U.S. Boiler Company INDEPENDENCE IN3PV Troubleshooting guide

103560-03 - 10/12 Price - $5.00
DNAGNITAREPO,NOITALLATSNI
ROFSNOITCURTSNIECIVRES
ECNEDNEPEDNI
®
VP
RELIOBDERIF-SAG
For service or repairs to boiler, call hour heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
IN_PVSNI_
Boiler Serial Number Installation Date
Heating Contractor Phone Number
Address
9700609

2
Figure 2: Tapping Locations
Table 2: Purpose of Tappings
Table 1: Dimensions and Clearances
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels, or to important information concerning product life.
The New York City Department of Buildings has approved the Independence® PV boiler: Approval No. MEA 154-93-E.
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® PV boiler. See the Massachusetts
Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest
Approval Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
Boiler Model
Dimensions [inches]
Minimum Clearances from Combustible Materials [inches] Approx.
Shipping
Weight Lbs.
(A) Width (B) Flue
Connector
Left
Side
Right
Side Front Rear Top Vent
IN3PV 14-1/2 4
18 6 Alcove 6 12 *
355
IN4PV 17-3/4 8-1/4 425
IN5PV 21 9-1/4 490
IN6PV 24-1/4 9-1/4 560
* Vent pipe minimum clearance to combustible material is ve (5) inches when vent is installed in a fully enclosed (chase) application or
four (4) inches when vent is installed with at least one side open, similar to a joist bay application.
Tapping Size IN3PV IN4PV - IN6PV
A 2 Supply Plugged
B 2 Plugged Supply
C ½ Pressure Gauge (with ½ x ¼ bushing)
D 2 Drain Valve (with 2 x ¾ bushing)
E ¾ Safety Valve
F 1 Surface Blow-Off, Plugged
G ½ Gauge Glass
H ¾ Limit (with ¾ x ¼ bushing)
L ¾ Low Water Cut-Off
M 1¼ Indirect Water Heater Return, Plugged
N 1¼ Indirect Water Heater Supply, Plugged
P ¾ Indirect Water Heater Control, Plugged
R 2 Return

3
Figure 1: Elevation Views
WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up,
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efciency.
This boiler is supplied with safety devices which may cause the 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 alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water or steam under pressure. Do not unscrew any pipe ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
pressure and temperature of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.

4
I. Pre-Installation
F. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes, or
National Fuel Gas Code, NFPA 54/ANSI Z223.1, Air
for Combustion and Ventilation.
The following guideline is based on the National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
A. Installation must conform to the requirements of
the authority having jurisdiction. In the absence of
such requirements, installation must conform to the
National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Where required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
B. Boilerisdesigncertiedforinstallationoncombustible
ooring.Theboilermustnotbeinstalledoncarpeting.
C. Provide clearance between boiler jacket and
combustiblematerialinaccordancewithlocalre
ordinance. Refer to Table 1 for minimum listed
clearance from combustible material. Recommended
service clearance is 24 inches from left side, right
side and front. Service clearances may be reduced to
minimum clearances to combustible materials.
D. Installonleveloor.Forbasementinstallationprovide
solidbase,suchasconcrete,ifoorisnotlevelorif
watermaybeencounteredonooraroundboiler.
E. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
Table of Contents
I. Pre-Installation.................................. 4
II. Unpack Boiler ................................... 5
III. Steam Piping and Trim...................... 6
IV. Gas Piping......................................... 8
V. Venting ........................................... 10
VI. Electrical ......................................... 16
VII. System Start-up............................... 17
VIII. Service Instructions ......................... 25
IX. Repair Parts..................................... 32
Appendix A - Figures....................... 40
Appendix B - Tables ........................ 41
WARNING
Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the boiler.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions,
including all those contained in component manufacturers manuals which are provided with the boiler
before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.
All cover plates, enclosures and guards must be in place at all times.

