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 ® P V G A S - F I R E D BO I L E R 9700609 For service or repairs to boiler, call hour heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number Boiler Serial Number Installation Date IN__PVNI Heating Contractor Phone Number Address 103560-04 - 8/13 Price - $5.
The New York City Department of Buildings has approved the Independence® PV boiler: Approval No. MEA 154-93-E. 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® PV 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.
Figure 1: Elevation Views WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, 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.
Table of Contents I. Pre-Installation................................... 4 VII. System Start-up................................ 17 II. Unpack Boiler.................................... 5 VIII. Service Instructions.......................... 25 III. Steam Piping and Trim....................... 6 IX. Repair Parts...................................... 32 IV. Gas Piping.......................................... 8 Appendix A - Figures........................ 40 V. Venting...............................
I. Pre-Installation (continued) 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 floors, between wall-ceiling joints, between wall panels, at plumbing and electrical penetrations, and at other openings. 5.
III. Steam 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.
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III. Steam Piping and Trim (continued) Figure 5: Steam Piping, IN4PVNI, IN5PVNI and IN6PVNI IV. Gas Piping 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. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure for natural gas is 4.5 inch w.c. 8 3.
IV. Gas Piping (continued) 2. Use thread (joint) compounds (pipe dope) resistant to action of liquefied petroleum gas. 4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, ANSI/NFPA 70. 3. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas control valve and outside jacket. See Figure 6.
V. Venting NOTICE The gasketed vent system components pictured below in Figure A are being phased in and each vent component is interchangeable with the previously supplied gasket-less venting components. The newer vent components are generally quicker and easier to join, as they do not require the sealant application and their clamp bands are attached. In the event a gasketed vent component and a gasketless vent component must be interconnected, follow the instructions associated with Figure 8B or 8C.
V. Venting (continued) 4. Do not install venting system components on the exterior of the building except as specifically required by these instructions. 5. Do not connect vent connectors serving appliances vented by natural draft into any portion of mechanical draft system operating under positive pressure. 6. Do not use cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone). 7. Do not cover non-metallic vent pipe and fittings with thermal insulation.
V. Venting (continued) 3. Provide and maintain minimum clearances to combustible materials. Use single wall thimble (Part No. 8116116) when penetrating combustible wall. Other wall thimble manufacturers are American Metal Products, Hart & Cooley, and Metal Fab. Silastic 732 RTV, Dow Corning Silastic 736 RTV, GE RTV106, Polybac #500 RTV, Sil-bond RTV 4500 (Acetoxy) and Sil-bond RTV 6500. Do not use other adhesives or sealants. E. Install Vent Pipe, U.S. Boiler Company Gasketed Vent System. 4.
V. Venting (continued) end of pipe is below locking band and rest against the end of the female pipe. Verify the factory-installed gasket is not dislodged or cut. d. Smooth sealant around joint for a continuous seal. Reapply sealant if necessary. e. Tighten locking band by HAND with a 5/16" nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM! f.
V. Venting (continued) Figure 10: Horizontal Vent Terminal from outside. Secure outside flange to wall with nails or screws, and seal with adhesive material. Install inside flange to inside wall, secure with nails or screws, and seal with adhesive material. 5. For noncombustible wall when thimble is not used, size opening such that female (bell) end with locking band attached cannot pass through. 6. Join vent terminal to vent pipe.
V. Venting (continued) Table 9: Minimum Vent Height Above Roof Figure 12: Vertical Vent Tee Installation Figure 13: Attic Offset Figure 14: Vertical Vent Termination Roof Pitch Minimum Height [H] Flat to 6/12 1 ft. Over 6/12 to 7/12 1 ft. 3 in. Over 7/12 to 8/12 1 ft. 6 in. Over 8/12 to 9/12 2 in. Over 9/12 to 10/12 2 ft. 6 in. Over 10/12 to 11/12 3 ft. 3 in. Over 11/12 to 12/12 4 ft. Over 12/12 to 14/12 5 ft. Over 14/12 to 16/12 6 ft. Over 16/12 to 18/12 7 ft.
VI. Electrical A. General Install wiring and ground boiler in accordance with requirements of authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/NFPA 70. B. Install thermostat. Locate on inside wall approximately 4 feet above floor. Do not install on outside wall, near fireplace, or where influenced by drafts or restricted air flow, hot or cold water pipes, lighting fixtures, television, or sunlight.
