegaeratahtni
nac,hguonehgihsemocebnoitartnecnocehtfi,hcihwerehpsomtaevisorrocasetaercreliob
fotluseraerasepyteruliafesehtforehtienecniS.edisniehtmorfhguorhtnoritsacehtedorroc
tneverpottseretnitsebs'enoyrevenisiti,ylraelC.ylppatonseodytnarrawehttcefedgnitsaca
.sihteveihcaotdohtemtsebehtsiytirgetnimetsysfoecnanetniamehT.eruliaffoepytsiht
ECITON
.launamsihtfokcabehtnodetnirpsihcihwfoypoca,ytnarrawdetimilasahreliobsihT
yltcerroceraslortnocllatahteesotrotcartnocgnillatsniehtfoytilibisnopserehtsitI
.etelpmocsinoitallatsniehtnehwylreporpgnitarepoeradnadellatsni
llewsassecorpgnirutcafunamehtotdetubirttaebyamsnoitcesnoritsacnotsurecafruS
ehttceffatonseoddnalamronsitsurecafruS.egarotsgnirudnoitasnednocsa
reliobafoytivegnolroecnamrofrep .

3
GNINRAW
ehtwolloF.ylefasetarepootecivresdnaecnanetniamralugerseriuqerreliobsihT
.launamsihtnideniatnocsnoitcurtsni
ytreporpesuacnacecnanetniamroecivres,noitaretla,tnemtsujda,noitallatsnireporpmI
erofeblaunameritneehtdnatsrednudnadaeR.efilfossolroyrujnilanosrep,egamad
ebtsumecivresdnanoitallatsnI.ecivresro,noitarepopu-trats,noitallatsnignitpmetta
.ycnegaecivresrorellatsnielbaegdelwonkdna,delliks,decneirepxenaybylnodemrofrep
.detnevylreporpebtsumreliobsihT
snoisivorperaerehtosdellatsniebtsumdnanoitarepoefasrofriahserfsdeenreliobsihT
.rianoitalitnevdnanoitsubmocetauqedarof
ehtfotratsehterofebdenaelcdnadetcepsniebtsummetsysgnitnevehtforoiretniehT
ynarofnosaesgnitaehehttuohguorhtyllacidoirepdetcepsniebdluohsdnanosaesgnitaeh
suoixonwollaotyrassecensimetsysgnitnevdetcurtsbonudnanaelcA.snoitcurtsbo
drawotetubirtnoclliwdnaylefastnevotefilfossolroyrujniesuacdluoctahtsemuf
.ycneiciffes'reliobehtgniniatniam
mirTdnagnipiPehteeS.dellatsnisievlav)feiler(ytefasasselnuetelpmoctonsinoitallatsnI
.sliatedroflaunamsihtfonoitceS
tondnanwodtuhsotreliobehtesuacyamhcihwsecivedytefashtiwdeilppussireliobsihT
metsysgnitaeheht,ytilibissopasisepipnezorfoteudegamadfI.ecivrestuohtiwtrats-er
dluohssmraladnasdraugefasetairporpparo;rehtaewdlocnidednettanutfelebtondluohs
.evitareponisireliobehtfiegamadtneverpotmetsysgnitaehehtnodellatsnieb
epipynawercsnutonoD.erusserprednumaetsroretawtohyrevsniatnocreliobsihT
gnirussaylevitisoptuohtiwreliobsihtfostnenopmocynatcennocsidottpmettaronsgnittif
tnempiuqednagnihtolcevitcetorpraewsyawlA.erusserponsahdnaloocsiretaweht
noylertonoD.seirujnidlacstneverpotreliobsihtgnicivresropugnitrats,gnillatsninehw
ehtfoerutarepmetdnaerusserpehtenimretedotseguagerutarepmetdnaerusserpeht
sireliobehtnehwtohyrevemocebhcihwstnenopmocsniatnocreliobsihT.reliob
.loocerayehtsselnustnenopmocynahcuottonoD.gnitarepo
,animulaniatnocleufehtdnanoitsubmocfostcudorp,noitcurtsnocfoslairetamrelioB
rocixotrehtoro/dnasedyhedla,sedixonegortin,edixonomnobrac,slatemyvaeh,acilis
ehtotnwonkerahcihwdnayrujnisuoiresrohtaedesuacnachcihwsecnatsbuslufmrah
esusyawlA.mrahevitcudorperrehtodnastcefedhtrib,recnacesuacotainrofilaCfoetats
ehtybraengnikrowrognicivresnehwtnempiuqednasrotaripser,gnihtolcytefasreporp
.ecnailppa
.htaedroyrujnilanosrepesuacnacredroreporpehtnisnoitcurtsnillawollofoteruliaF
slaunamsrerutcafunamtnenopmocnideniatnocesohtllagnidulcni,snoitcurtsnilladaeR
rogniniatniam,gnitarepo,pugnitrats,gnillatsnierofebreliobehthtiwdedivorperahcihw
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NOITUAC
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ehtninoitanimatnocelbissopotdesopxesieborpeht,noitareporiehtnietatsdiloserasecived
,etelpmocrofsnoitcurtsnIecivreSffotuCretaWwoLotrefeR.gniluofottcejbusdnaretawreliob
.snoitcurtsnigninaelcdnanoitcepsnipets-yb-pets

