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

Page 1: ...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 l i o B e d i v o r p r e b m u N l e d o M r e l i o B N I r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I r o...

Page 2: ...l operation it is necessary to add water to this boiler more frequently than once a month consult a qualified service technician to check your system for leaks A leaky system will increase the volume...

Page 3: ...boiler to shut down and not re start without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarm...

Page 4: ...4 Figure 1 Dimensional Drawing...

Page 5: ...1 9 4 IN9I 760 34 37 3 4 8 17 8 x 15 ft 13 5 10 5 IN10 815 37 1 4 45 38 3 4 45 1 2 18 5 8 3 4 2 14 9 11 6 IN11 885 40 1 2 9 20 1 4 9 x 15 ft 16 3 12 7 IN12 955 43 3 4 21 7 8 1 17 7 13 8 1 15 chimney h...

Page 6: ...r Optional Return Bush to Drain Valve and or Optional Return G 2 Optional Supply IN3I 6 Required Supply IN7I 12 Optional Supply IN3I 6 Required Supply IN7I 12 H Bush to Syphon Limit Bush to Pressure G...

Page 7: ...accordance with applicable provisions of local building codes or with Air for Combustion and Ventilation section of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or Sections 8 2 8 3 or 8 4 of Natura...

Page 8: ...ut of all equipment in space Duct cross sectional area shall be same as opening free area Alternate method for boiler located within confined space Use indoor air if two permanent openings communicate...

Page 9: ...centered over screws protruding from top of base Lower boiler onto base taking care not to disturb ceramic fiber gasket Secure with 5 16 locknuts and washers provided See Figure 5 4 Loosen nuts on tie...

Page 10: ...ls 2 Raise rear panel under rear flange of canopy and rest on floor Position rear panel and secure to jacket side panels with sheet metal screws For Models IN10 IN12 secure jacket upper rear panels to...

Page 11: ...burner in burner tray slot ii Position burner over the orifice NOTE The burner to the right may need to be lifted from the orifice to install pilot burner assembly Reinstall lifted burner over the ori...

Page 12: ...Mount ignition module mounting bracket to inside of right side panel using 2 6 x sheet metal screws provided 2 Mount ignition module to bracket using 2 8 x sheet metal screws provided 3 Install 3 wir...

Page 13: ...and 2 Tighten with wrench applied to square shank on back of gauge DO NOT APPLY PRESSURE ON GAUGE CASE since this may destroy calibration of gauge d Install Low Water Cutoff Probe into Tapping K NPT H...

Page 14: ...o 2 blunt sheet metal screws provided b Mount transformer on Junction Box For Canadian boiler provide strain relief by loosely securing Transformer to Junction Box with wire tie inserted through Trans...

Page 15: ...in the conduit to the two 2 unused screw terminals IV Packaged Boiler Assembly Figure 19 Draft Hood Attachment E Install Jacket Front Panel F Install Draft Hood Models IN3I through IN9I 1 Locate and...

Page 16: ...B R Residential Hydronic Heating Installation and Design Guide 3 Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refriger...

Page 17: ...igure 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 Trim conti...

Page 18: ...of hot water G If a long term pressure test of the hydronic system is required the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler To perform a...

Page 19: ...than those listed above refer to the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 or size system using standard engineering methods accept...

Page 20: ...reater than 2 000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1 000 feet above sea level per the National Fuel Gas Code NFPA 54 ANSI Z223 1 Canadian boiler...

Page 21: ...before proceeding CAUTION Do not use one vent damper to control two heating appliances Provide adequate clearance for servicing 6 152 mm minimum clearance between damper and combustible construction N...

Page 22: ...ed Arrange venting system so boiler is served by vent damper device 3 Where two or more appliances vent into a common vent the area of the common vent should be at least equal to the area of the large...

Page 23: ...nt install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s au syst me d vacuation commun et tous les ventilateurs d extraction comme les hottes de c...

Page 24: ...by avoiding placement of furniture near thermostat Set heat anticipator to match system requirements See Table 7 In general setting heat anticipator too low will cause boiler to short cycle without b...

Page 25: ...0 a Vent Damper is continuously powered at Terminal 1 b When there is a call for heat the damper relay coil is energized through Terminal 5 if all limits ahead of the damper are satisfied c Relay coil...

Page 26: ...26 Figure 31 Wiring Diagrams Steam Continuous Ignition Standing Pilot IN10 thru IN12 Only Probe Low Water Cutoff VIII Electrical continued...

