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