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U.S. Boiler Company INDEPENDENCE IN3I Installation, Operating And Service Instructions

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INDEPENDENCE
Installation, Operating and Service Instructions for
Residential
Models:
• IN3I
• IN4I
• IN5I
• IN6I
• IN7I
• IN8I
• IN9I
Manual Contents
Before Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4. Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Locating Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Knocked-Down Boiler Assembly . . . . . . . . . . . . . . . . . . 10
7. Semi-Pak Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . 13
8. Packaged Boiler Assembly . . . . . . . . . . . . . . . . . . . . . . . 15
9. Air for Combustion and Ventilation . . . . . . . . . . . . . . . . 16
10. Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11. Steam Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12. Indirect Water Heating Piping . . . . . . . . . . . . . . . . . . . . . 26
13. Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
14. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15. Start-Up and Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . 34
16. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
17. Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 43
18. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
19. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Attention Installer - Affix these instructions
adjacent to boiler. Provide model number and serial
number when seeking information and support.
Read these instructions carefully before installing. This boiler must only be installed, serviced, or repaired
by a qualified installer, service agency or gas supplier. Improper installation, adjustment, alteration, service,
or maintenance can cause severe personal injury, death, or substantial property damage. For assistance or
additional information, consult a qualified installer, service agency or gas supplier.
103538-11 - 7/24
• Steam Boiler
• Cast Iron
• Chimney Vent
• Gas Fired
Page
!
WARNING
Attention Building Owner - Retain these
instructions for future reference. Contact a qualified
installer, service agency or gas supplier for all
issues and support.
!
WARNING
9700609

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Summary of Contents for U.S. Boiler Company INDEPENDENCE IN3I

  • Page 1: Table Of Contents

    INDEPENDENCE Installation, Operating and Service Instructions for Residential • Steam Boiler • Cast Iron Models: • Chimney Vent • IN3I • IN4I • Gas Fired • IN5I • IN6I • IN7I • IN8I • IN9I Manual Contents Page 1. Qualified Installer, Service Agency, or Gas Supplier Read Before Proceeding .
  • Page 2 Installation, Operating & Service Instructions Independence The Massachusetts Board of Plumbers and Gas Fitters has approved these boilers. See the Massachusetts Board of Plumbers and Gas Fitters website 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.

  • Page 3: Qualified Installer, Service Agency, Or Gas Supplier Read

    Independence Installation, Operating & Service Instructions Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding WARNING WARNING • Burn Hazard. This boiler contains very hot water Asphyxiation Hazard. Fire Hazard. and steam under high pressure. Do not unscrew Explosion Hazard. This boiler any pipe fittings nor attempt to disconnect any requires regular maintenance and components of this boiler without positively...

  • Page 4: User/Homeowner Read Before Proceeding

    Installation, Operating & Service Instructions Independence User/Homeowner Read Before Proceeding WARNING CAUTION Asphyxiation Hazard. Fire Hazard. Burn Hazard. Keep children and pets away from hot surfaces • A qualified installer, service agency or gas of the boiler including boiler piping, vent piping, supplier should annually inspect boiler.

  • Page 5: Specifications

    Independence Installation, Operating & Service Instructions Specifications Figure 3-1: IND Boilers - General Configuration 103538-11 - 7/24...
  • Page 6 Installation, Operating & Service Instructions Independence Specifications (continued) 103538-11 - 7/24...
  • Page 7 Independence Installation, Operating & Service Instructions Specifications (continued) Figure 3-3: Tapping Locations (See Text For Tapping Uses) Table 3-4: Trim and Control Installation in Section Tappings Size Tapping Boiler with Probe L.W.C.O. Boiler with Float L.W.C.O. (NPT) Supply Supply Bush to ¼ ½...

  • Page 8: Pre-Installation

    Installation, Operating & Service Instructions Independence Pre-Installation 4. Make sure the boiler is properly sized. A WARNING steam boiler must be sized to match the Carefully read all instructions before installing amount of connected radiation. If the boiler. Failure to follow all instructions in proper boiler is undersized for the connected order can cause personal injury or death.