Page 27: ...ses pilot flame and causes gas valve to turn off main burner and pilot burner gas flow should pilot burner flame extinguish H Steam Boiler with Continuous Ignition Standing Pilot and Probe Low Water C...

Page 28: ...28 Figure 32 Wiring Diagrams Steam Intermittent Ignition EI Probe Low Water Cutoff VIII Electrical continued...

Page 29: ...tes after shutdown Ignition Module restarts ignition sequence For Electronic Ignition Trouble Shooting Guide see Page 49 For LED Status Codes see Table 9 on Page 38 I Steam Boiler with Intermittent Ig...

Page 30: ...30 Figure 33 Wiring Diagrams Steam Continuous Ignition Standing Pilot IN10 thru IN12 Only Float Low Water Cutoff VIII Electrical continued...

Page 31: ...on resumes when system pressure falls below set point b Low Water Cutoff LWCO Automatically interrupts main burner operation when surface of boiler water falls to lowest permissible operating level No...

Page 32: ...32 Figure 34 Wiring Diagrams Steam Intermittent Ignition EI Float Low Water Cutoff VIII Electrical continued...

Page 33: ...w set point 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...

Page 34: ...rential pressure DIFF for 5 PSI These pressures may be varied to suit individual requirements of the system See Figure 16 3 Remove front removable panel See Figure 35 4 Connect manometer to gas valve...

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: ...n self corrects within 10 seconds control returns to normal sequence If flame out of sequence remains longer than 10 seconds control will resume normal opera tion 1 hour after error is corrected Check...

Page 39: ...ycle i Restore boiler power at circuit breaker or fuse box ii Set thermostat to call for heat iii Watch ignition sequence at burner iv If spark does not stop after pilot lights replace ignition module...

Page 40: ...er cutoff steam only 1 Adjust thermostat to highest setting 2 With boiler operating open drain and slowly drain boiler CAUTION Do not drain below gauge glass 3 Main burners will extinguish when water...

Page 41: ...l one 1 drill size larger drill size is stamped on orifice iii Reinstall gas orifices and main burners Measure input rate 6 Recheck Main Burner Flame 7 Return other gas fired appliances to previous co...

Page 42: ...eatment a Remove safety valve b Pour recommended compound into boiler through safety valve opening c Reinstall safety valve in Tapping E with spindle in vertical position See Figures 1 and 2 d Follow...

Page 43: ...art sample from lower Gauge Glass fitting If sample is not clear repeat cycle of draining boiler and return main and refilling boiler until sample is clear o If after normal operation boiler water bec...

Page 44: ...on If scale or contamination exceeds 0 2 inches clean probe more frequently g Clean Tapping K to remove old pipe dope and other foreign matter h Apply moderate amount of good quality pipe dope to prob...

Page 45: ...se fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other lau...

Page 46: ...r See Figure 35 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 ad...

Page 47: ...Remove Pilot Assembly for Servicing Remove machine screw s holding pilot burner to pilot bracket after first removing burner with pilot assembly as described in Paragraph F number 8 above l Use a rou...

Page 48: ...t as sediment the salts coat the inside of the boiler and the oxygen escapes as a gas The accumulation of sediment eventually isolates the water from contacting the cast iron When this happens the cas...

Page 49: ...ARY TO RECYCLE THE CALL FOR HEAT MORE THAN ONCE TO CLEAR THE PILOT SUPPLY TUBES OF AIR NOTE IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY RESET THE CALL FOR HEAT CHECK CONTINUITY OF IGNITION CABLE AND G...

Page 50: ...ompany 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 repa...

Page 51: ...1 1D Tie Rod 3 8 16 x 10 80861071 2 Tie Rod 3 8 16 x 12 1 2 80861010 2 Tie Rod 3 8 16 x 17 80861011 2 Tie Rod 3 8 16 x 20 3 4 80861012 2 Tie Rod 3 8 16 x 23 80861049 2 Tie Rod 3 8 16 x 27 1 2 80861014...

Page 52: ...Rear Draft Hood Carton Assembly 61110033 1 61110043 1 61110053 1 61110063 1 61110073 1 61110083 1 61110093 1 2C Canopy Draft Hood Carton Assembly complete 61110102 1 61110112 1 61110122 1 2D Carriage...

Page 53: ...91 1 718600491 1 718600591 1 718600691 1 718600791 1 718600891 1 718600991 1 718601091 1 718601191 1 718601291 1 3B Base Wrapper 718600311 1 718600411 1 718600511 1 718600611 1 718600711 1 718600811 1...