4
Figure 1: Dimensional Drawing

5
Dimensional Data
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'A' 'B' 'C' 'D' 'E' 'F' 'G' maetS
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3NI 053 2/1-41
04
4/3-33 4
4/1-04
4/3-4 4/1-7 .tf51x"4
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1.5 8.7 9.3
4NI 024 4/3-71 4/3-43 5 8/7-8 .tf51x"5 5.6 0.01 0.5
5NI 584 12 4/3-53 6 4/1-5 2/1-01 .tf51x"6 9.7 2.21 1.6
ASU6NI 555 ¼42 8/1-21 3.9 4.41 2.7
adanaC6NI
4/3-63 7
2/1-7
.tf51x"7
7NI 026 2/1-72 4/3-31
"4/3
7.01 6.61 3.8
ASU8NI 096 4/3-03 8/3-51 1.21 8.81 4.9
adanaC8NI 4/3-73 8 .tf51x"89NI 067 43 71 5.31 0.12 5.01
ASU01NI
518 ¼73
54 4/3-83 2/1-54
8/5-81 "4/3
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9.41 2.32 6.11
01NI
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9 .tf51x"9
11NI 588 2/1-04 4/1-02 3.61 4.52 7.21
21NI 559 4/3-34 8/7-12 "1 7.71 6.72 8.31
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.TPN1si)toliPgnidnatS(noitingIsuounitnoC11NI-01NInoezisnoitcennocsaG)2(
levelffotucretawwolot)levelretawlamron(LWNmorfemulovretaw:"emulovretawelbamaets"s'reliobmaetS)3(
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 ............16
V. Piping and Trim ...........................17
VI. Gas Piping.................................... 23
VII. Venting.........................................25
VIII. Electrical.......................................27
IX. System Start-up ............................60
X. Service Instructions ......................73
XI. Repair Parts..................................79
XII. Appendix
Low Water Cut Off (LWCO)....... 102

6
Figure 2: Section Tappings
Table 1: Trim and Control Installation in Section Tappings
gnippaT eziS
)TPN(
eborPhtiwrelioBmaetS
.O.C.W.L
htiwrelioBmaetS
.O.C.W.LtaolF relioBretaW sselknaThtiwrelioBretaW retaeH
A 2 ylppuS ylppuS ylppuS ylppuS
B ½ ¼othsuB
eguaGerusserP gulP gulP gulP
C ½ ssalGeguaG
,eguaGnoinU½&elppiN
,woblEteertS.O.C.W.L
timiL&nohpyS
hsuBgnippaTrewoLgulP
gnippaTreppU¼ot
eguaG.pmeT/.sserP
othsuBgnippaTrewoLgulP
gnippaTreppU¼
eguaG.pmeT/.sserP
D 2 nruteR nruteR
,woblE,lpN"3,½1othsuB
,egnalF.criC,lpN"2
nruteRrotalucriC,teksaG
,woblE,lpN"3,½1othsuB
,egnalF.criC,lpN"2
nruteRrotalucriC,teksaG
E ¾ woblEteertS&elppiN"3
evlaVfeileRytefaS
woblEteertS&elppiN"3
evlaVfeileRytefaS
woblEteertS&elppiN"3
evlaVfeileRytefaS
woblEteertS&elppiN"3
evlaVfeileRytefaS
F 2 evlaVniarD¾othsuB
nruteRlanoitpOro/dna
evlaVniarD¾othsuB
nruteRlanoitpOro/dna
ro/dnaevlaVniarD¾othsuB
nruteRytivarGlanoitpO
ro/dnaevlaVniarD¾othsuB
nruteRytivarGlanoitpO
G 2
)6-3NI(deggulPyrotcaF
)6-3NI(ylppuSlanoitpO
)21-7NI(ylppuSderiuqeR
)6-3NI(deggulPyrotcaF
)6-3NI(ylppuSlanoitpO
)21-7NI(ylppuSderiuqeR
)6-3NI(deggulPyrotcaF
)21-7NI(gulP
ylppuSytivarGlanoitpO
)6-3NI(deggulPyrotcaF
)21-7NI(gulP
ylppuSytivarGlanoitpO
H ¾ nohpyS&¼othsuB
timiL
¼othsuB
eguaGerusserP
lleW
timiL
lleW
timiL
J ¾ elbacilppAtoN elbacilppAtoN elbacilppAtoN retaeHsselknaT
K ¾ ffotuCretaWwoL gulP gulP gulP
L 1 deggulPyrotcaF
ffO-wolBecafruS
deggulPyrotcaF
ffO-wolBecafruS deggulPyrotcaF deggulPyrotcaF
M ¼1 deggulPyrotcaF
nruteRecnaillA
deggulPyrotcaF
nruteRecnaillA deggulPyrotcaF deggulPyrotcaF
N ¼1 deggulPyrotcaF
ylppuSecnaillA
deggulPyrotcaF
ylppuSecnaillA deggulPyrotcaF deggulPyrotcaF
P ¾ deggulPyrotcaF
timiLecnaillA
deggulPyrotcaF
timiLecnaillA deggulPyrotcaF deggulPyrotcaF