  • Page 9: Locating Boiler

    Independence Installation, Operating & Service Instructions Locating Boiler 2. The boiler must be installed on a hard level WARNING surface. This surface may be combustible. Failure to observe the following location 3. Do not install this boiler in a location where requirements could result in a fire, explosion or gasoline or other flammable vapors or liquids, Carbon Monoxide (CO) hazard.

  • Page 10: Knocked-Down Boiler Assembly

    Installation, Operating & Service Instructions Independence Knocked-Down Boiler Assembly WARNING Note: If tankless heater is not installed, heater opening cover plate must remain in place. Installation of this boiler should be undertaken 3. Test boiler for leaks before connecting to system only by trained and skilled personnel from a and installing controls, trim and jacket.

  • Page 11: Install Canopy

    Independence Installation, Operating & Service Instructions Knocked-Down Boiler Assembly (continued) B. Position canopy on ceramic fiber gasket. See 4. Install Canopy. Figure 6-5. A. Install ½ in. thick x 1 in. wide ceramic fiber C. Attach canopy using ¼ in. carriage bolts, nuts, gasket.
  • Page 12 Installation, Operating & Service Instructions Independence Knocked-Down Boiler Assembly (continued) H. Install black plastic rings into 1-3/32 inch diameter holes located below upper louvers of front removable door. I. 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...

  • Page 13: Semi-Pak Boiler Assembly

    Independence Installation, Operating & Service Instructions Semi-Pak Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. DANGER • Use precautions and appropriate rigging apparatus when moving heavy objects. •...
  • Page 14 Installation, Operating & Service Instructions Independence Semi-Pak Boiler Assembly (continued) located at bottom of control. iii. The L404F pressure limit employs a snap action switch and does not require leveling. See Figure 7-1. iv. Install pressure gauge into Tapping "H" (¾ NPT bushed to ¼...

  • Page 15: Packaged Boiler Assembly

    Independence Installation, Operating & Service Instructions Packaged Boiler Assembly WARNING 6. Install Draft Hood. Installation of this boiler should be undertaken A. Locate and open "Drafthood Carton Assembly". only by trained and skilled personnel from a B. Position Draft Hood on Canopy Rear Flange. qualified service agency.

  • Page 16: Air For Combustion And Ventilation

    Installation, Operating & Service Instructions Independence Air for Combustion and Ventilation Each of the above methods is described in more WARNING detail in the following sections. The National Fuel • This boiler is not designed for use in a Gas Code also describes some acceptable space that is depressurized relative to variations on these techniques that do not appear the outdoors.
  • Page 17 Independence Installation, Operating & Service Instructions Air for Combustion and Ventilation (continued) 6. Do not use the Indoor Combustion Air Method Example: described above if either of the following are true: A 103MBH input boiler and a water heater are to be installed in a room measuring A.
  • Page 18 Installation, Operating & Service Instructions Independence Air for Combustion and Ventilation (continued) Figure 9-2: All Air From Outdoors, Ventilated Crawl Space and Attic 6” MAX 6” MAX Figure 9-3: All Air From Outdoors, Via Ventilated Attic Using the Outdoor Combustion Air B.

  • Page 19: Mechanical Combustion Air Supply

    Independence Installation, Operating & Service Instructions Air for Combustion and Ventilation (continued) Mechanical Combustion Air Supply 3. The system must be interlocked to prevent A mechanical system may be used to bring all operation of the fuel burning appliances in the combustion air to the boiler which meets all of the boiler room if the system is not operating.

  • Page 20: Venting

    Installation, Operating & Service Instructions Independence Venting WARNING CAUTION • Improper venting may result in property Do not use one vent damper to control two damage and/or the release of flue gases, heating appliances. which contain deadly Carbon Monoxide Provide adequate clearance for servicing - 6 in. (CO), into the home, which can cause (152 mm) minimum clearance between damper severe personal injury or death.
  • Page 21 Independence Installation, Operating & Service Instructions Venting (continued) Exception: National Fuel Gas Code, ANSI Z223.1/ NFPA 54, and Natural Gas and Propane Installation Code, CAN/ CSA B149.1, allow vent downsizing when vent size determined by their Vent Sizing Tables is smaller than draft hood outlet/ vent damper.
  • Page 22 Installation, Operating & Service Instructions Independence Venting (continued) E. Test for spillage at the draft hood relief opening C. Dans la mesure du possible, fermer toutes les after five (5) minutes of main burner operation. portes et les fenêtres du bâtiment et toutes Use the flame of a match or candle, or smoke les portes entre l’espace où...