Page 54: ...41 1 618600841 1 618600941 1 618601041 1 618601141 1 618601241 1 3D Burner Tray 1 Inch Main Burners 718600305 1 718600405 1 718600505 1 718600605 1 718600705 1 718600805 1 718600905 1 718601005 1 7186...

Page 55: ...1 1 1 1 1 1 1 1 3H Right End Jacket Attachment Bracket 7046012 1 1 1 1 1 1 1 1 1 1 3J Base Sealant 6206002 1 1 1 1 1 1 1 1 1 1 3K Screw Self Tapping Type F Phillips Pan Head 1 4 20 x 1 2 Plated 808607...

Page 56: ...56 Manifold and 1 Main Burners XI Repair Parts continued...

Page 57: ...82260063 1 82260073 1 82260083 1 82260093 1 82260103 1 82260113 1 82260123 1 4D Natural Gas Only Main Burner Orifice 45 Pink 822711 3 5 7 9 Main Burner Orifice 47 White 822710 12 14 16 18 21 23 4D LP...

Page 58: ...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 Bra...

Page 59: ...ice 42 822728 4 5 6 7 8 LP Gas High Altitude 5000 9000 Ft USA Only 4D Main Burner Orifice 54 822734 2 Main Burner Orifice 53 822722 3 4 5 6 7 8 Natural Gas High Altitude 2000 4500 Ft Canada Only 4D Ma...

Page 60: ...8146AG Included with 5A 1 1 1 5C Compression Nut Fitting 1 4 OD x 1 4 C C Included with 5A 8236109 2 2 2 5D Pilot Tubing 1 4 OD x 40 8236123 1 1 1 5E Gas Valve Robertshaw 7000ERHC S7C 81660156 1 1 1 G...

Page 61: ...1 1 5H Compression Fitting 1 4 OD x 1 4 CC Honeywell 386449 1 B 8236109 1 1 1 1 1 1 1 1 1 1 5 Pilot Burner and Gas Valve Intermittent Ignition EI LP Propane 5A Pilot Burner Honeywell Q3481B1420 with...

Page 62: ...62 XI Repair Parts continued...

Page 63: ...anel 60410033 1 60410043 1 60410053 1 60410063 1 60410073 1 60410083 1 60410093 1 60410103 1 60410113 1 60410123 1 4 Vestibule Panel 60410034 1 60410044 1 60410054 1 60410064 1 60410074 1 60410084 1 6...

Page 64: ...64 XI Repair Parts continued...

Page 65: ...Front Top Panel 60410036 1 60410046 1 60410056 1 60410066 1 60410076 1 60410086 1 60410096 1 60410106 1 60410116 1 60410126 1 6B Rear Top Panel 604100361 1 604100461 1 604100561 1 604100661 1 60410076...

Page 66: ...e See Key No 8B 80160725 Low Water Cutoff McDonnell Miller 67 BC 1 Float Type 80160517 8B Probe for CG400 80160629 1 9 Gauge Glass Extended Shank with Probe LWCO Only 8056128 1 Gauge Glass Standard Sh...

Page 67: ...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 Phillips Head Blunt 80860019 2 2 2 2 2 2 2 2 2 2...

Page 68: ...1 1 1 1 1 1 1 1 1 1 13 Flame Rollout Switch 13A Flame Rollout Switch 80160044 1 1 1 1 1 1 1 1 1 1 13B Flame Rollout Switch Bracket 7186018 1 1 1 1 1 1 1 1 1 1 14 Blocked Vent Switch 14 Blocked Vent S...

Page 69: ...ition EI IN12 Only Figure 14 12 Blocked Vent Switch Installation IN3I through IN9I Figure 15 12 Blocked Vent Switch Installation IN10 through IN12 Section III Semi Pak Boiler Assembly Figure 16 13 L40...

Page 70: ...gnition System 7000 ERHC Gas Valve Figure 39 36 Operating Instructions Intermittent Ignition System VR8204 and VR8304 except IN12 Gas Valves Figure 40 37 Operating Instructions Intermittent Ignition S...

Page 71: ...Section IX System Start Up Table 8 38 Ignition Module Terminal Cross Reference Table 9 38 Green LED Status Codes Table 10 42 Input Rate Section X Service Instructions Table 11 47 Pilot Burner Location...

Page 72: ...72 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...