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

Gas - fired boiler
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Price - $5.00

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  • Page 1 ® 9700609 103538-04 - 8/13 Price - $5.00...
  • Page 2 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.
  • Page 3 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.
  • Page 4 Figure 1: Dimensional Drawing...

  • Page 5: Table Of Contents

    Table 1: Dimensional Data Recommended Water Volume Approx. Dimensions (in inches) Min. Round (Gal.) Boiler Shipping Chimney Size Conn. Model Weight Steam (Diameter x Height) (NPT) Lbs. Boiler IN3I 14-1/2 33-3/4 7-1/4 4" x 15 ft. 4-3/4 IN4I 17-3/4 34-3/4 8-7/8 5"...
  • Page 6 Figure 2: Section Tappings Table 2: Trim and Control Installation in Section Tappings Size Steam Boiler with Tapping Steam Boiler with Probe L.W.C.O. (NPT) Float L.W.C.O. Supply Supply ½ Bush to ¼ Pressure Gauge Plug Nipple & ½ Union Gauge, L.W.C.O. Street Elbow, ½...

  • Page 7: Pre-Installation

    I. Pre-Installation Provide 1/2" (1.3 cm) between combustible WARNING construction and steam/hot water piping. If you do not follow these instructions exactly, Install boiler on level floor as close to chimney as a fire or explosion may result causing property possible.
  • Page 8 I. Pre-Installation (continued) Figure 3: Clearance to Combustible Materials 5. For boiler located in an unconfined space in a Alternate method for boiler located within confined building of other than unusually tight construction, space. Use indoor air if two permanent openings adequate combustion and ventilation air is normally communicate directly with additional space(s) of provided by fresh air infiltration through cracks...

  • Page 9: Knockdown Boiler Assembly

    II. Knocked-Down Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. 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.
  • Page 10 II. Knocked-Down Boiler Assembly (continued) Install Canopy. 2. Position canopy on ceramic fiber gasket. See Figure 1. Install ½" thick x 1" wide ceramic fiber gasket. See Figure 7. 3. Attach canopy using ¼" carriage bolts, nuts, and washers provided. Inspect joints between sections.
  • Page 11 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.
  • Page 12 II. Knocked-Down Boiler Assembly (continued) Intermittent Ignition (EI): Install Ignition Module. Continue to Section III: Semi-Pak Boiler Assembly, 1. Mount ignition module mounting bracket to inside Paragraph C. of right side panel using (2) #6 x ¾" sheet metal screws provided. 2.

  • Page 13: Semi-Pak Boiler Assembly

    III. Semi-Pak Boiler Assembly WARNING Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. 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.
  • Page 14 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. Remove center knockout in rear of Junction Box and insert black plastic snap bushing in hole.

  • Page 15: Packaged Boiler Assembly

    IV. Packaged Boiler Assembly Install Jacket Front Panel. WARNING Install Draft Hood. Models IN3I through IN9I. Installation of this boiler should be undertaken 1. Locate and open "Rear Draft Hood Carton". only by trained and skilled personnel from a qualified service agency. 2.

  • Page 16: Piping And Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler Company’s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
  • Page 18 V. Piping and Trim (continued) 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.

  • Page 19: Gas Piping

    VI. Gas Piping For materials or conditions other than those listed WARNING above, refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Failure to properly pipe gas supply to boiler may Installation Code, CAN/CSA B149.1, or size system result in improper operation and damage to the using standard engineering methods acceptable to boiler or structure.
  • Page 20 VI. Gas Piping (continued) 2. Using soap solution, or similar non-combustible 4. All above ground gas piping upstream from manual solution, electronic leak detector or other approved gas valve must be electrically continuous and method. Check that boiler gas piping valves, and all bonded to a grounding electrode.