5
rating of 1 perm or less with openings gasketed
and sealed, and;
b. Weather-stripping has been added on openable
windows and doors, and;
c. Caulking or sealants applied in joints around
window and door frames, between sole plates
andoors,betweenwall-ceilingjoints,between
wall panels, at plumbing and electrical
penetrations, and at other openings.
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
providedbyfreshairinltrationthroughcracks
around windows and doors.
6. For boiler located within unconned space in
building of unusually tight construction or within
conned space, provide outdoor air through two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 3
inches. Size each opening per following:
a. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 Btu per hour
input of all equipment in space.
b. Vertical ducts. Minimum free area of 1 square
inch per 4,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1 square
inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
 Alternatemethodforboilerlocatedwithinconned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcientvolumesuchthatcombinedvolumeofall
spacesmeetcriteriaforunconnedspace.Sizeeach
opening for minimum free area of 1 square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
androdents.Louversandgrillesmustbexedin
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
G. Donotinstallboilerwheregasolineorotherammable
vapors or liquids, or sources of hydrocarbons (i.e.
bleaches, cleaners, chemicals, sprays, paint removers,
fabric softeners, etc.) are used or stored.
CAUTION
Avoid operating this boiler in an environment
where saw dust, loose insulation bers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
F. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.
I. Pre-Installation (continued)

6
III. Steam Piping and Trim
A. Design and install boiler and system piping to prevent
oxygen contamination of boiler water.
Oxygen contamination sources are system leaks
requiringadditionofmakeupwater,ttings,and
oxygen permeable materials in distribution system.
Eliminate oxygen contamination sources by repairing
systemleaks,repairingttings,andusingnonpermeable
materials in distribution system.
B. Connect system supply and return piping to boiler.
Refer to Figure 4 for IN3PV or Figure 5 for IN4PV,
IN5PV and IN6PV. Also consult Residential Hydronic
Heating Installation and Design I=B=R Guide.
Maintain minimum ½ inch clearance from combustible
materials.
C. Install Safety Valve in Tapping "E". See Figure 3. Use
¾ NPT x 3" nipple and ¾ NPT elbow provided. Safety
Valve must be installed with spindle in vertical position.
WARNING
Installation is not complete unless a safety valve
is installed.
WARNING
Safety valve discharge piping must be piped near
oor to eliminate potential of severe burns. DO
NOT pipe in any area where freezing could occur.
DO NOT install any shut-off valves.
D. Install Drain Valve in Tapping "D". See Figure 3. Use 2
NPT x ¾ NPT bushing provided.
E. Alliance SL™ Indirect Water Heater (if used). Refer
to Alliance SL™ Installation, Operating and Service
Instructions for additional information.
1. Supply and Return Piping. Connect supply piping to
Tapping "N" and return piping to Tapping "M". See
Figure 2. Install zone circulator and strainer in
supply piping. Install check valve to prevent gravity
circulation of boiler water.
2. Limit. Install temperature limit control (Honeywell
L4006A or equal) in Tapping "P". See Figure 3. Set
at 180°F to prevent steam production during non-
space heating periods.
NOTICE
Before using copper for steam piping, consider the following characteristics of copper piping:
1) high coefcient of thermal expansion can induce mechanical stresses and cause expansion/
contraction noises if not accounted for in the piping system design and installation,
2) high heat transfer rate (heat loss) of uninsulated copper piping must be included in the normal
piping and pickup factors used to size the boiler,
3) soldering or brazing pastes and uxes that end up in the system can cause poor heat transfer,
surging, an unsteady water line and wet steam if not thoroughly removed during the boil out
procedure and,
4) galvanic corrosion of the adjoining metal may occur due to dissimilar metals in certain water
chemistries if dielectric unions are not used.
WARNING
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
Do not use softened water in steam boilers. Accelerated boiler corrosion will result. Tie in fresh water
supply to the boiler upstream of a water softener.
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can
lead to boiler failure. U.S. Boiler Company’s Standard Warranty does not cover problems caused by
oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

