INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR INDEPENDENCE® GAS - FIRED BOILER 9700609 For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Model Number IN Heating Contractor Boiler Serial Number Installation Date Phone Number Address 103538-08 - 3/18 Price - $5.
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.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.
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 4 103538-08 - 3/18
Table 1: Dimensional Data Boiler Model Approx. Shipping Weight Lbs. IN3I 350 IN4I IN5I Dimensions (in inches) 'A' 'C' 'D' 14-1/2 33-3/4 4 420 17-3/4 34-3/4 5 485 21 IN6I 555 24-1/4 IN7I 620 27-1/2 IN8I 690 30-3/4 IN9I 760 34 IN10 815 37-1/4 IN11 885 40-1/2 IN12 955 43-3/4 'B' 40 35-3/4 36-3/4 37-3/4 45 38-3/4 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 Min.
Figure 2: Section Tappings Table 2: Trim and Control Installation in Section Tappings 6 Tapping Size (NPT) Boiler with Probe L.W.C.O. Boiler with Float L.W.C.O. A 2 Supply Supply B ½ Bush to ¼ Pressure Gauge Plug C ½ Gauge Glass Nipple & ½ Union Gauge, L.W.C.O.
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 b. Known air infiltration rate. Must be used where air infiltration rate is less than 0.40 air changes per hour (ACH). Do not use an infiltration rate greater than 0.60 ACH. Volume > (21 ft3 x Iother ) + (15 ft3 x Ifan) ACH where: Iother = total input rate of all appliances other than fan-assisted (Mbh) Ifan = total input of fan-assisted appliances (Mbh) ACH = air changes per hour Mbh = 1000 Btu per hour c.
I. Pre-Installation (continued) 4. Combination indoor and outdoor combustion air. a. Indoor openings, when used, must comply with paragraph 2c above. b. Outdoor opening(s) location must comply with paragraph 3 above. c. Calculate outdoor opening size per the following: i. Determine ratio of interior spaces: available volume of all communicating spaces divided by required volume. ii. Determine outdoor size reduction factor: 1 minus ratio of interior spaces iii.
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. Models IN7I-IN12: remove 3 inch diameter knockouts in jacket top panels.
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) 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. K. Continue to Section III: Semi-Pak Boiler Assembly, Paragraph C. 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.
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) f. Attach "Frequent Water Addition" Label above the "Lowest Permissible Water Level" Plate. 3. All Steam Boiler Controls Cartons a. Install Junction Box. See Figure 17A. 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.
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 35. C. Remove poly bag from vestibule area. E. Install Jacket Front Panel. F. Install Draft Hood. Models IN3I through IN9I. 1. Locate and open "Drafthood Carton Assembly". 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.
Failure to pipe boiler as specified in this manual may result in excessive system noise, water line fluctuations and water carry over. 103538-08 - 3/18 NOTICE Figure 22: Steam Boiler Piping (Minimum) V.
V. Piping and Trim (continued) F. Tankless Heater (if used). See Figure 25. 1. Install automatic tempering or mixing valve to prevent delivery of scalding hot water to fixtures. 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 fixtures.
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) Table 4: Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less Length\ [Feet] ½ 10 20 30 40 50 60 70 80 90 100 132 92 73 63 56 50 46 43 40 38 0.3 inch w.c. Pressure Drop ¾ 1 278 190 152 130 115 105 96 90 84 79 520 350 285 245 215 195 180 170 160 150 1¼ ½ 1,050 730 590 500 440 400 370 350 320 305 175 120 97 82 73 66 61 57 53 50 0.5 inch w.c.
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 27. 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. Exception: National Fuel Gas Code, ANSI Z223.1/ NFPA 54, and Natural Gas and Propane Installation Code, CAN/CSA B149.
VII. Venting (continued) 4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate continuously. 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. 6.
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) E. Alliance SL™ Indirect Water Heater (if used). G. Wiring diagram and sequence of operation. Locate 1. For wiring refer to wiring diagrams located in this section and Alliance SL™ Installation Operating and Service Instructions. 2. Attach junction box extension (4 - 11/16 square) to junction box on boiler. the system type you are interested in from Table 7, then refer to the page indicated. 1. Vent Damper Sequence of Operation. See Figure 30. a.
Figure 31: Wiring Diagrams, Steam, Continuous Ignition [Standing Pilot (IN10 thru IN12 Only)], Probe Low Water Cutoff VIII.
VIII. Electrical (continued) H. Steam Boiler with Continuous Ignition (Standing Pilot) and Probe Low Water Cutoff. See Figure 31. 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. Vent damper, if used, must be in open position when appliance main burners are operating.
Figure 32: 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 32. 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.
Figure 33: Wiring Diagrams, Steam, Continuous Ignition [Standing Pilot (IN10 thru IN12 Only)], Float Low Water Cutoff VIII.
VIII. Electrical (continued) J. Steam Boiler with Continuous Ignition (Standing Pilot) and Float Low Water Cutoff. See Figure 33. 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. Vent damper, if used, must be in open position when appliance main burners are operating.
Figure 34: 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 34. 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.
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) 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. Trying to measure the pilot flame current in series with the wiring will not yield the accurate reading. d. The minimum steady pilot flame signal must be 1 μAmp (microampere) DC (direct current). e. For reliable operation the flame current should be 2 μAmp or greater. f. To ensure adequate flame current: i.