  • Page 23: Steam Piping

    Independence Installation, Operating & Service Instructions Steam Piping Avoid the three common piping mistakes shown in WARNING Figure 11-3. This applies even if the existing boiler has • Do not use softened water in steam boilers. one of the piping mistakes shown in Figure 11-3 and Accelerated boiler corrosion will result.
  • Page 24 Installation, Operating & Service Instructions Independence Steam Piping (continued) B. Providing a means of monitoring the amount 3. Install drain valve into tapping on boiler right side of fresh water added to the system will allow using the 2 x 3/4 bushing provided (see Figure an increase in water loss to be identified, 11-1).
  • Page 25 Independence Installation, Operating & Service Instructions Steam Piping (continued) Figure 11-1: Installation of Factory Supplied Fittings Figure 11-2: Steam Boiler Piping (Minimum) 103538-11 - 7/24...

  • Page 26: Indirect Water Heating Piping

    Installation, Operating & Service Instructions Independence Steam Piping (continued) Figure 11-3: Common Near-Boiler Piping Mistakes Indirect Water Heater Piping 1. Circulator - Mount the circulator as shown in NOTICE: Figure 12-1. The circulator should be located as • Some indirect water heaters may not be low and as close to the boiler as practical.

  • Page 27: Gas Piping

    Independence Installation, Operating & Service Instructions Gas Piping Table 13-2: Rated Input WARNING Boiler Rated Capacity • Shut off gas supply before servicing the boiler. Model [cubic feet per hour] Connection • All gas piping must be gas tight. Use thread Number Size Natural...
  • Page 28 Installation, Operating & Service Instructions Independence Gas Piping (continued) 2. Connect boiler gas valve to gas supply system - DANGER A. Use methods and materials in accordance Explosion Hazard. Do not use matches, with local plumbing codes and requirements candles, open flames or other ignition source to of gas supplier.In absence of such check for leaks.

  • Page 29: Wiring

    Independence Installation, Operating & Service Instructions Wiring iv. Install cable clamp around flexible Vent WARNING Damper Harness. Attach to jacket top • All wiring and grounding must be done in panel. See Figure 14-2. accordance with the authority having jurisdiction B.

  • Page 30: Heat Anticipator Setting

    Installation, Operating & Service Instructions Independence Wiring (continued) Table 14-3: Thermostat Heat Anticipator Settings Ignition System System Type Heat Anticipator Setting Intermittent (EI) All Sizes Probe (McDonnell & Miller PS-802 or Hydrolevel CGB-400) Figure 14-4, Page 31 Low Water Cutoff Float (McDonnell &...
  • Page 31 Independence Installation, Operating & Service Instructions Wiring (continued) 103538-11 - 7/24...
  • Page 32 Installation, Operating & Service Instructions Independence Wiring (continued) 103538-11 - 7/24...
  • Page 33 Independence Installation, Operating & Service Instructions Wiring (continued) Indirect Water Heater Wiring Figure 14-6 shows field wiring for an indirect water heater. A Honeywell R845A or equivalent DPST relay and transformer is required. The high limit described in Part 12 must also be supplied by the installer. A call for heat from the indirect water heater thermostat will energize the relay making both sets of contacts.

