IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR IN D E P E N D E N C E ® G A S - F I R E D BO I L E R 9700609 F o r s e rvi c e o r r e p a i rs to b o i le r, c a ll yo ur he a ti ng c o ntra c to r. W he n s e e k i ng i nfo rma ti o n o n b o i le r, p ro vi d e B o i le r Mo d e l Numb e r a nd S e ri a l Numb e r a s s ho wn o n Ra ti ng L a b e l.
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/pl_products/pb_pre_form.
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.
Figure 1: Dimensional Drawing
Dimensional Data Dimensions (in inches) Boiler Model Approx. Shipping Weight Lbs. IN3 350 IN4 IN5 IN6 555 24-1/4 40 IN7 620 27-1/2 IN8 690 30-3/4 'A' 'B' 'C' 'D' 14-1/2 33-3/4 4 420 17-3/4 34-3/4 5 485 21 35-3/4 36-3/4 IN9 760 34 IN10 815 37-1/4 37-3/4 IN11 885 40-1/2 45 38-3/4 IN12 955 43-3/4 6 'E' 'F' 4-3/4 40-1/4 5-1/4 7-1/4 4" x 15 ft. 8-7/8 5" x 15 ft. 10-1/2 12-1/8 13-3/4 7 15-3/8 8 9 'G' Recommended Water Volume (Gal.) Min.
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 A 2 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.
I. Pre-Installation WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. DANGER Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored.
I. Pre-Installation (continued) Figure 3: Clearance to Combustible Materials 5. For boiler located in an unconfined space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. 6.
II. Knocked-Down Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified 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: PreInstallation). B.
II. Knocked-Down Boiler Assembly (continued) D. Install Canopy. 1. Install ½" thick x 1" wide ceramic fiber gasket. See Figure 7. 2. Position canopy on ceramic fiber 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.
II. Knocked-Down Boiler Assembly (continued) 8. Install black plastic rings into 1-3/32 inch diameter holes located below upper louvers of front removable door. 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.
II. Knocked-Down Boiler Assembly (continued) 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. I. Install Blocked Vent Switch with sheet metal screws. 1. Models IN3 - IN9. Install on rear flange of canopy. See Figure 15. Figure 16: Blocked Vent Switch Installation, IN10 through IN12 4. Secure harness to right side jacket panel with clamp. 5.
III. Semi-Pak Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified 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 thick piece of wood and then onto floor. Do not bump boiler jacket against floor. 3. Do not drop boiler at any time. B. Move Boiler To Permanent Position. Refer to Section I: Pre-Installation. C.
III. Semi-Pak Boiler Assembly (continued) 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.
IV. Packaged Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. 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. E. Install Jacket Front Panel. F. Install Draft Hood. Models IN3 through IN9. 1. Locate and open "Rear Draft Hood Carton". 2.
V. Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. 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. U.S.
NOTICE Figure 24: Steam Boiler Piping (Minimum) Failure to pipe boiler as specified in this manual may result in excessive system noise, water line fluctuations and water carry over. V.
Figure 25: Recommended Water Piping for Circulator Zoned Heating System V.
Figure 25A: Recommended Water Piping for Zone Valve Zoned Heating System V.
V. Piping and Trim (continued) 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. E. Alliance SL™ Indirect Water Heater (if used).
V. Piping and Trim (continued) WARNING Install automatic mixing valve at tankless heater outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. 2. Install flow 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. G.
VI. Gas Piping WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An additional gas pressure regulator may be needed. Consult gas supplier. A. Size gas Piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler.
VI. Gas Piping (continued) 4. All above ground gas piping upstream from manual gas valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as a grounding electrode. Refer to the National Electrical Code, ANSI/NFPA 70 and/or CSA C22.1 Electrical Code. ½ psig or less, isolate boiler from gas supply piping by closing boiler's individual manual shut-off valve. 2. Using soap solution, or similar non-combustible solution, electronic leak detector or other approved method.
VII. Venting WARNING This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation instructions of this manual. Do not operate boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.
VII. Venting (continued) D. Install Vent Connector from draft hood or vent damper to chimney. See Figure 30. 1. Do not connect into same leg of chimney serving an open fireplace. 2. Vent pipe to chimney must not be smaller than outlet on draft hood or vent damper. Type B is recommended, but single-wall vent pipe may be used. Arrange venting system so boiler is served by vent damper device. 3.