IX. System Start-up (continued) G. Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. H. Check ignition system shutoff. Gas valve should close and pilot and main burners extinguish. 1. Continuous Ignition (Standing Pilot): disconnect thermocouple from gas valve. 2. Electronic Ignition (EI): disconnect igniter/sensor cable from ignition module terminal "9". I. Check low water cutoff. 1. Adjust thermostat to highest setting. 2.
IX. System Start-up (continued) K. Adjust gas input rate to boiler. Natural Gas. WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the boiler. Improper and unsafe boiler operation may result. 1. Adjust thermostat to highest setting. 2. Check manifold gas pressure. Manifold pressure is listed on Rating Label. a. Models IN10-IN12 with Standing Pilot and IN3I-IN11 with Electronic Ignition.
IX. System Start-up (continued) Table 10: 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) f. Close all radiator valves. Remove all supply main air valves. Plug openings in supply main. g. Drain approximately 5 gallons of boiler water into container. Mix in recommended boil-out compound. h. Remove safety valve. Pour recommended compound into boiler through safety valve opening. Reinstall safety valve in Tapping "E" with spindle in vertical position. See Figures 1 and 2. i. Follow Lighting or Operating Instructions to place boiler in operation.
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) 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 above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
X. Service Instructions (continued) Figure 46: Boiler Flueway Cleaning 2. McDonnell & Miller 67 Float Style Only. a. Weekly (or more frequently if necessary). Open blow-off valve to flush sediment chamber. Follow instructions on Blow-Down Card affixed to Jacket adjacent to low water cutoff. b. Annually. Dismantle to extent necessary to remove obstructions and insure proper function of working parts. i. Inspect connecting lines to boiler for accumulation of mud and scale. Clean as necessary. ii.
X. Service Instructions (continued) 2. Remove Burner Access Panel and Burners. See Paragraph F. Clean Burners if necessary. 3. Remove Jacket Top Panels. Boiler Size Pilot Located Between Burners* 1 inch 40mm 5. Thoroughly clean the flueways with flue brush. See Figure 46. IN3I 1&2 1&2 IN4I 2&3 2&3 6. Clean boiler heating surface accessible from combustion chamber with straight handle wire brush. Reinstall burners and connect gas train. See Paragraphs F & G.
X. Service Instructions (continued) M. Excessive Make-Up Water CAUTION IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS. Model No. Gallons Per Month Gallons Per Year IN3I 0.1 1 IN4I 0.1 1 IN5I 0.2 2 IN6I 0.2 2 IN7I 0.2 3 IN8I 0.2 3 IN9I 0.3 3 IN10 0.3 4 IN11 0.3 4 IN12 0.
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.
XI. Repair Parts All Independence® Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408. Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 1.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 2.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 3.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 3.
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XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 4.
XI. Repair Parts (continued) Manifold and 40mm Main Burners Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I 8236135 1 2 3 4 5 6 7 8236136 1 1 1 1 1 1 1 4.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I 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 IN10 IN11 IN12 1 1 1 5. Pilot Burner and Gas Valve, Continuous Ignition (Standing Pilot), Natural Gas 5A Pilot Burner, Honeywell Q327A1006 8236022 5B Pilot Orifice, Honeywell 388146AG Included with 5A 1 1 1 5C Compression Nut/Fitting, 1/4" OD x 1/4 C.C.
XI. Repair Parts (continued) Key Description Part No. No. IN3I IN4I IN5I 5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas 5A 5B 5C 5D 5E 5F 5G 5H Pilot Burner, Honeywell Q3481B1206 with Fiberglass Insulated Integral 36" lg. Igniter/Sensor Cable Pilot Burner Orifice, Honeywell KF24, 0.024" dia. Compression Fitting, 7/16" Hex x 5/8" lg.
103538-08 - 3/18 XI.
XI. Repair Parts (continued) Key No. Description Part No.
103538-08 - 3/18 XI.
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 PSE-802-24 (Probe Included) 104206-01 Low Water Cutoff, Hydrolevel CG400-2090 (Less Probe - See Key No.
XI. Repair Parts (continued) Key No. Description Part No.
XI. Repair Parts (continued) Key No. Description Part No. Quantity IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 12. Transformer 12A Junction Box, 4-11/16" x 4-11/16" x 2-1/8" Refer to Table on Page 67 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 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 10 Base Gasket Installation Figure 5 10 Section Assembly Attachment Figure 6 10 Hydrostatic Pressure Test Figure 7 11 Canopy Gasket Installation Figure 8 11 Canopy Installation Figure 9 11 Jacket Assembly Figure 10 12 Combustion Chamber
Appendix B - Figures (continued) Figure Number Page Number Description Section VIII - Electrical Figure 28 25 Vent Damper Connection Detail Figure 29 25 Vent Damper Harness to Junction Box Figure 30 26 Vent Damper Schematic Wiring Diagram Figure 31 27 Wiring Diagrams, Steam, Continuous Ignition [Standing Pilot (IN10 thru In12 Only)], Probe Low Water Cutoff Figure 32 29 Wiring Diagrams, Steam, Intermittent Ignition (EI), Probe Low Water Cutoff Figure 33 31 Wiring Diagrams, Steam, Continuo
Appendix C - Tables Table Number Page Number Table 1 5 Dimensional Data Table 2 6 Trim and Control Installation in Section Tappings Description Section VI - Gas Piping TAble 3a 20 Minimum Inlet Gas Pressure Table 3b 20 Rated Input Table 4 21 Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