  • Page 34: Start-Up And Checkout

    Installation, Operating & Service Instructions Independence System Start-Up and Checkout WARNING Do not leave the boiler in service if it fails any of the following start-up checks. Doing so may result in fire, explosion, or Carbon Monoxide (CO) poisoning. WARNING •...
  • Page 35 Independence Installation, Operating & Service Instructions System Start-Up and Checkout (continued) Figure 15-3: Operating Instructions, Intermittent Ignition System, VR8204 and VR8304 Gas Valves 103538-11 - 7/24...
  • Page 36 Installation, Operating & Service Instructions Independence System Start-Up and Checkout (continued) Table 15-4: Ignition Module Terminal Cross-Reference Ignition Module Wiring Ladder Diagram Terminal Designation Terminal Number MV/PV 24V (GND) SPARK Figure 15-5: Location of LED Table 15-6: Green LED Status Codes Green LED Flash Indicates...
  • Page 37 Independence Installation, Operating & Service Instructions System Start-Up and Checkout (continued) b. Flame current must be measured with vi. If needed, adjust pilot flame by pilot valve open/pilot lit but the main turning the gas valve pilot adjustment valve closed. screw clockwise to decrease or counterclockwise to increase pilot c.
  • Page 38 Installation, Operating & Service Instructions Independence System Start-Up and Checkout (continued) C. 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.
  • Page 39 Once the system has run Contact your U.S. Boiler Company for a number of days, subsequent skimming(s) may wholesale distributor for alternate main be required.
  • Page 40 Installation, Operating & Service Instructions Independence System Start-Up and Checkout (continued) J. Reopen the manual fill valve slightly so the Table 15-11: Input Rate steam of water coming from the pipe nipple Size of Gas Meter Dial is no larger than a wooden pencil. Slower flow Seconds is best.

  • Page 41: Operation

    Independence Installation, Operating & Service Instructions Operation Sequence of Operation 10. The way in which the ignition module handles (Refer to Figures 14-4 failure to establish pilot or the loss of an already & 14-5 for connection and ladder diagrams) established pilot depends upon the exact ignition 1.
  • Page 42 Installation, Operating & Service Instructions Independence Operation (continued) Figure 16-1: Vent Damper Schematic Wiring Diagram 103538-11 - 7/24...

  • Page 43: Service And Maintenance

    Independence Installation, Operating & Service Instructions Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
  • Page 44 Installation, Operating & Service Instructions Independence Service and Maintenance (continued) 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.
  • Page 45 Independence Installation, Operating & Service Instructions Service and Maintenance (continued) vii. Clean Tapping 'K' to remove old pipe dope and other foreign matter. viii. Apply moderate amount of good quality pipe dope to probe threads, leaving two end threads bare. Install probe in Tapping 'K'.
  • Page 46 Installation, Operating & Service Instructions Independence Service and Maintenance (continued) Figure 17-1: Boiler Flueway Cleaning 3. Water Feeder and Additional Low Water Cutoff. D. Remove Canopy from top of boiler. Refer to manufacturer's instructions. E. Thoroughly clean the flueways with flue brush. 4.
  • Page 47 Independence Installation, Operating & Service Instructions Service and Maintenance (continued) Table 17-2: Pilot Burner Location sensor/ground. See Table 17-2 for Pilot Burner Pilot Located Between Burners* location. Boiler Size 9. Lubrication. Manufacturers Instruction should 1 inch 40mm be followed on all parts installed on boiler IN3I 1 &...
  • Page 48 Installation, Operating & Service Instructions Independence Service and Maintenance (continued) 13. Excessive Make-Up Water A leaky system will increase the volume of make-up water supplied to the boiler, which can CAUTION significantly shorten the life of the boiler. Entrained IF, DURING NORMAL OPERATION, IT IS in make-up water are dissolved minerals, salts, NECESSARY TO ADD MORE WATER THAN and oxygen.

  • Page 49: Troubleshooting

    Independence Installation, Operating & Service Instructions Troubleshooting The following pages contain trouble shooting tables 7. If the charts indicate that the transformer is for use in diagnosing control problems. When using defective, it is possible that this transformer has these tables the following should be kept in mind: been destroyed by a short circuit in the boiler wiring.
  • Page 50 Installation, Operating & Service Instructions Independence Troubleshooting (continued) Troubleshooting Chart for Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs and Vent Dampers Caution: Read page 49 before attempting to use this chart START Vent damper open? Is there an audible Thermostat click as R8225 relay calls for heat...
  • Page 51 Independence Installation, Operating & Service Instructions Troubleshooting (continued) Do burners Do burners shut Main shut down when down when water burners pressure level drops below light? exceeds limit cut-off point? setting? 24 volts across red damper lead * Defective damper * Defective and yellow * Defective or loose...
  • Page 52 Installation, Operating & Service Instructions Independence Troubleshooting (continued) Ignition System Troubleshooting Chart Caution: Read page 49 before attempting to use this chart START (24 volts is present across 24V and 24V (GND) on ignition module but main burners do not light) Does Spark Main...