7
Figure 4: Steam Piping, IN3PV
Figure 3: Trim Installation
III. Steam Piping and Trim (continued)

8
IV. Gas Piping
A. Size gas piping. Design system to provide adequate gas
supply to boiler. Consider these factors:
1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure for natural gas is
4.5 inch w.c.
2. Maximum gas demand. Table 3 lists boiler input
rate. Also consider existing and expected future gas
utilization equipment (i.e. water heater, cooking
equipment).
3. Lengthofpipingandnumberofttings.Referto
Table 4 for maximum capacity of Schedule 40 pipe
carrying natural gas. Table 5 lists equivalent pipe
lengthforstandardttings.
4. Specicgravityofgas.Correctionsforthespecic
gravity of natural gas can be found in Table 6.
For materials or conditions other than those listed
above, refer to National Fuel Gas Code, NFPA
54/ANSI Z223.1, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
B. Connect boiler gas valve to gas supply system.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
Table 3: Rated Input
Figure 5: Steam Piping, IN4PV, IN5PV and IN6PV
Boiler Model
Number
Input Rate
[cubic feet per hour] Gas
Connection
Size
Natural Gas
IN3PV 62 ½
IN4PV 105 ½
IN5PV 140 ½
IN6PV 175 ½
III. Steam Piping and Trim (continued)

9
Table 4: Maximum Capacity of Schedule 40 Pipe in CFH of Natural Gas For Gas Pressures of 0.5 psig or Less
Table 5: Fitting Equivalent Lengths
Figure 6: Recommended Gas Piping
Table 6: Specic Gravity Correction Factors for
Natural Gas
2. Use thread (joint) compounds (pipe dope) resistant
toactionofliqueedpetroleumgas.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve
and outside jacket. See Figure 6.
4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, ANSI/NFPA 70.
C. Pressure test. The boiler and its gas connection must be
leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector,soapandwater,orsimilarnonammable
solution.Donotusematches,candles,openames,
or other ignition source.
Length
[Feet]
0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop
½ ¾ 1 1¼ ½ ¾ 1 1¼
10 132 278 520 1,050 175 360 680 1,400
20 92 190 350 730 120 250 465 950
30 73 152 285 590 97 200 375 770
40 63 130 245 500 82 170 320 660
50 56 115 215 440 73 151 285 580
60 50 105 195 400 66 138 260 530
70 46 96 180 370 61 125 240 490
80 43 90 170 350 57 118 220 460
90 40 84 160 320 53 110 205 430
100 38 79 150 305 50 103 195 400
Fitting Nominal Pipe Size
½ ¾ 1 1¼
45° Ell 0.7 1.0 1.2 1.6
90° Ell 1.6 2.1 2.6 3.5
Tee
(As Elbow) 3.1 4.1 5.2 6.9
Specic Gravity Multiplier
0.55 1.40
0.60 1.00
0.65 0.96
0.70 0.93
0.75 0.90
0.80 0.87
IV. Gas Piping (continued)

