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