- DL manuals
- U.S. Boiler Company
- Boiler
- INDEPENDENCE
- Installation, Operating And Service Instructions
U.S. Boiler Company INDEPENDENCE Installation, Operating And Service Instructions
103538-04 - 8/13
Price - $5.00
,
r
e
li
o
b
n
o
n
o
it
a
m
r
o
f
n
i
g
n
i
k
e
e
s
n
e
h
W
.r
o
t
c
a
r
t
n
o
c
g
n
it
a
e
h
r
u
o
y
ll
a
c
,
r
e
li
o
b
o
t
s
r
i
a
p
e
r
r
o
e
c
i
v
r
e
s
r
o
F
.l
e
b
a
L
g
n
it
a
R
n
o
n
w
o
h
s
s
a
r
e
b
m
u
N
l
a
i
r
e
S
d
n
a
r
e
b
m
u
N
l
e
d
o
M
r
e
li
o
B
e
d
i
v
o
r
p
r
e
b
m
u
N
l
e
d
o
M
r
e
li
o
B
N
I
r
e
b
m
u
N
l
a
i
r
e
S
r
e
li
o
B
e
t
a
D
n
o
it
a
ll
a
t
s
n
I
r
o
t
c
a
r
t
n
o
C
g
n
it
a
e
H
r
e
b
m
u
N
e
n
o
h
P
s
s
e
r
d
d
A
D
N
A
G
N
I
T
A
R
E
P
O
,
N
O
I
T
A
L
L
A
T
S
N
I
R
O
F
S
N
O
I
T
C
U
R
T
S
N
I
E
C
I
V
R
E
S
E
C
N
E
D
N
E
P
E
D
N
I
®
R
E
L
I
O
B
D
E
R
I
F
-
S
A
G
9700609
Summary of INDEPENDENCE
Page 1
103538-04 - 8/13 price - $5.00 , r e li o b n o n o it a m r o f n i g n i k e e s n e h w .R o t c a r t n o c g n it a e h r u o y ll a c , r e li o b o t s r i a p e r r o e c i v r e s r o f .L e b a l g n it a r n o n w o h s s a r e b m u n l a i r e s d n a r e b m u n l e d o m r e li o b e ...
Page 2
2 the new york city department of buildings has approved the independence® series boiler: approval no. Mea 154-93-e vol. Iii. 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 indep...
Page 3
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, ...
Page 4
4 figure 1: dimensional drawing.
Page 5
5 table 1: dimensional data heating surface: 4.35 sq. Ft. Per flueway (steam); 5.72 sq. Ft. Per flueway (water) boiler model approx. Shipping weight lbs. Dimensions (in inches) recommended min. Round chimney size (diameter x height) (1) gas conn. (npt) water volume (gal.) 'a' 'b' 'c' 'd' 'e' 'f' 'g'...
Page 6
6 table 2: trim and control installation in section tappings tapping size (npt) steam boiler with probe l.W.C.O. Steam 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. Street elbow, syphon & limit d 2 return return e ¾ 3"...
Page 7
7 i. Pre-installation a. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of boiler to carrier in good condition. Any claim for damage or shortage in shipment must be filed immediately against c...
Page 8
8 figure 3: clearance to combustible materials 5. For boiler located in an unconfined space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. 6. For boiler located ...
Page 9
9 figure 4: base gasket installation 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 (ga...
Page 10
10 figure 9: jacket assembly figure 7: canopy gasket installation figure 8: canopy installation 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 p...
Page 11
11 figure 12: pilot and gas piping, intermittent ignition (ei) (in3i through in11 only) figure 11: pilot and gas piping, continuous ignition (standing pilot) (in10 through in12 only) figure 13: pilot and gas piping, intermittent ignition (ei) (in12 only) 8. Install black plastic rings into 1-3/32 in...
Page 12
12 figure 15: blocked vent switch installation, in10 through in12 figure 14: blocked vent switch installation, in3i through in9i 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 provid...
Page 13
13 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 in...
Page 14
14 figure 18: thermostat isolation relay attachment 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 sna...
Page 15
15 figure 20: securing draft hood to canopy 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. D. On steam boilers with probe low water cutoff the l404 pressu...
Page 16
16 v. Piping and trim a. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Sources of oxygen contamination are system leaks requiring addition of makeup water, fittings, and oxygen permeable materials in distribution system. Eliminate oxygen contamination b...
Page 17
17 figure 22: steam boiler piping (minimum) notice failure to pipe boiler as specified in this manual may result in excessive system noise, water line fluctuations and water carry over . V. Piping and t rim (continued).
Page 18
18 figure 24: recommended piping for indirect water heater figure 25: tankless heater piping figure 23: recommended piping for combination heating and cooling (refrigeration) systems f. Tankless heater (if used). See figure 25. 1. Install automatic tempering or mixing valve to prevent delivery of sc...
Page 19
19 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....
Page 20
20 table 5: fitting equivalent lengths table 6: specific gravity correction factors for natural gas 4. All above ground gas piping upstream from manual gas valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as a grounding electrode. Refer to the national...
