Burnham IN10 manual II. Knocked-Down Boiler Assembly, Install Base-Burner-Manifold Assembly

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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: 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 flange with screw heads on underside of flange. Note: Screws are located in fiber gasket parts bag.

2.Install ceramic fiber gasket. See Figure 4.

4.Loosen nuts on tie rods until only finger tight.

5.If Steam boiler or Water boiler less tankless heater, proceed to Step C.

6.Water Boiler with tankless heater. Remove heater opening cover plate and install tankless heater as 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 flat 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 fill valve and piping to return tapping and purge valve to supply tapping. See Figure 6.

Figure 4: Base Gasket Installation

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 fiber gasket. Secure with 5/16" locknuts and washers provided. See Figure 5.

Figure 5: Section Assembly Attachment

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.

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Contents 8141049R26-10/08 Price $5.00 IndependencePage Page Dimensional Drawing Table of Contents Probe L.W.C.O Float L.W.C.O Tankless Heater Pre-Installation Clearance to Combustible Materials II. Knocked-Down Boiler Assembly Install Base-Burner-Manifold AssemblyInstall assembled cast iron sections on base assembly Canopy Gasket Installation Install CanopyCombustion Chamber Intermittent Ignition EI Install Ignition Module Install Blocked Vent Switch with sheet metal screwsInstall Trim and Controls III. Semi-Pak Boiler AssemblyRemove Crate Steam Boiler with Probe Low Water CutoffWater Boiler Junction Box and Mounting Bracket AssemblyIV. Packaged Boiler Assembly Install Jacket Front PanelRemove Jacket Front Panel. See Figure Piping and Trim Page Recommended Water Piping for Circulator Zoned Heating System Recommended Water Piping for Zone Valve Zoned Heating System Recommended Piping for Indirect Water Heater Page VI. Gas Piping Rated InputConnect boiler gas valve to gas supply system Specific Gravity Correction Factors for Natural Gas Fitting Equivalent LengthsBoiler Equipped With Vent Damper VII. VentingIf an Existing Boiler is Removed Typical Vent InstallationVIII. Electrical Wire Vent Damper if usedAlliance Indirect Water Heater if used Thermostat Heat Anticipator SettingsVent Damper Harness to Limit This page Left Intentionally Blank Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Fill boiler with water IX. System Start-upPrepare to check operation Follow Lighting or Operating InstructionsPage Page Page Page Ignition Module Terminal Cross-Reference Ignition Module Wiring Ladder Diagram Terminal DesignationOFF Green LED Status CodesPilot Burner Flame, Honeywell Q350 Check low water cutoff steam only Adjust gas input rate to boiler. Natural GasDo not drain below gauge glass Check LimitInput Rate Adjust gas input rate to boiler. LP/PropanePage Page Maintenance of Low Water Cutoff Service InstructionsClean Boiler Flueways Boiler Flueway CleaningTankless Heater Pilot Burner LocationModel No Gallons Per Month Year Excessive Make-Up WaterHoneywell Electronic Ignition Trouble Shooting Guide Honeywell Hot Surface to Pilot Trouble Shooting Guide Avoid Breathing Fiber Particulates and Dust Service Record XI. Repair PartsSection Assembly Canopy and Draft Hood Canopy/Draft Hood Parts Base Tray Base AssemblyBurner Tray 1 Inch Main Burners Manifold and 1 Main Burners Manifold and Main Burners 1 Inch Main Burners Only Manifold and Main Burners 40MM Main Burners only Manifold and 40mm Main BurnersIntermittent Ignition Only Volt Continuous Ignition Standing Pilot Natural GasNatural Gas, High Altitude 5000-9000 Ft. USA Only LP Gas, High Altitude 2000-5000 Ft. USA OnlyLP Gas, High Altitude 5000-9000 Ft. USA Only Natural Gas, High Altitude 2000-4500 Ft. Canada OnlyPilot Burner, Honeywell Q350A1321 Pilot Burner, Honeywell Q348A1002 Page Jacket Assembly Front Top Panel Jacket Assembly Refer to Figure onSteam Trim Page Water Trim Quantity This page Left Blank Intentionally Page Blocked Vent Switch Flame Rollout SwitchTransformer Steam and Gravity Water Only Ignition Module Intermittent Ignition OnlyWiring of Typical Lwco XII. Low Water Cut Off LwcoLwco Location Limited Warranty Limited Warranty