Installation Date
INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR
INDEPENDENCE
GAS - FIRED BOILER
DANGER
All cover plates, enclosures and guards must be in place at all times
This boiler must be properly vented
Figure 1 Dimensional Drawing
VIII
Table of Contents
Appendix
Figure 2 Section Tappings
Table 1 Trim and Control Installation in Section Tappings
DANGER
I. Pre-Installation
Figure 3 Clearance to Combustible Materials
A. Install Base-Burner-Manifold Assembly
II. Knocked-Down Boiler Assembly
B. Install assembled cast iron sections on base assembly
Figure 4 Base Gasket Installation
Figure 7 Canopy Gasket Installation
D. Install Canopy
Figure 8 Canopy Installation
F. Install Jacket. See Figure
Figure 12 Pilot and Gas Piping, Continuous Ignition
Figure 10 Combustion Chamber
Standing Pilot IN10 through IN12 Only
Figure 13 Pilot and Gas Piping, Intermittent Ignition
Figure 15 Blocked Vent Switch Installation IN3 through IN9
I. Install Blocked Vent Switch with sheet metal screws
Figure 16 Blocked Vent Switch Installation IN10 through IN12
J. Intermittent Ignition EI Install Ignition Module
D. Install Trim and Controls
III. Semi-Pak Boiler Assembly
A. Remove Crate
C. Identify Trim and Controls
Figure 19B Junction Box and Transformer Assembly
Figure 19A Junction Box and Mounting Bracket Assembly
4. Water Boiler
Figure 20 Thermostat Isolation Relay Attachment
E. Install Jacket Front Panel
IV. Packaged Boiler Assembly
B. Remove Jacket Front Panel. See Figure
Figure 22 Securing Draft Hood to Canopy
Figure 23 Trim Installation
V. Piping and Trim
Figure 24 Steam Boiler Piping Minimum
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Figure 28 Tankless Heater Piping
Figure 27 Recommended Piping for Indirect Water Heater
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Table 2 Rated Input
VI. Gas Piping
B. Connect boiler gas valve to gas supply system
Figure 29 Recommended Gas Piping
Table 4 Fitting Equivalent Lengths
DANGER
Table 5 Specific Gravity Correction Factors for Natural Gas
less than 2000 ft. elevation
DANGER
VII. Venting
C. Boiler Equipped With Vent Damper
Do not use one vent damper to control two heating appliances
E. If an Existing Boiler is Removed
Figure 30 Typical Vent Installation
Never jump out or make inoperative any safety or operating controls
VIII. Electrical
B. Wire Vent Damper if used
DANGER
E. Alliance Indirect Water Heater if used
Table 6 Thermostat Heat Anticipator Settings
Figure 33 Vent Damper Harness to Limit
Figure 34 Vent Damper Schematic Wiring Diagram
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c. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation
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level. Normal operation resumes when water returns to normal level
2. Safety Shutdown
c. Blocked Vent Switch. Automatically interrupts
1. Normal Operation
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c. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation
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level. Normal operation resumes when water returns to normal level
2. Safety Shutdown
c. Blocked Vent Switch. Automatically interrupts
1. Normal Operation
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b. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation a. Thermostat calls for heat
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b. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation a. Thermostat calls for heat
d. Sensor proves presence of pilot flame. Main
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b. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation
Page
b. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation
d. Sensor proves presence of pilot flame. Main
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b. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation
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b. Blocked Vent Switch. Automatically interrupts
2. Safety Shutdown
1. Normal Operation
d. Sensor proves presence of pilot flame. Main
C. Fill boiler with water
IX. System Start-up
D. Prepare to check operation
Figure 46 Gas Valve Pressure Tap Honeywell Gas Valves
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except IN12 Gas Valves
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Wiring Ladder Diagram
Service Action
Table 7 Ignition Module Terminal Cross-Reference
Figure 52 LED Locations TABLE 8 Yellow LED Flame Codes
Green LED
Recommended Service Action
Flash Code
Indicates
Figure 54 Pilot Burner Flame, Honeywell Q327
Figure 53 Pilot Burner Flame, Honeywell Q350
Figure 55 Pilot Burner Flame, Honeywell Q348
Figure 56 40mm Main Burner Flame Figure 57 1 Main Burner Flame
I. Check low water cutoff steam only
K. Adjust gas input rate to boiler. Natural Gas
Do not drain below gauge glass
J. Check Limit
Table 10 Input Rate
L. Adjust gas input rate to boiler. LP/Propane
4. Add Boiler Water Treatment a. Remove safety valve
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B. Maintenance of Low Water Cutoff
X. Service Instructions
DANGER
DANGER
E. Clean Boiler Flueways
Figure 58 Boiler Flueway Cleaning
Table 11 Pilot Burner Location
Figure 59 Honeywell Q348 Spark Gap
L. Tankless Heater
M. Excessive Make-Up Water
Honeywell Electronic Ignition Trouble Shooting Guide
Honeywell Hot Surface to Pilot Trouble Shooting Guide
Precautionary Measures
Important Product Safety Information Refractory Ceramic Fiber Product
First Aid Procedures
AVOID Breathing Fiber Particulates and Dust
SERVICE RECORD
XI. Repair Parts
SERVICE PERFORMED
DATE
1. Section Assembly
2. Canopy and Draft Hood Canopy/Draft Hood Parts
Base Tray
3. Base Assembly
Base Wrapper
Base End Insulation
3. Base Assembly Continued
Burner Access Panel
3. Base Assembly Continued
Manifold and 1 Main Burners
4. Manifold and Main Burners 1 Inch Main Burners Only
4. Manifold and Main Burners 40MM MAIN BURNERS ONLY
Manifold and 40mm Main Burners
Intermittent Ignition Only
24-Volt Continuous Ignition Standing Pilot Natural Gas
Natural Gas, High Altitude 2000-5000 Ft. USA Only
4. Manifold and Main Burners 40MM MAIN BURNERS ONLY Continued
LP Gas, High Altitude 2000-5000 Ft. USA Only
Natural Gas, High Altitude 5000-9000 Ft. USA Only
5. Pilot Burner and Gas Valve, Continuous Ignition Standing Pilot, Natural Gas
5. Pilot Burner and Gas Valve, Intermittent Ignition EI, LP/Propane
5. Pilot Burner and Gas Valve, Intermittent Ignition EI, Natural Gas
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Jacket Assembly
Jacket Assembly Continued - Refer to Figure on Page
Steam Trim
Page
Water Trim
Quantity
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14. Blocked Vent Switch
13. Flame Rollout Switch
12. Transformer Steam and Gravity Water Only
15. Ignition Module Intermittent Ignition Only
How to Pipe
XII. Low Water Cut Off LWCO
How to Wire
How to Test
ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS
Limited Warranty
LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER
PROCEDURE FOR OBTAINING WARRANTY SERVICE
FIRST YEAR - LIMITED WARRANTY FOR RESIDENTIAL CAST IRON STEAM BOILERS
Limited Warranty
SECOND THROUGH 10 YEAR - LIMITED WARRANTY FOR THE CAST IRON SECTION
ASSEMBLY OF RESIDENTIAL CAST IRON STEAM BOILERS