Page 21
21 vii. Venting a. Install vent system in accordance with local building codes; or local authority having jurisdiction; or "venting of equipment", of the national fuel gas code, ansi z223.1/nfpa 54, or "venting systems and air supply for appliances", of the national gas and propane installation code...
Page 22
22 placed in operation, while the other appliances remaining connected to the common venting system are not in operation: 1. Seal any unused openings in the common venting system. 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restri...
Page 23
23 vii. Venting (continued) 7. Any improper operation of the common venting system should be corrected so the installation conforms with the national fuel gas code, ansi z223.1/nfpa 54, and/or the natural gas and propane installation code, can/csa b149.1. When resizing any portion of the common vent...
Page 24
24 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 and/or the canadian electrical code part 1, csa 22.1, electrical code. B. Wire vent damper (if used). 1. Ste...
Page 25
25 table 7: thermostat heat anticipator settings e. Alliance sl™ indirect water heater (if used). 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 bo...
Page 26
26 figure 31: w iring diagrams, steam, continuous ignition [standing pilot (in10 thru in12 only)], probe low w ater cutoff viii. Electrical (continued).
Page 27
27 b. Low water cutoff (lwco): automatically interrupts main burner operation when surface of boiler water falls to lowest permissible operating level. Normal operation resumes when water returns to normal level. C. Blocked vent switch. Automatically interrupts main burner operation when excessive v...
Page 28
28 figure 32: w iring diagrams, steam, intermittent ignition (ei), probe low w ater cutoff viii. Electrical (continued).
Page 29
29 b. Low water cutoff (lwco): automatically interrupts main burner operation when surface of boiler water falls to lowest permissible operating level. Normal operation resumes when water returns to normal level. C. Blocked vent switch. Automatically interrupts main burner operation when excessive v...
Page 30
30 figure 33: w iring diagrams, steam, continuous ignition [standing pilot (in10 thru in12 only)], float low w ater cutoff viii. Electrical (continued).
Page 31
31 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 v...
Page 32
32 figure 34: w iring diagrams, steam, intermittent ignition (ei), float low w ater cutoff viii. Electrical (continued).
Page 33
33 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...
Page 34
34 ix. System start-up figure 37: gas valve pressure tap, robertshaw gas valve figure 36: gas valve pressure tap, honeywell gas valves figure 35: front door removal warning completely read, understand and follow all instructions in this manual before attempting start up. A. Safe lighting and other p...
Page 35
35 figure 38: lighting instructions, continuous ignition system, 7000 erhc gas valve ix. System start-up (continued).
Page 36
36 figure 39: operating instructions, intermittent ignition system, vr8204 and vr8304 (except in12) gas valves ix. System start-up (continued).
Page 37
37 figure 40: operating instructions, intermittent ignition system (ei), vr8304 (in12 only) gas valves ix. System start-up (continued).
Page 38
38 table 8: ignition module terminal cross-reference figure 41a: location of led table 8: green led status codes ignition module terminal designation wiring ladder diagram terminal number mv 1 mv/pv 2 pv 3 gnd 4 24v (gnd) 5 24v 6 spark 9 green led flash code a indicates next system action recommende...
Page 39
39 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 pi...
Page 40
40 figure 43: typical pilot flame, honeywell q3481b figure 42: pilot burner flame, honeywell q327 figure 44: 40mm main burner flame figure 45: 1" main burner flame ix. System start-up (continued) g. Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. H...
Page 41
41 3. Adjust limit to setting above observed reading. Main burners should reignite. 4. Adjust thermostat to lowest setting. Adjust limit to desired setting. K. Adjust gas input rate to boiler. Natural gas. 1. Adjust thermostat to highest setting. 2. Check manifold gas pressure. Manifold pressure is ...
Page 42
42 table 10: input rate appliance. See figure 38, 39 or 40. Drain boiler and system piping. H. Remove drain valve. Thoroughly wash boiler water passages with high pressure spray through drain valve tapping. I. Reinstall drain valve in tapping "f". See figures 1 and 2. 3. Second boil-out for stubborn...
Page 43
43 figure 38, 39 or 40. 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 v...
Page 44
44 x. Service instructions caution label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Attention. Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Les erreurs de câblage peuvent nuire au bon...
Page 45
45 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 contac...
Page 46
46 c. Five (5) years or 100,000 switch cycles. Replace switch and float mechanisms. C. Water feeder and additional low water cutoff. Refer to manufacturer's instructions. D. Vent system. Check annually for: 1. Obstructions 2. Accumulations of soot 3. Deterioration of vent pipe or vent accessories du...
Page 47
47 2. Remove burner access panel and burners. See paragraph f. Clean burners if necessary. 3. Remove jacket top panels. 4. Remove canopy from top of boiler. 5. Thoroughly clean the flueways with flue brush. See figure 46. 6. Clean boiler heating surface accessible from combustion chamber with straig...
Page 48
48 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...
Page 49
49 honeywell electronic ignition trouble shooting guide "call for heat." power to module? (24 v nominal) no yes 30 second prepurge delay?(s8670 only) yes spark across ignitor/ sensor gap? Yes no check line voltage power, low voltage transformer, limit controller, thermostat (controller), and wiring....