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/
CGA B149 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/CGA B149 Installation Codes, Sections 7.2, 7.3
or 7.4.
GNINRAW
rianoitalitnevdnanoitsubmocetauqedA
reporperussaotdedivorpebtsum
.noitsubmoc
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
GNINRAW
snoitcurtsniesehtwolloftonoduoyfI
tluseryamnoisolpxeroerifa,yltcaxe
lanosreproegamadytreporpgnisuac
.yrujni
REGNAD
rehtoroenilosagerehwreliobllatsnitonoD
fosecruosro,sdiuqilrosropavelbammalf
,srenaelc,sehcaelb.e.i(snobracordyh
cirbaf,srevomertniap,syarps,slacimehc
.derotsrodesuera).cte,srenetfos
ECITON
,reliobehtfotnetnocretawwolehtoteuD
ehtotdragerhtiwreliobehtfognizis-sim
evissecxenitluserlliwdaolmetsysgnitaeh
tnenopmocdetareleccadnagnilcycreliob
tnarrawTONSEODmahnruB.eruliaf
reliobdezis-simybdesuacseruliaf
otreliobehtezisrevoTONOD.snoitacilppa
.metsyseht

8
Figure 3: Clearance to Combustible Materials
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.
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
GNINRAW
ebdluohsreliobsihtfonoitallatsnI
delliksdnadeniartybylnonekatrednu
.ycnegaecivresdeifilauqamorflennosrep
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, 14 or 15.
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 17: Blocked Vent Switch Installation,
IN10 through IN12
Figure 16: 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 16.
Figure 15: Pilot and Gas Piping, Intermittent
Ignition (HSP) (IN3 Through IN9)
2. Models IN10 - IN12. Install on right side of draft
hood. See Figure 17. 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-PakBoiler Assembly
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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:
l. 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 18A or 18B.
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.
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c. The L404F pressure limit employs a snap action
switch and does not require leveling. See Figure
18B.
d. 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.
e. Install Low Water Cutoff Probe into Tapping "K"
(¾ NPT). HANDLE PROBE WITH CARE.
f. Attach Low Water cutoff Control to Probe by
following instructions packed with control.
g. Install gauge glass ttings into Tappings "C"
(½ NPT). See Figures 1 and 2. Lower tting has
small drain valve.
Figure 18B: L404F Pressure Limit Control
Figure 18A: L404A Pressure Limit Control

14
Figure 20: Thermostat Isolation Relay Attachment
h. Install gauge glass and protective rods in ttings.
i. Attach "Lowest Permissible Water Level" Plate
with sheet metal screws in location indicated in
Figure 9.
j. 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. Level the L404A pressure limit by carefully
bending the syphon until the limit's levelling
indicator hangs freely with its pointer directly
over the index mark inside the back of the case.
See Figure 18A.
d. The L404F pressure limit employs a snap action
switch and does not require leveling. See Figure
18B.
e. 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.
f. Attach "Lowest Permissible Water Level" Plate
with sheet metal screws in location indicated in
Figure 9.
g. Attach "Frequent Water Addition" Label above
the "Lowest Permissible Water Level" Plate.
3. All Steam Boilers and Water Boilers except
"EZW" and "WC" Controls Cartons
a. Install Junction Box. See Figure 19A.
Figure 19B: Junction Box and Transformer
Assembly
Figure 19A: Junction Box and Mounting Bracket
Assembly
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 and blue (HSP only)
wire(s) 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.

15
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.
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.

16
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 50.
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 Figures 18A or
18B.
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.
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17
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
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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.
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.desutonerasnoinucirtceleidfiseirtsimehc

18
Figure 24: Steam Boiler Piping (Minimum)
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19
Figure 25: Recommended Water Piping for Circulator Zoned Heating System

20
Figure 25A: Recommended Water Piping for Zone Valve Zoned Heating System