  • Page 21: Venting

    Provide adequate clearance for servicing - Propane Installation Code, CAN/CSA B149.1. 6" (152 mm) minimum clearance between Install any of the following for this Independence Series damper and combustible construction. Category I, draft hood equipped appliance: 1. Type B or Type L gas vent. Install in accordance NOTICE with listing and manufacturer's instructions.
  • Page 22 VII. Venting (continued) 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.
  • Page 23 VII. Venting (continued) 7. Any improper operation of the common venting système d’évacuation commun et tous les system should be corrected so the installation ventilateurs d’extraction comme les hottes de conforms with the National Fuel Gas Code, ANSI cuisinière et les ventilateurs des salles de bain. Z223.1/NFPA 54, and/or the Natural Gas and S’assurer que ces ventilateurs fonctionnent à...

  • Page 24: Electrical

    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.
  • Page 25 VIII. Electrical (continued) Alliance SL™ Indirect Water Heater (if used). Wiring diagram and sequence of operation. Locate the system type you are interested in from Table 7, then 1. For wiring refer to wiring diagrams located in this refer to the page indicated. section and Alliance SL™...
  • Page 27 VIII. Electrical (continued) b. Low Water Cutoff (LWCO): Automatically Steam Boiler with Continuous Ignition (Standing Pilot) interrupts main burner operation when surface of and Probe Low Water Cutoff. See Figure 31. boiler water falls to lowest permissible operating 1. Normal Operation level.
  • Page 29 VIII. Electrical (continued) b. Low Water Cutoff (LWCO): Automatically Steam Boiler with Intermittent Ignition (EI) and Probe interrupts main burner operation when surface of Low Water Cutoff. See Figure 32. boiler water falls to lowest permissible operating 1. Normal Operation level.
  • Page 31 VIII. Electrical (continued) b. Low Water Cutoff (LWCO): Automatically Steam Boiler with Continuous Ignition (Standing Pilot) interrupts main burner operation when surface of and Float Low Water Cutoff. See Figure 33. boiler water falls to lowest permissible operating 1. Normal Operation level.
  • Page 33 VIII. Electrical (continued) b. Low Water Cutoff (LWCO): Automatically Steam Boiler with Intermittent Ignition (EI) and Float interrupts main burner operation when surface of Low Water Cutoff. See Figure 34. boiler water falls to lowest permissible operating 1. Normal Operation level.

  • Page 34: System Start-Up

    IX. System Start-up WARNING Completely read, understand and follow all instructions in this manual before attempting start up. 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 Low- Pressure Steam and Hot Water Boilers, ANSI Z21.13.
  • Page 35 IX. System Start-up (continued) Figure 38: Lighting Instructions, Continuous Ignition System, 7000 ERHC Gas Valve...
  • Page 36 IX. System Start-up (continued) Figure 39: Operating Instructions, Intermittent Ignition System, VR8204 and VR8304 (except IN12) Gas Valves...
  • Page 37 IX. System Start-up (continued) Figure 40: Operating Instructions, Intermittent Ignition System (EI), VR8304 (IN12 only) Gas Valves...
  • Page 38 IX. System Start-up (continued) Table 8: Ignition Module Terminal Cross-Reference Ignition Module Wiring Ladder Diagram Terminal Designation Terminal Number MV/PV 24V (GND) SPARK Figure 41A: Location of LED TABLE 8: Green LED Status Codes Green LED Flash Indicates Next System Action Recommended Service Action Code No “Call for Heat”...
  • Page 39 IX. System Start-up (continued) b. Flame current must be measured with pilot screw cover and tighten securely upon valve open/pilot lit but the main valve closed. completion to assure proper gas valve operation. c. Disconnect MV lead wire from the module g.
  • Page 40 IX. System Start-up (continued) Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. 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.
  • Page 41 IX. System Start-up (continued) 3. Adjust limit to setting above observed reading. Main Measure input rate. burners should reignite. 6. Recheck Main Burner Flame. 4. Adjust thermostat to lowest setting. Adjust limit to 7. Return other gas-fired appliances to previous desired setting.
  • Page 42 IX. System Start-up (continued) Table 10: Input Rate boiler through safety valve opening. e. Reinstall safety valve in Tapping "E" with Size of Gas Meter Dial Seconds spindle in vertical position. See Figures 1 and 2. for One One-Half Five f.
  • Page 43 IX. System Start-up (continued) Figure 38, 39 or 40. boiler until sample is clear. f. Close all radiator valves. Remove all supply o. If after normal operation boiler water becomes main air valves. Plug openings in supply main. dirty from additional system piping sediment returning to boiler.