Page 50
50 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 r...
Page 51
51 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 1. Section assembly 1a left end section (less tankless heater) 717100022 1 1 1 1 1 1 1 1 1 1 left end section (with tankless heater) 717100042 1 1 1 1 1 1 1 1 1 1 1b center section 717100031 1 2 3 4 5 6 7 8 9 ...
Page 52
52 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 2. Canopy and draft hood canopy/draft hood parts 2a canopy assembly 6111003 1 --- --- --- --- --- --- --- --- --- 6111004 --- 1 --- --- --- --- --- --- --- --- 6111005 --- --- 1 --- --- --- --- --- --- --- 611...
Page 53
53 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 3. Base assembly 3a base tray 718600391 1 --- --- --- --- --- --- --- --- --- 718600491 --- 1 --- --- --- --- --- --- --- --- 718600591 --- --- 1 --- --- --- --- --- --- --- 718600691 --- --- --- 1 --- --- ---...
Page 54
54 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 3. Base assembly (continued) 3b2 base rear insulation 72060035 1 --- --- --- --- --- --- --- --- --- 72060045 --- 1 --- --- --- --- --- --- --- --- 72060055 --- --- 1 --- --- --- --- --- --- --- 72060065 --- -...
Page 55
55 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 3. Base assembly (continued) 3f burner access panel 718600361 1 --- --- --- --- --- --- --- --- --- 718600461 --- 1 --- --- --- --- --- --- --- --- 718600561 --- --- 1 --- --- --- --- --- --- --- 718600661 ---...
Page 56
56 manifold and 1" main burners xi. Repair parts (continued).
Page 57
57 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 4. Manifold and main burners (1 inch main burners only) 4a main burner 8236099 2 4 6 8 11 13 15 17 20 22 4b main burner with pilot bracket (continuous ignition) (q327 pilot) 8236098 --- --- --- --- --- 1 1 1 1...
Page 58
58 manifold and 40mm main burners key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i 4. Manifold and main burners (40mm main burners only) 4a main burner 8236135 1 2 3 4 5 6 7 intermittent ignition only 4b main burner with 41° pilot bracket 8236136 1 1 1 1 1 1 1 xi. Repair part...
Page 59
59 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 l...
Page 60
60 key no. Description part no. Quantity in10 in11 in12 5. Pilot burner and gas valve, continuous ignition (standing pilot), natural gas 5a pilot burner, honeywell q327a1006 8236022 1 1 1 5b pilot orifice, honeywell 388146ag included with 5a 1 1 1 5c compression nut/fitting, 1/4" od x 1/4 c.C. (incl...
Page 61
61 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 5. Pilot burner and gas valve, intermittent ignition (ei), natural gas 5a pilot burner, honeywell q3481b1206 with fiberglass insulated integral 36" lg. Igniter/sensor cable 103704-01 1 1 1 1 1 1 1 1 1 1 5b pil...
Page 62
62 xi. Repair parts (continued).
Page 63
63 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 jacket assembly 1 left side panel 60410013 1 1 1 1 1 1 1 --- --- --- 60410023 --- --- --- --- --- --- --- 1 1 1 2 right side panel 60410012 1 1 1 1 1 1 1 --- --- --- 60410022 --- --- --- --- --- --- --- 1 1 1 ...
Page 64
64 xi. Repair parts (continued).
Page 65
65 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 jacket assembly (continued) 5a upper left rear panel (not shown) 604101051 --- --- --- --- --- --- --- 1 1 1 5b upper right rear panel (not shown) 604101052 --- --- --- --- --- --- --- 1 1 1 6a front top panel...
Page 66
66 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 8a low water cutoff, mcdonnell & miller ps-802-24 (probe included) 80160720 1 ...
Page 67
67 key no. Description part no. Quantity in3i in4i in5i in6i in7i in8i in9i in10 in11 in12 transformer/j-box adapter plate 1 junction box, 4-11/16" x 4-11/16" x 2-1/8" 81361761 1 1 1 1 1 1 1 1 1 1 2 transformer/j-box adapter plate 7011001 1 1 1 1 1 1 1 1 1 1 3 sheet metal screw, #8 x 1/2, type b, ph...
Page 68
68 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, ...
Page 69
69 appendix b - figures figure number page number description figure 1 4 dimensional drawing figure 2 6 section tappings section i - pre-installation figure 3 8 clearance to combustible materials section ii - knocked-down boiler assembly figure 4 9 base gasket installation figure 5 9 section assembl...
Page 70
70 figure number page number description section viii - electrical figure 28 24 vent damper connection detail figure 29 24 vent damper harness to junction box figure 30 25 vent damper schematic wiring diagram figure 31 26 wiring diagrams, steam, continuous ignition [standing pilot (in10 thru in12 on...
Page 71
71 appendix c - tables table number page number description table 1 5 dimensional data table 2 6 trim and control installation in section tappings section vi - gas piping table 3 19 rated input table 4 20 maximum capacity of schedule 40 pipe in cfh for natural gas pressures of 0.5 psig or less table...
Page 72
72 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.