10
NOTICE
The gasketed vent system components pictured below in FigureAare being phased in and each vent component
is interchangeable with the previously supplied gasket-less venting components. The newer vent components
are generally quicker and easier to join, as they do not require the sealant application and their clamp bands
are attached.
In the event a gasketed vent component and a gasket-
less vent component must be interconnected, follow the
instructions associated with Figure 8B or 8C. The two
guiding principles of these instructions are as follows:
1) Any joining of vent components that involves
at least one gasket-less vent component
always requires the sealant application.
2) The female end of a gasket-less vent
component always requires a clamp band,
regardless of the design of the mating male
vent component.
Each gasket-less vent component is supplied with a clamp band and sealant.
A Vent Transition Kit, part number 6116302, is available that contains one clamp band and one 3 ounce tube
of sealant.
Table 7: Maximum Equivalent Vent Length
V. Venting
Figure A: U.S. Boiler Company Vent
A. General Guidelines
1. Vent system installation must be in accordance with
National Fuel Gas Code, NFPA 54/ANSI Z221.3,
Venting of Equipment, or applicable provisions of
localbuildingcodes.Contactlocalbuildingorre
ofcialsaboutrestrictionsandinstallationinspection
in your area.
2. This boiler requires a Special Gas Vent. The product
is designed to use supplied AL 29-4C® Stainless
Steel vent system components. The following
manufacturer's offer similar AL 29-4C®components
and are approved for use with this product: Heat-
Fab - Saf-T-Vent (800-772-0739); Flex-L
International - Star-34 (800-561-1980); Protech
Systems, Inc. - FasNSeal™ (800-766-3473); and Z-
Flex U. S., Inc. - Z-Vent (800-654-5600). The use
of these alternate manufacturer's venting systems
will require adapters to connect to the supplied vent
connector and vent terminal. These adapters are not
supplied with this boiler and should be obtained
from the supplier of the alternate manufacturer's
venting system. See Table 8 for complete parts list.
WARNING
Do not use this boiler with galvanized, 304 or 316
stainless steel or any other non AL29-4C® based
vent systems.
3. Vent length restrictions are based on equivalent
length of vent pipe (total length of straight pipe plus
equivalentlengthofttings).Maximumventlength
is listed in Table 7. Do not exceed maximum
lengths. Minimum vent length is 8 feet. Table 8 lists
equivalentlengthforttings.DonotincludeVent
Terminal in equivalent feet calculation.
4. Do not install venting system components on the
exteriorofthebuildingexceptasspecically
required by these instructions.
B. Removal of Existing Boiler. For installations not
involving the replacement of an existing boiler, proceed
to Step C.
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the remaining
appliances. At the time of removal of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system
are not in operation:
1. Seal any unused openings in the common venting
system.
IN3PV IN4PV IN5PV IN6PV
45 35 35 35

11
Table 8: Vent System Components C. Install Vent Connector.
1. Remove vent connector from vent accessory carton.
2. Removegaskets,oriceplateandhardwarefrom
bloweroutletange.
3. Assembleoriceplategaskets,oriceplate,and
vent connector. See Figure 7.
4. Secure vent connector with washers and locknuts.
Do not overtighten.
2. Visually inspect the venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deciencieswhichcouldcauseanunsafecondition.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn
on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
replacedampers.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the drafthood relief opening after
5minutesofmainburneroperation.Usetheame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors,windows,exhaustfans,replacedampersand
any other gas burning appliance to their previous
conditions of use.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part 11 in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.
Figure 7: Vent Connector Installation
D. Install Vent Pipe, General.
1. Plan venting system to avoid possible contact with
plumbing or electrical wires. Start at vent
connector. Work toward vent terminal.
2. Use non-combustible ¾ inch pipe strap to support
horizontal runs and maintain vent location and slope
while preventing sags in pipe. Do not restrict
thermal expansion or movement. Maximum support
spacing is 5 feet. Do not penetrate any part of the
venting system with fasteners.
3. Provide and maintain minimum clearances to
combustible materials. Use single wall thimble
(Part No. 8116116) when penetrating combustible
wall. Other wall thimble manufacturers are
American Metal Products, Hart & Cooley, and
Metal Fab.
4. Once a vent pipe manufacturer and system is chosen
never mix and match vent systems.
5. If a non-standard length pipe is required, the use of
the adjustable length pipe (P/N 8116319U) is
recommended to complete a non-standard pipe
length. This pipe requires a minimum installed
Vent System
Component
Part
Number
Equivalent
Feet of Pipe
3" Dia. Pipe x 1 Ft 8116296U 1
3" Dia. Pipe x 3 Ft 8116298U 3
3" Dia. Pipe x 5 Ft 8116300U 5
3" Dia. Pipe x Adjustable 8116319U
Equal to
Installed Length
(1.1 to 1.7)
3" Dia. 90° Elbow 8116294U 5
3" Dia. 45° Elbow 8116292U 5
3" Dia. Horizontal Drain Tee 8116302U ½
3" Dia. Vertical Drain Tee 8116304U 7½
3" Single Wall Thimble 8116116 ---
3" Double Wall Thimble 103877-01 ---
V. Venting (continued)