  • Page 44: Service And Maintenance

    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 disassem- bly or service.
  • Page 45 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 about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 46 X. Service Instructions (continued) Figure 46: Boiler Flueway Cleaning 2. McDonnell & Miller 67 Float Style Only. c. Five (5) Years or 100,000 switch cycles. Replace switch and float mechanisms. a. Weekly (or more frequently if necessary). Open blow-off valve to flush sediment chamber. Water Feeder and Additional Low Water Cutoff.
  • Page 47 X. Service Instructions (continued) Table 11: Pilot Burner Location 2. Remove Burner Access Panel and Burners. See Paragraph F. Clean Burners if necessary. Pilot Located Between Burners* 3. Remove Jacket Top Panels. Boiler Size 1 inch 40mm 4. Remove Canopy from top of boiler. IN3I 1 &...
  • Page 48 X. Service Instructions (continued) Excessive Make-Up Water A leaky system will increase the volume of make-up water supplied to the boiler, which can significantly CAUTION shorten the life of the boiler. Entrained in make-up water are dissolved minerals, salts, and oxygen. When IF, DURING NORMAL OPERATION, IT IS the fresh, cool make-up water is heated in the boiler, the NECESSARY TO ADD MORE WATER THAN...
  • Page 49 Honeywell Electronic Ignition Trouble Shooting Guide "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.