  • Page 53: Service 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.
  • Page 54 Installation, Operating & Service Instructions Independence Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I 2. Canopy and Draft Hood Canopy/Draft Hood Parts 6111003 6111004 6111005 6111006 6111007 6111008 6111009 Canopy Assembly Drafthood Carton 61110033 6111043 61110053 61110063...
  • Page 55 Independence Installation, Operating & Service Instructions Service Parts (continued) 103538-11 - 7/24...
  • Page 56 Installation, Operating & Service Instructions Independence Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I 3. Base Assembly Base Tray Base Wrapper 3B1 Base End Insulation 3B2 Base Rear Insulation Base Front Panel Assembly Burner Tray (1 Inch Main Burners) Burner Tray (40mm Main Burners)
  • Page 57 Independence Installation, Operating & Service Instructions Service Parts (continued) Manifold and 1 in. Main Burners 103538-11 - 7/24...
  • Page 58 Installation, Operating & Service Instructions Independence Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I 4. Manifold and Main Burners (1 Inch Main Burners Only) Main Burner 112600-01 [3 burners per kit] Main Burner with Pilot 112599-01 [1] Bracket 82260033...
  • Page 59 Independence Installation, Operating & Service Instructions Service Parts (continued) Manifold and 40mm Main Burners Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I 4. Manifold and Main Burners (40MM MAIN BURNERS ONLY) Main Burner 8236135 [1] 8236135 [2] 8236135 [3] 8236135 [4] 8236135 [5]...
  • Page 60 Installation, Operating & Service Instructions Independence Service Parts (continued) Part Number[Quantity] Description 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 #39 822727 #39 822727 #38 822720 #38 822720 #38 822720...
  • Page 61 Independence Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I 5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas Pilot Burner, Honeywell Q3481B1206 with Fiberglass 106125-01 [1] Insulated Integral 36 in. lg. Igniter/Sensor Cable Pilot Burner Orifice, Honeywell KF24, 0.024 in.
  • Page 62 Installation, Operating & Service Instructions Independence Service Parts (continued) 103538-11 - 7/24...
  • Page 63 Independence Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I Jacket Assembly Left Side Panel 60410013 [1] Right Side Panel 60410012 [1] Front Removable 60410033 60410043 60410053 60410063 60410073 60410083 60410093 Panel 60410034...
  • Page 64 Installation, Operating & Service Instructions Independence Service Parts (continued) Part No. Description [Quantity] Steam Trim Safety Valve, 3/4 NPT, 15 psi, Conbraco 13-511-08 Elbow, 3/4 NPT Obtain Locally Nipple, 3/4 NPT x 3-1/2 in. Nipple, 3/4 NPT x 4 in. Low Water Cutoff, McDonnell &...
  • Page 65 Independence Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I Transformer/J-Box Adapter Plate Junction Box, 4-11/16 in. x 81361761 [1] 4-11/16 in. x 2-1/8 in. Transformer/J-Box Adapter 7011001 [1] Plate Sheet Metal Screw, #8 x 1/2, Type B, Phillips Head, 80860019 [2]...
  • Page 66 Installation, Operating & Service Instructions Independence Service Parts (continued) 103538-11 - 7/24...
  • Page 67 Independence Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Description IN3I IN4I IN5I IN6I IN7I IN8I IN9I 12. Transformer Junction Box, 4-11/16 in. x 4-11/16 in. x Obtain Locally [1] 2-1/8 in. Transformer, 50 VA, Honeywell AT150D1019 80160186 [1] Relay, SPST, Honeywell R8222K1000 80160127 [1]...
  • Page 68 Installation, Operating & Service Instructions Independence U.S. Boiler Company, LLC P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 103538-11 - 7/24...

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