12
a. Clean the male end of each joint using an alcohol
pad to remove any dirt and grease.
b. Apply a continuous ¼ inch bead of sealant
around male end of joint no more than 1/8 inch
from end.
c. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint. Ensure bead in male end of
pipe is below locking band and rest against the
end of the female pipe. Verify the factory-
installed gasket is not dislodged or cut.
d. Smooth sealant around joint for a continuous
seal. Reapply sealant if necessary.
e. Tighten locking band by HAND with a 5/16" nut
driver until snug plus ¼ turn. DO NOT
SECURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT
PUNCTURE THE VENT SYSTEM!
f. Once the installation is complete, operate boiler
andinspectalljointstoensurethatuegases
and/or liquid condensate will not escape.
length of 12¾ inch and can adjust across a 7 inch
gap up to a maximum of 19¾ inch long. (Note for
the adjustable pipe the installed length should be
measured from the centerline of the bead on the
maleendoftherstpipetotheendofthefemale
pipe excluding the locking band of the second pipe
with a single gasket.)
WARNING
Never exceed maximum installed length of 19¾
inches for adjustable length pipe.
Risk of ue gas leakage is possible.
Only in the event the adjustable length pipe is not
sufcientastandardlengthpipemaybecutusing
the following procedure.
Carefully cut pipe to length using a hacksaw with
minimum 32 teeth per inch or circular saw with
metal abrasive wheel. Remove male (bead) end
only–female(bell)endacceptsnextttingorpipe.
NOTICE
Cut must be square with pipe and led or
sanded smooth before joining. Carefully ensure
roundness of cut pipe by hand with gloves before
installing. Seal joint with RTV specied in this
manual.
6. Seal all U.S. Boiler Company Gasket-Less vent, U.
S. Boiler Company mixed vent (Gasket-Less and
Gasketed)andeldcutjointsusingDowCorning
Silastic 732 RTV, Dow Corning Silastic 736 RTV,
GE RTV106, Polybac #500 RTV, Sil-bond RTV
4500 (Acetoxy) and Sil-bond RTV 6500. Do not
use other adhesives or sealants.
E. Install Vent Pipe, U.S. Boiler Company Gasketed
Vent System.
1. Procedure for Joining U.S. Boiler Company
Gasketed Vent Pipe and Fittings. See Figure 8A.
a. Wipe the male end of each joint using an alcohol
pad to remove any dirt and grease.
b. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint. Ensure bead in male end of
pipe is below locking band and rest against the
end of the female pipe. Verify the factory-
installed gasket is not dislodged or cut.
c. Tighten locking band by HAND with a 5/16" nut
driver until snug plus ¼ turn. DO NOT
SECURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT
PUNCTURE THE VENT SYSTEM!
d. Once the installation is complete, operate boiler
andinspectalljointstoensurethatuegases
and/or liquid condensate will not escape.
F. Install Vent Pipe, U.S. Boiler Company Gasket-Less
& Gasketed Vent System.
1. Procedure for joining the male end of U.S. Boiler
Company Gasket-Less Vent with the female end of
U.S. Boiler Company Gasketed Vent. See Figure
8B.
Figure 8A: U.S. Boiler Company Gasketed Vent Joint Detail
Figure 8B: U.S. Boiler Company Gasket-Less Male and
Gasketed Female Vent Joint Detail
V. Venting (continued)