VIII. Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.
VIII. Electrical (continued) Set heat anticipator to match system requirements. See Table 6. In general, setting heat anticipator too low will cause boiler to short cycle without bringing heated space up to temperature. Setting heat anticipator too high will allow boiler to operate longer than necessary and overheat space. 1. A separate electrical circuit must be run from the main electrical service with an over-current device/ disconnect in the circuit.
VIII.
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Figure 35: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low Water Cutoff VIII.
VIII. Electrical (continued) H. Steam Boiler with Continuous Ignition (Standing Pilot) and Probe Low Water Cutoff. See Figure 35. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Gas Valve(s) is energized allowing main gas flow and ignition of Main Burners. d. After Thermostat is satisfied Gas Valve(s) is deenergized, extinguishing main flame.
Figure 36: Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low Water Cutoff VIII.
VIII. Electrical (continued) I. Steam Boiler with Intermittent Ignition (EI) and Probe Low Water Cutoff. See Figure 36. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Ignition Module is energized. Pilot Valve opens and Igniter is energized to ignite Pilot Burner. d. Sensor proves presence of pilot flame. Main Valve(s) opens and ignites Main Burners. e.
Figure 37: Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Float Low Water Cutoff VIII.
VIII. Electrical (continued) J. Steam Boiler with Continuous Ignition (Standing Pilot) and Float Low Water Cutoff. See Figure 37. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Gas Valve(s) is energized allowing main gas flow and ignition of Main Burners. d. After Thermostat is satisfied Gas Valve(s) is deenergized, extinguishing main flame.
Figure 38: Wiring Diagrams, Steam, Intermittent Ignition (EI), Float Low Water Cutoff VIII.
VIII. Electrical (continued) K. Steam Boiler with Intermittent Ignition (EI) and Float Low Water Cutoff. See Figure 38. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Ignition Module is energized. Pilot Valve opens and Igniter is energized to ignite Pilot Burner. d. Sensor proves presence of pilot flame. Main Valve(s) opens and ignites Main Burners. e.
Figure 39: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Intermittent Circulation VIII.
VIII. Electrical (continued) L. Water Boiler with Continuous Ignition (Standing Pilot) and Intermittent Circulation. See Figure 39. 1. Normal Operation a. Thermostat calls for heat. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Gas Valve(s) is energized allowing main gas flow and ignition of Main Burners. d. After Thermostat is satisfied Gas Valve(s) is deenergized, extinguishing main flame. Vent Damper (if used) closes. 2. Safety Shutdown a.
Figure 40: Wiring Diagrams, Water, Intermittent Ignition (EI), Intermittent Circulation VIII.
VIII. Electrical (continued) M. Water Boiler with Intermittent Ignition (EI) and Intermittent Circulation. See Figure 40. 1. Normal Operation a. Thermostat calls for heat. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Ignition Module is energized. Pilot Valve opens and Igniter is energized to ignite Pilot Burner. d. Sensor proves presence of pilot flame. Main Valve(s) opens and ignites Main Burners. e.
Figure 41: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Gravity Circulation VIII.
VIII. Electrical (continued) N. Water Boiler with Continuous Ignition (Standing Pilot) and Gravity Circulation. See Figure 41. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Gas Valve(s) is energized allowing main gas flow and ignition of Main Burners. d. After Thermostat is satisfied Gas Valve(s) is deenergized, extinguishing main flame.
Figure 42: Wiring Diagrams, Water, Intermittent Ignition (EI), Gravity Circulation VIII.
VIII. Electrical (continued) O. Water Boiler with Intermittent Ignition (EI) and Gravity Circulation. See Figure 42. 1. Normal Operation a. Thermostat calls for heat. Thermostat Isolation Relay is energized, closing contacts. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Ignition Module is energized. Pilot Valve opens and Igniter is energized to ignite Pilot Burner. d. Sensor proves presence of pilot flame. Main Valve(s) opens and ignites Main Burners. e.
Figure 43: Wiring Diagrams, Water, Continuous Ignition (Standing Pilot), Tankless Heater VIII.
VIII. Electrical (continued) P. Water Boiler with Continuous Ignition (Standing Pilot) and Tankless Heater. See Figure 43. 1. Normal Operation a. Thermostat calls for heat or low limit senses water temperature below set point. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Gas Valve(s) is energized allowing main gas flow and ignition of Main Burners. d. After Thermostat or low limit is satisfied Gas Valve(s) is de-energized, extinguishing main flame.