  • Page 50: 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...
  • Page 51 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 1. Section Assembly Left End Section (less tankless heater) 717100022 Left End Section (with tankless heater) 717100042 Center Section 717100031 Right End Section 717100011 Tie Rod, 3/8-16 x 10"...
  • Page 52 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 2. Canopy and Draft Hood Canopy/Draft Hood Parts 6111003 6111004 6111005 Canopy Assembly 6111006 6111007 6111008 6111009 61110033 61110043 61110053 Rear Draft Hood Carton Assembly 61110063 61110073 61110083...
  • Page 53 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 3. Base Assembly 718600391 718600491 718600591 718600691 718600791 Base Tray 718600891 718600991 718601091 718601191 718601291 718600311 718600411 718600511 718600611 718600711 Base Wrapper 718600811 718600911 718601011...
  • Page 54 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 3. Base Assembly (Continued) 72060035 72060045 72060055 72060065 72060075 3B2 Base Rear Insulation 72060085 72060095 72060105 72060115 72060126 618600341 618600441 618600541 618600641 618600741 Base Front Panel Assembly 618600841...
  • Page 55 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 3. Base Assembly (Continued) 718600361 718600461 718600561 718600661 718600761 Burner Access Panel 718600861 718600961 718601061 718601161 718601261 Left End Jacket Attachment Bracket 7046011 Right End Jacket Attachment Bracket 7046012...
  • Page 56 XI. Repair Parts (continued) Manifold and 1" Main Burners...
  • Page 57 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 4. Manifold and Main Burners (1 Inch Main Burners Only) Main Burner 8236099 Main Burner with Pilot Bracket 8236098 (Continuous Ignition) (Q327 Pilot) Main Burner with Pilot Bracket 8236098 (Intermittent Ignition) (Q3481B Pilot)
  • Page 58 XI. Repair Parts (continued) Manifold and 40mm Main Burners Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I 4. Manifold and Main Burners (40MM MAIN BURNERS ONLY) Main Burner 8236135 Intermittent Ignition Only Main Burner with 41° Pilot Bracket 8236136...
  • Page 59 XI. Repair Parts (continued) Quantity Description Part No. 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 Main Burner Orifice #39 822727 Main Burner Orifice #38 822720 LP Gas, High Altitude (2000-5000 Ft.) USA Only Main Burner Orifice #53...
  • Page 60 XI. Repair Parts (continued) Quantity Description Part No. IN10 IN11 IN12 5. Pilot Burner and Gas Valve, Continuous Ignition (Standing Pilot), Natural Gas Pilot Burner, Honeywell Q327A1006 8236022 Pilot Orifice, Honeywell 388146AG Included with 5A Compression Nut/Fitting, 1/4" OD x 1/4 C.C. (Included with 5A) 8236109 Pilot Tubing, 1/4"...
  • Page 61 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 5. Pilot Burner and Gas Valve, Intermittent Ignition (EI), Natural Gas Pilot Burner, Honeywell Q3481B1206 with Fiberglass Insulated Integral 36" lg. 103704-01 Igniter/Sensor Cable Pilot Burner Orifice, Honeywell NE22, 0.022"...
  • Page 63 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 Jacket Assembly 60410013 Left Side Panel 60410023 60410012 Right Side Panel 60410022 60410033 60410043 60410053 60410063 60410073 Front Removable Panel 60410083 60410093 60410103 60410113 60410123...
  • Page 65 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 Jacket Assembly (Continued) Upper Left Rear Panel (not shown) 604101051 Upper Right Rear Panel (not shown) 604101052 60410036 60410046 60410056 60410066 60410076 Front Top Panel 60410086 60410096...
  • Page 66 XI. Repair Parts (continued) Description Part No. Quantity Steam Trim Safety Valve, 3/4 NPT, 15 psi, Conbraco 13-511-08 81660530 Elbow, 3/4 NPT 806601502 Nipple, 3/4 NPT x 3-1/2" 806600038 Nipple, 3/4 NPT x 4" 806600014 Low Water Cutoff, McDonnell & Miller PS-802-24 (Probe Included) 80160720 Low Water Cutoff, Hydrolevel CG400-2090 (Less Probe - See Key No.
  • Page 67 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 Transformer/J-Box Adapter Plate Junction Box, 4-11/16" x 4-11/16" x 2-1/8" 81361761 Transformer/J-Box Adapter Plate 7011001 Sheet Metal Screw, #8 x 1/2, Type B, 80860019 Phillips Head, Blunt O/CL Bushing, Heyco OCB-875...
  • Page 68 XI. Repair Parts (continued) Quantity Description Part No. IN3I IN4I IN5I IN6I IN7I IN8I IN9I IN10 IN11 IN12 12. Transformer Junction Box, 4-11/16" x 4-11/16" x 2-1/8" Refer to Table on Page 67 Transformer, 50 VA, Honeywell AT150D1019 80160186 Relay, SPST, Honeywell R8222K1000 80160127 13.

  • Page 69: Appendix B - Figures

    Appendix B - Figures Figure Page Description Number Number Figure 1 Dimensional Drawing Figure 2 Section Tappings Section I - Pre-Installation Figure 3 Clearance to Combustible Materials Section II - Knocked-Down Boiler Assembly Figure 4 Base Gasket Installation Figure 5 Section Assembly Attachment Figure 6 Hydrostatic Pressure Test...
  • Page 70 Appendix B - Figures (continued) Figure Page Description Number Number Section VIII - Electrical Figure 28 Vent Damper Connection Detail Figure 29 Vent Damper Harness to Junction Box Figure 30 Vent Damper Schematic Wiring Diagram Wiring Diagrams, Steam, Continuous Ignition [Standing Pilot (IN10 thru In12 Only)], Figure 31 Probe Low Water Cutoff Figure 32...

  • Page 71: Appendix C = Tables

    Appendix C - Tables Table Page Description Number Number Table 1 Dimensional Data Table 2 Trim and Control Installation in Section Tappings Section VI - Gas Piping Table 3 Rated Input Table 4 Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less Table 5 Fitting Equivalent Lengths Table 6...
  • Page 72 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...

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