13
Figure 8C: U.S. Boiler Company Gasket-Less
Female and Gasketed Male Vent Joint Detail
2. Procedure for joining the female end of U.S. Boiler
Company Gasket-Less Vent with the male end of
U.S. Boiler Company Gasketed Vent. See Figure
8C.
a.Cleanjointsofpipeorttingsusinganalcohol
pad to remove any dirt and grease.
b. Slip a locking band over female (bell) end of
pipe/tting.
c. Apply a continuous ¼ inch bead of sealant
around male end of joint no more than 1/8 inch
from end.
d. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint.
e. Smooth sealant around joint for a continuous
seal. Reapply sealant if necessary.
f. Slip the locking band over joint and align closest
bead in locking band with bead in male end of
pipe.
g. Tighten locking band by HAND with a 5/16" nut
driver until snug plus ¼ turn. DO NOT
SECURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT
PUNCTURE THE VENT SYSTEM!
h. Once the installation is complete, operate boiler
andinspectalljointstoensurethatuegases
and/or liquid condensate will not escape.
G. Horizontal (Through Wall) Vent Installation.
1. Recommended Installation: Maintain minimum ¼
inch per foot slope in horizontal runs. Slope toward
vent terminal. Position weld seams in vent pipes in
all horizontal runs at the top to avoid condensate
from lying on the seams. See Figure 9.
2. Alternate Installation: Maintain minimum ¼ inch
per foot slope in horizontal runs. Slope toward
boiler. Install a horizontal condensate drain tee after
rstelbow.Positionseamsinventpipesin
horizontal runs at top to avoid condensate from
lying on the seams.
Figure 9: Horizontal Vent Installation
V. Venting (continued)
CAUTION
Moisture and ice may form on surfaces around
vent terminal. To prevent deterioration, surfaces
should be in good repair (sealed, painted etc.)
3. Vent terminal location restricted per following:
a. Minimum 12 inches above grade or normally
expected snow accumulation level, or 7 feet
above grade if located adjacent to public
walkway. Do not install over public walkway
where local experience indicates condensate or
vapor from Category III appliances creates a
nuisance or hazard .
b. Minimum 3 feet above any forced air inlet
located within 10 feet.
c. Minimum 4 feet below, 4 feet horizontally from,
or 1 foot above any door, window, or gravity air
inlet.
d. Minimum 4 feet horizontally from electric
meters, gas meters, regulators, and relief valves.
e. Minimum 12 inches from overhang or corner.
4. Use single wall thimble when passing through
combustible outside wall (thimble use optional for
noncombustible wall). Insert thimble through wall
fromoutside.Secureoutsideangetowallwith
nails or screws, and seal with adhesive material.
Installinsideangetoinsidewall,securewithnails
or screws, and seal with adhesive material.
5. For noncombustible wall when thimble is not used,
size opening such that female (bell) end with
locking band attached cannot pass through.
6. Join vent terminal to vent pipe. Locate vent pipe
suchthatbell/lockingbandisushwithoutsidewall
(oroutsideangeofthimble,ifused)whenjoinedto
inside vent piping. See Figure 10.
7. Insert vent pipe through thimble/opening from
outside and join to vent system. Apply sealant
between vent pipe and opening/thimble to provide
weathertight seal.

14
Figure 11: Vertical Vent Installation
Figure 10: Horizontal Vent Terminal
V. Venting (continued)
H. Vertical (Through Roof) Vent Installation
1. Install vertical vent drain tee. See Figures 11 and 12.
Attach tee directly to elbow or horizontal pipe from
elbow.
2. Slope horizontal runs minimum ¼ inch per foot.
Slope toward vertical vent drain tee. Position weld
seams in vent pipes in all horizontal runs at the top
to avoid condensate from lying on the seams.
3. Installrestopsatoorandceilingwherevent
passesthroughoor,ceiling,orframedwall.The
restopmustclosetheoororceilingopening
between vent pipe and structure.
4. Enclose vent passing through unoccupied or
occupied spaces above the boiler with materials
havingareresistanceratingatleastequaltothe
ratingofadjoiningoororceiling.Maintain
minimum clearance to combustible materials.
 Note:Forone-ortwo-familydwellingsre
resistance rating requirement may not need to be
met, but is recommended.
5. Whenever possible install vent straight through roof.
Refer to Figure 13 if offset is necessary. Maintain
minimum clearance to combustible materials.
6. Install Vent Terminal. See Figure 14.
a. Locate roof opening to allow vertical vent
penetration. Size opening to maintain minimum
clearance from combustible materials.
b. Installroofashing.
c. Extend vent pipe to maintain minimum height
[H]aboveroofasspeciedinTable9.Vent
terminal must be minimum 2 feet horizontally
from roof surface and minimum 8 feet from any
vertical wall or similar obstruction. Provide
bracing as required in Table 9.

