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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
®
INDEPENDENCE
GAS - FIRED BOILER
For service or repairs to boiler, call your heating contractor. When seeking information on boiler,
provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Serial Number Installation Date
Boiler Model Number
IN
Heating Contractor Phone Number
Address
8141049R26-10/08 Price - $5.00
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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 Independence® Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask your local Sales Rep
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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, step-by-step inspection and cleaning instructions. WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper instal
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4 Figure 1: Dimensional Drawing
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Dimensional Data Dimensions (in inches) Recommended Water Volume (Gal.) Approx. Min. Round Gas Boiler Shipping Chimney Size Conn. Steam Water Model Weight 'A' 'B' 'C' 'D' 'E' 'F' 'G' (3) (Diameter x Height) (NPT) Boiler Boiler Lbs. (1) IN3 350 14-1/2 33-3/4 4 7-1/4 4" x 15 ft. 5.1 7.8 3.9 4-3/4 IN4 420 17-3/4 34-3/4 5 8-7/8 5" x 15 ft. 6.5 10.0 5.0 IN5 485 21 10-1/2 7.9 12.2 6.1 1/2" 35-3/4 6 5-1/4 6" x 15 ft. IN6 USA 555 24-1/4 12-1/8 9.3 14.4 7.2 IN6 40-1/4 Canada 40 36-3/4 7 7" x 15 ft
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Figure 2: Section Tappings Table 1: Trim and Control Installation in Section Tappings Size Steam Boiler with Steam Boiler with Water Boiler with Tapping Water Boiler (NPT) Probe L.W.C.O. Float L.W.C.O. Tankless Heater A 2 Supply Supply Supply Supply Bush to ¼ B ½ Plug Plug Plug Pressure Gauge Nipple & ½ Union Plug Lower Tapping Bush Plug Lower Tapping Bush to C ½ Gauge Glass Gauge, L.W.C.O. Street to ¼ Upper Tapping ¼ Upper Tapping Elbow, Syphon & Limit Press./Temp. Gauge Press./Tem
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I. Pre-Installation front. Additional clearance may be required on left side WARNING if optional tankless heater is installed. Service clearances may be reduced to minimum clearances to If you do not follow these instructions exactly, combustible materials. a fire or explosion may result causing property damage or personal injury. E. Install boiler on level floor as close to chimney as possible. For basement installation provide a solid base, such as concrete, steel or masonry if floor i
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Figure : Clearance to Combustible Materials 5. For boiler located in an unconfined space in a Alternate method for boiler located within confined building of other than unusually tight construction, space. Use indoor air if two permanent openings adequate combustion and ventilation air is normally communicate directly with additional space(s) of provided by fresh air infiltration through cracks sufficient volume such that combined volume of all around windows and doors. spaces meet criteri
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II. Knocked-Down Boiler Assembly 4. Loosen nuts on tie rods until only finger tight. WARNING 5. If Steam boiler or Water boiler less tankless heater, proceed to Step C. Installation of this boiler should be undertaken only by trained and skilled personnel from a 6. Water Boiler with tankless heater. Remove heater qualified service agency. opening cover plate and install tankless heater as follows: A. Install Base-Burner-Manifold Assembly a. Place rubber gasket over heater coil and ag
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3. Attach canopy using ¼" carriage bolts, nuts, and D. Install Canopy. washers provided. 1. Install ½" thick x 1" wide ceramic fiber gasket. See Figure 7. E. Inspect joints between sections. They were factory sealed. If there are any openings due to shipment or handling, reseal with boiler putty. F. Install Jacket. See Figure 9. 1. Models IN7-IN12 steam boilers: remove 3 inch diameter knockouts in jacket top panels. 2. Raise rear panel under rear flange of canopy and rest on floor. Pos
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9. Install front removable door by engaging upper side edges of panel with side receiving flanges, sliding up and under top panel flange - seating front door fully - then sliding down to engage bottom flange behind lower front tie bar. G. Install Pilot/Burner Assembly (shipped in Gas Controls Carton). See Figure 10. Figure 12: Pilot and Gas Piping, Continuous Ignition Figure 10: Combustion Chamber (Standing Pilot) (IN10 through IN12 Only) 1. Remove jacket front removable door. a. Remov
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I. Install Blocked Vent Switch with sheet metal screws. 1. Models IN3 - IN9. Install on rear flange of canopy. See Figure 15. Figure 16: Blocked Vent Switch Installation, IN10 through IN12 5. Insert harness through ¾ inch hole in right side jacket panel. Secure with strain relief bushing J. Intermittent Ignition (EI): Install Ignition Module. Figure 15: Blocked Vent Switch Installation, 1. Mount ignition module mounting bracket to inside IN through IN9 of right side panel using (2) #6 x ¾"
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III. Semi-Pak Boiler Assembly b. The L404F pressure limit employs a snap action WARNING switch and does not require leveling. See Figure Installation of this boiler should be undertaken 18. only by trained and skilled personnel from a c. Install pressure gauge into Tapping "B" (½ NPT qualified service agency. bushed to ¼ NPT). See Figures 1 and 2. Tighten with wrench applied to square shank on back of A. Remove Crate gauge. DO NOT APPLY PRESSURE ON 1. Remove all hold down screws and br
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3. All Steam Boilers and Water Boilers except b. Install hot water temperature limit and/or "EZW" and "WC" Controls Cartons combination control. Remove well from control. Screw well into Tapping "H" (¾ NPT). See a. Install Junction Box. See Figure 19A. Figure 1 and 2. Install bulb in well as far as i. Remove center knockout in rear of Junction possible, then tighten set screw. Box and insert black plastic snap bushing in c. On boilers equipped with a circulator without hole. tankless
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IV. Packaged Boiler Assembly E. Install Jacket Front Panel. WARNING F. Install Draft Hood. Models IN3 through IN9. Installation of this boiler should be undertaken 1. Locate and open "Rear Draft Hood Carton". only by trained and skilled personnel from a qualified service agency. 2. Position Draft Hood on Canopy Rear Flange. See Figure 21. Top canopy flange must fully engage A. Remove crate and move boiler to permanent position "U"-shaped draft hood flange for proper installation as detai
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V. Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. A. Design and install boiler and system piping to prevent WARNING oxygen contamination of boiler water. Sources of oxygen contamination are system leaks requiring Safety (relief) valve discharge piping must be addition of makeup water, fittings, and oxygen piped such that the potential of severe burns permeable materials in distribution system. Eliminate is elim
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1 Figure 24: 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.
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18 Figure 25: Recommended Water Piping for Circulator Zoned Heating System
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19 Figure 25A: Recommended Water Piping for Zone Valve Zoned Heating System
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E. Alliance Indirect Water Heater (if used). Refer to Alliance Installation, Operating and Service Instructions for additional information. 1. Steam. See Figure 27 for piping recommendations. a. Supply and Return Piping. Connect supply piping to Tapping "N" (1¼ NPT) and return piping to Tapping "M" (1¼ NPT). Install zone circulator and strainer in supply piping. Install check valve to prevent gravity circulation of boiler water. b. Limit. See Figure 23. Install temperature limit control