VII. System Start-up A. Safe operation and other performance criteria were met with 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. Fill boiler with water to normal water line. C. Prepare to check operation. 1. Obtain gas heating value (in Btu per cubic foot) from gas supplier. 2. Adjust limit.
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VII. System Start-up (continued) 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 17B. 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.
VII. System Start-up (continued) Honeywell Electronic Ignition Troubleshooting 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.
VII. System Start-up (continued) F. Check pilot burner flame. See Figure 19. Flame should be steady, medium hard blue enveloping 3/8 to ½ inch of sensing probe. J. Check low water cutoff. 1. Adjust thermostat to highest setting. 2. With boiler operating, open drain valve and slowly drain boiler. CAUTION Do not drain below gauge glass. 3. Main burners and pilot burner will extinguish and blower stop when water level drops below low water cutoff probe.
VII. System Start-up (continued) Figure 21: Operating Instructions i. Remove Main Burners per procedure in Section VIII: Service. ii. Remove gas orifices. Drill one (1) drill size larger (drill size is stamped on orifice, or see Key No. 4D). iii. Reinstall gas orifices and main burners. Measure input rate. 22 6. Recheck Main Burner Flame. 7. Return other gas-fired appliances to previous conditions of use. M. Clean Heating System.
VII. System Start-up (continued) Table 13: Gas Flow Rate in Cubic Feet per Hour Size of Gas Meter Dial 6. Follow Operating instructions to place boiler in operation. See Figure 21. Check controls operation per Paragraphs F to K. Boil water for at least 5 hours. Seconds for One Revolution One-Half Cu. Ft. 30 60 120 240 32 56 113 225 34 53 106 212 36 50 100 200 38 47 95 189 40 45 90 180 42 43 86 172 44 41 82 164 46 39 78 157 1.
VII. System Start-up (continued) 15. Fill boiler to normal water line. Follow Operating Instructions to place boiler in operation. See Figure 21. 16. Operate boiler for at least 30 minutes after condensate begins to run hot. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 21. 17. Close all radiator valves. Remove all supply main air valves. Plug openings in supply main. 18. Drain approximately 5 gallons of boiler water into container. Mix in recommended boil-out compound. 25.
VIII. Service Instructions 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.
VIII. Service Instructions (continued) A. General Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 21. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. B. Low water cutoff Clean probe. 1. Drain boiler to point below Tapping "L". 2.
VIII. Service Instructions (continued) Table 14: Pilot Burner Location Boiler Model Main Burner with 60° Pilot Bracket * Pilot Burner Located Between Main Burners * IN3PVNI 1 1&2 IN4PVNI 2 2&3 IN5PVNI 3 3&4 IN6PVNI 4 4&5 * Main burners numbered left to right as viewed from front of boiler. Figure 22: Cleaning Boiler Flue Passages 14. Install Canopy/Blower Assembly. Tighten Carriage Bolts to fully compress Gasket. 15. Install Blower Access Panel. 16.
VIII. Service Instructions (continued) Table 15: Minimum Vacuum Boiler Model Minimum Vacuum IN3PVNI -0.40 inches w.c. IN4PVNI -0.40 inches w.c. IN5PVNI -0.70 inches w.c. IN6PVNI -0.70 inches w.c. I. Housekeeping 1. Boiler area to be clear and free from combustible materials, gasoline and other flammable vapors and liquids. 2. Remove obstructions to flow of combustion and ventilation air.
SERVICE RECORD DATE SERVICE PERFORMED 29
TURN OFF GAS SUPPLY. ADJUST THERMOSTAT TO CALL FOR HEAT. NO DOES BLOWER ENERGIZE? GO TO PAGE 31 YES SPARK PRESENT AT PILOT IGNITER/ SENSOR? NO 24 VOLTS AT SUCTION PRESSURE SWITCH TERMINAL 'NO'? YES NO YES DISCONNECT IGNITER/SENSOR CABLE FROM IGNITION MODULE TERMINAL (9). HOLD CABLE NO NEAR TERMINAL. IS SPARK PRESENT? NO HOSE SECURELY NO CONNECT HOSE CONNECT MANOMETER TO TO CANOPY CONNECTED TO SUCTION PRESSURE SWITCH CANOPY? (SEE Figure 24). IS SUCTION PRESSURE GREATER THAN: YES -0.