15
Figure 13: Attic Offset
Figure 12: Vertical Vent Tee Installation
Figure 14: Vertical Vent Termination
Table 9: Minimum Vent Height Above Roof
Roof Pitch Minimum Height [H]
Flat to 6/12 1 ft.
Over 6/12 to 7/12 1 ft. 3 in.
Over 7/12 to 8/12 1 ft. 6 in.
Over 8/12 to 9/12 2 in.
Over 9/12 to 10/12 2 ft. 6 in.
Over 10/12 to 11/12 3 ft. 3 in.
Over 11/12 to 12/12 4 ft.
Over 12/12 to 14/12 5 ft.
Over 14/12 to 16/12 6 ft.
Over 16/12 to 18/12 7 ft.
Over 18/12 to 20/12 7 ft. 6 in.
Over 20/12 to 18/12 8 ft.
d. Install storm collar on vent pipe immediately
aboveashing.Applysealantbetweenventpipe
and storm collar.
e. Attach Vent Terminal.
7. Install condensate drain line. Use 3/8 inch i.d. high
temperatureexibletubingsuchassiliconerubber
or EPDM. See Figure 12.
a. Form condensate trap with 6 inch diameter loop.
Secure loop with plastic cable tie. Fill with
water.
b. Secure to vertical vent tee with hose clamp or
plastic cable tie.
c. Runcondensatedrainlinetooordrainor
condensate pump. Condensate disposal must be
acceptable to authority having jurisdiction.
V. Venting (continued)

16
Figure 15: Wiring Diagram
VI. Electrical
A. General Install wiring and ground boiler in accordance
with requirements of authority having jurisdiction, or
in absence of such requirements the National Electrical
Code, ANSI/NFPA 70.
B. Install thermostat. Locate on inside wall
approximately4feetaboveoor.Donotinstallon
outsidewall,nearreplace,orwhereinuencedby
draftsorrestrictedairow,hotorcoldwaterpipes,
lightingxtures,television,orsunlight.Allowfreeair
movement by avoiding placement of furniture near
thermostat.
C. Wire thermostat. Remove transformer from junction
box. Provide Class II circuit between thermostat and
boiler. Connect circuit to blue wires to provide power
to thermostat. Connect circuit to brown wire to control
boiler operation. Set thermostat heat anticipator to 0.4
amps. See Figure 15.
D. Alliance SL™ Indirect Water Heater (if used) See
Figure 15, Ladder Diagram.
1. Attach extension junction box to junction box.
2. Provide two wire circuit between junction box and
temperature limit control (See Section III: Steam
Piping and Trim, Paragraph E.2). Use one red and
one orange wire if possible. Refer to Alliance SL™
Installation, Operating and Service Instructions.
E. Wire boiler. Boiler is rated for 120 VAC, 60 hertz,
less than 12 amperes. A separate electrical circuit must
be run from the main electrical service with an over-
current device/disconnect in the circuit. Connect circuit
to black and white wires and green ground screw. A
service switch is recommended and may be required by
some local jurisdictions. See Figure 15.
F. Mount transformer on junction box.