Figure 44: Wiring Diagrams, Water, Intermittent Ignition (EI), Tankless Heater VIII.
VIII. Electrical (continued) Q. Water Boiler with Intermittent Ignition (EI) and Tankless Heater. See Figure 44. 1. Normal Operation a. Thermostat calls for heat or low limit senses water temperature below set point. b. Vent Damper (if used) opens as stated in Vent Damper Sequence of Operation. c. Ignition Module is energized. Pilot Valve opens and Igniter is energized to ignite Pilot Burner. d. Sensor proves presence of pilot flame. Main Valve(s) opens and ignites Main Burners. e.
IX. System Start-up WARNING Completely read, understand and follow all instructions in this manual before attempting start up. A. 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 LowPressure Steam and Hot Water Boilers, ANSI Z21.13. B. Check Main Burners. Main burners must be in slots in rear of burner tray and seated on main burner orifices. C.
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IX. System Start-up (continued) 3. Flame Current Measurement Procedure See Figure 52B "Measuring Pilot Flame Current with Micro-ammeter". a. Pilot flame current in micro amps can be measured using any standard micro-ammeter by inserting the meter probes into the module holes labeled FLAME CURRENT as shown in Figure 52B. b. Flame current must be measured with pilot valve open/pilot lit but the main valve closed. c. Disconnect MV lead wire from the module before measuring flame current.
IX. System Start-up (continued) Figure 53: Pilot Burner Flame, Honeywell Q350 Figure 55: Pilot Burner Flame, Honeywell Q348 Figure 56: 40mm Main Burner Flame Figure 54: Pilot Burner Flame, Honeywell Q327 CAUTION Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation. 2.
IX. System Start-up (continued) CAUTION Do not drain below gauge glass. 3. Main burners will extinguish when water level drops below low water cutoff. Water should still be visible in gauge glass. Verify limit, thermostat or other controls have not shut off boiler. 4. Adjust thermostat to lowest setting. Refill boiler to normal water line. J. Check Limit. 1. Adjust thermostat to highest setting. 2. Steam: Observe pressure gauge. When pressure is indicated, adjust limit to setting below observed pressure.
IX. System Start-up (continued) Table 9: Input Rate Size of Gas Meter Dial Seconds for One One-Half One Two Five Revolution Cu. Ft. Cu. Ft. Cu. Ft. Cu. Ft.
IX. System Start-up (continued) d. Follow Lighting or Operating Instructions to place boiler in operation. See Figure 48, 49, 50, or 51. e. Boil water or heat water to 180°F. f. Measure boiler water alkalinity. pH should be between 7 and 11. Add recommended water treatment chemicals, if necessary, to bring the pH within the specified range. 5. If unsteady water line, foaming or priming persist: a. Follow Lighting or Operating Instructions to place boiler in operation. See Figure 48, 49, 50, or 51. b.
IX. System Start-up (continued) e. Start firing equipment. f. Circulate the water through the entire system. g. Vent the system, including the radiation. h. Allow boiler water to reach operating temperature, if possible. i. Continue to Circulate the water for a few hours. j. Stop the firing equipment. k. Drain the system in a manner and to a location that hot water can be discharged with safety. l.
X. Service Instructions DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler.
X. Service Instructions (continued) Figure 58: Boiler Flueway Cleaning i. Inspect connecting lines to boiler for accumulation of mud and scale. Clean as necessary. ii. Examine wiring for brittle or worn insulation and clean electrical contact. iii. Inspect solder joints on bellows and float. Check float for evidence of collapse. Check mercury bulb (where applicable) for mercury separation or discoloration. Do not attempt to repair mechanisms in field.
X. Service Instructions (continued) 7. Place boiler in operation in accordance with Lighting or Operating instructions. Test gas line for leaks in accordance with Section VI: Gas Piping, Paragraph C. 8. Replace Jacket Front Removable Door. CAUTION When necessary to remove burners, be sure to reinstall them in the original manner by engaging the orifice and locating hole in the rear of the burner tray. Burners must be aligned with the burner manifold. F.
X. Service Instructions (continued) L. Tankless Heater. 1. Flushing of Heater. All water contains some sediment which settles on inside of coil. Consequently, heater should be periodically backwashed. See Figure 28. Allow water at city pressure to run into hosebib A, through heater, and out hosebib B until discharge is clear. The tees in which the hosebibs are located should be the same size as heater connections to minimize pressure drop. 2.