Troubleshooting Tree for Section VII, Step E WATERLINE ABOVE LOWEST PERMISSIBLE LEVEL? NO FILL BOILER TO NORMAL WATERLINE YES GAUGE PRESSURE LESS THAN LIMIT CUT-IN SETTING? NO ALLOW SYSTEM PRESSURE TO FALL BELOW LIMIT CUT-IN PRESSURE, OR INCREASE LIMIT CUT-IN SETTING. YES CAUTION NO CONTINUITY ACROSS FLAME ROLLOUT SWITCH (FRS)? YES 24 VOLTS AT SPST RELAY COIL? NO YES REPLACE FLAME ROLLOUT SWITCH.
IX. Repair Parts All Independence® PV 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 1.
IX. Repair Parts (continued) Key No. Description [Quantity] Part Number IN3PVNI IN4PVNI IN5PVNI IN6PVNI 3.
IX. Repair Parts (continued) Key No. Description (Quantity) Part Number IN3PVNI IN4PVNI IN5PVNI IN6PVNI [2] 8236099 [4] 8236099 [6] 8236099 [8] 8236099 4.
IX. Repair Parts (continued) Key No. Description (Quantity) Part Number IN3PVNI IN4PVNI IN5PVNI IN6PVNI 5. Gas Train Group 5A Pilot Assembly, Natural Gas, Honeywell Q3481B1206 [1] 103704-01 5B Pilot Orifice, Natural Gas Honeywell 388146NE 5C Compression Nut/Fitting, 1/8" OD x 1/4 NPT 5D Pilot Tubing, 1/8" OD x 40" [1] 8236100 5E Gas Valve, 1/2 x 1/2, Natural Gas, Honeywell VR8204C6000 [1] 81660176 5G Ground Wire Assembly [1] 6136054 Included with Key No. 5A Included with Key No.
IX. Repair Parts (continued) Key No. Description (Quantity) Part Number IN3PVNI IN4PVNI IN5PVNI IN6PVNI 6.
IX. Repair Parts (continued) Key No. 7A 7B 8 Description (Quantity) Part Number IN3PVNI IN4PVNI IN5PVNI McDonnell & Miller PS-802 [1] 80160720 Hydrolevel CG400-2090 [1] 80160725 Probe, [Included with 7A] ---- Safety Valve, 3/4, 15 psi, Conbraco 13-511-08 [1] 81660530 9A Steam Gauge, 0-30 psi, 2-1/2" Dia.
IX. Repair Parts (continued) Key No. Description (Quantity) Part Number IN3PVNI IN4PVNI IN5PVNI IN6PVNI 10. Controls 10A Ignition Module with Prepurge, Honeywell S8670E3003 10B Ignition Module Support Bracket 10C [1] 100959-01 [1] 7016001 Flame Roll-out Switch [1] 80160044 10C1 Screw, Sheet Metal, #8 x 3/4" [1] 80860030 10D [1] 7186018 Flame Roll-out Switch Mounting Bracket 10D1 Screw, Sheet Metal, #8 x 1/2" 10E Suction Pressure Switch [Red] Suction Pressure Switch [Lt.
IX. Repair Parts (continued) Key No. Description 11.
Appendix A - Figures Figure Number Page Number Figure 1 3 Elevation Views Figure 2 2 Tapping Locations Description Section III - Steam Piping and Trim Figure 3 7 Trim Installation Figure 4 7 Steam Piping, IN3PVNI Figure 5 8 Steam Piping, IN4PVNI, IN5PVNI and IN6PVNI Section IV - Gas Piping Figure 6 9 Recommended Gas Piping Section V - Venting Figure A 10 U.S. Boiler Company Vent Figure 7 11 Vent Connector Installation Figure 8A 12 U.S.
Appendix B - Tables Table Number Page Number Table 1 2 Dimensions and Clearances Table 2 2 Purpose of Tappings Description Section III - Steam Piping and Trim Table 3 8 Rated Input Table 4 9 Maximum Capacity of Schedule 40 Pipe in CFH of Natural Gas For Gas Pressures of 0.
SERVICE RECORD DATE SERVICE PERFORMED 42
SERVICE RECORD DATE SERVICE PERFORMED 43
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