Honeywell Electronic Ignition Trouble Shooting Guide "CALL FOR HEAT." POWER TO MODULE? (24 V NOMINAL) NO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) IS MADE. YES 30 SECOND PREPURGE DELAY?(S8670 ONLY) NO REPLACE S8670 YES PULL IGNITION LEAD AND CHECK SPARK AT MODULE.
Honeywell Hot Surface to Pilot Trouble Shooting Guide 67
Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
XI. Repair Parts All Independence® Repair Parts may be obtained through your local Burnham product distributor. Should you require assistance in locating a Burnham product distributor in your area, or have questions regarding the availability of Burnham brand products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 1.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 4.
XI. Repair Parts (continued) Manifold and 40mm Main Burners Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 4.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 4. Manifold and Main Burners (40MM MAIN BURNERS ONLY) Continued Natural Gas, High Altitude (2000-5000 Ft.) USA Only 4D Main Burner Orifice #39 822727 2 3 --- --- --- --- --- Main Burner Orifice #38 822720 --- --- 4 5 6 7 8 822722 2 3 4 5 6 7 8 LP Gas, High Altitude (2000-5000 Ft.) USA Only 4D Main Burner Orifice #53 Natural Gas, High Altitude (5000-9000 Ft.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 5.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas 5A Pilot Burner, Honeywell Q348A1002 8236072 1 1 1 1 1 1 1 1 1 1 5B Pilot Orifice, Honeywell 388146NE Included with 5A 1 1 1 1 1 1 1 1 1 1 5C Compression Nut/Fitting, 1/4" OD x 1/4 C.C.
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XI. Repair Parts (continued) Key No. Description Part No.
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XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No. Quantity Steam Trim 7A Safety Valve, 3/4 NPT, 15 psi, Conbraco 13-511-08 81660530 1 7B Elbow, 3/4 NPT 806601502 2 7C Nipple, 3/4 NPT x 3-1/2" 806600038 1 7D Nipple, 3/4 NPT x 4" 806600014 1 Low Water Cutoff, McDonnell & Miller PS-802-24 (Probe Included) 80160720 Low Water Cutoff, Hydrolevel CG400-2090 (Less Probe - See Key No.
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XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3 IN4 IN5 IN6 IN7 IN8 IN9 IN10 IN11 IN12 12. Transformer (Steam and Gravity Water Only) 12A Junction Box, 4-11/16" x 4-11/16" x 2-1/8" Refer to Table on Page 88 12B Transformer, 50 VA, Honeywell AT150D1019 80160186 1 1 1 1 1 1 1 1 1 1 12C Relay, SPST, Honeywell R8222K1000 80160127 1 1 1 1 1 1 1 1 1 1 13.
APPENDIX A - Low Water Cut Off (LWCO) WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same floor level as the boiler).
Appendix B - Figures Figure Number Page Number Figure 1 4 Dimensional Drawing Figure 2 6 Section Tappings Description Section I - Pre-Installation Figure 3 8 Clearance to Combustible Materials Section II - Knocked-Down Boiler Assembly Figure 4 9 Base Gasket Installation Figure 5 9 Section Assembly Attachment Figure 6 9 Hydrostatic Pressure Test Figure 7 10 Canopy Gasket Installation Figure 8 10 Canopy Installation Figure 9 10 Jacket Assembly Figure 10 11 Combustion Chamber F
Appendix B - Figures (continued) Figure Number Page Number Description Section VIII - Electrical Figure 31 26 Vent Damper Connection Detail Figure 32 26 Vent Damper Harness to Junction Box Figure 33 28 Vent Damper Harness to Limit Figure 34 28 Vent Damper Schematic Wiring Diagram Figure 35 30 Wiring Diagrams, Steam, Continuous Ignition (Standing Pilot), Probe Low Water Cutoff Figure 36 32 Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low Water Cutoff Figure 37 34 Wiring Di
Appendix C - Tables Table Number Page Number Table 1 6 Description Trim and Control Installation in Section Tappings Section VI - Gas Piping Table 2 22 Rated Input Table 3 23 Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.
SERVICE RECORD DATE SERVICE PERFORMED 94
SERVICE RECORD DATE SERVICE PERFORMED 95
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 (717) 397-4701 www.usboiler.