17
VII. System Start-up
A. Safe operation and other performance criteria were
met with gas manifold and control assembly provided
onboilerwhenboilerunderwenttestsspeciedin
American National Standard for Gas-Fired Low-
Pressure Steam and Hot Water Boilers, ANSI Z21.13.
Figure 16: Sequence of Operation
B. Fill boiler with water to normal water line.
C. Prepare to check operation.
1. Obtain gas heating value (in Btu per cubic foot)
from gas supplier.
2. Adjust limit. Set cutout pressure (MAIN scale) on
the pressure limit for (1) PSI and differential
pressure (DIFF.) for .5 PSI. These pressures may be
varied to suit individual requirements of the system.
See Figure 25.
3. Connect manometer to gas manifold. Use 1/8 NPT
tapping provided.
4. Temporarilyturnoffallothergas-redappliances.
D. Follow Operating Instructions to place boiler in
operation. See Figure 21.
E. Sequence of Operation See Figure 16.
1. If boiler fails to operate properly, see
Troubleshooting Tree on pages 30 and 31.
2. Enhanced Electronic Ignition Module with single
Status LED indicator. See Figure 17A “ Location of
LED”.
Figure 17A: Location of LED
Table 10 “Ignition Module Terminal Cross-
reference” cross-references the ignition module
terminal designations to the ignition terminal
numbers in the wiring ladder diagrams.
Table 11 “ Green LED Status Codes” provides green
LED status codes and recommended service action
where applicable.
See Figure 18 for Troubleshooting Guide.
3. Flame Current Measurement Procedure
See Figure 17B “Measuring Pilot Flame Current
with Micro-ammeter”.

18
Table 11: Green LED Status Codes
Ignition Module
Terminal Designation Wiring Ladder Diagram Terminal Number
MV 1
MV/PV 2
PV 3
GND 4
24V (GND) 5
24V 6
SPARK 9
Table 10: Ignition Module Terminal Cross-Reference
Green LED
Flash
Codea
Indicates Next System Action Recommended Service Action
OFF No “Call for Heat” N/A None
Flash Fast Power up - internal check N/A None
Heartbeat Normal startup - ignition sequence
started (including prepurge) N/A None
4 Seconds ON
then “x” ashes
Device in run mode.
“x” = ame current to the nearest µA. N/A None
2
5 minute Retry Delay
- Pilot ame not detected during trial
for ignition
Initiate new trial for ignition after
retry delay completed.
If system fails to light on next trial for
ignition check gas supply, pilot burner,
spark and ame sense wiring, ame rod
contamination or out of position, burner
ground connection.
3Recycle
- Flame failed during run
Initiate new trial for ignition. Flash
code will remain through the igni-
tion trial until ame is proved.
If system fails to light on next trial for igni-
tion, check gas supply, pilot burner, ame
sense wiring, contamination of ame rod,
burner ground connection.
4 Flame sensed out of sequence
If situation self corrects within 10
seconds, control returns to normal
sequence. If ame out of sequence
remains longer than 10 seconds,
control will resume normal opera-
tion 1 hour after error is corrected.
Check for pilot ame. Replace gas valve
if pilot ame present. If no pilot ame,
cycle “Call for Heat.” If error repeats,
replace control.
6 Control Internal Error
Control remains in wait mode.
When the fault corrects, control
resumes normal operation.
Cycle “Call for Heat”. If error repeats,
replace control.
7 Flame rod shorted to ground
Control remains in wait mode.
When the fault corrects, control
resumes normal operation.
Check ame sense lead wire for damage
or shorting. Check that ame rod is
in proper position. Check ame rod
ceramic for cracks, damage or tracking.
8Low secondary voltage supply- (be-
low 15.5 Vac)
Control remains in wait mode.
When the fault corrects, control
resumes normal operation.
Check transformer and AC line for proper
input voltage to the control. Check with
full system load on the transformer.
aFlash Code Descriptions:
- Flash Fast: rapid blinking
- Heartbeat: Constant ½ second bright, ½ second dim cycles.
- 4 second solid on pulse followed by “x” 1 second ashes indicates ame current to the nearest µA. This is only available in
run mode.
- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then repeats the
sequence.
VII. System Start-up (continued)

19
a. Pilotamecurrentinmicroampscanbe
measured using any standard micro-ammeter by
inserting the meter probes into the module holes
labeled FLAME CURRENT as shown in Figure
17B.
b. Flame current must be measured with pilot
valve open/pilot lit but the main valve closed.
c. Disconnect MV lead wire from the module
beforemeasuringamecurrent.Tryingto
measurethepilotamecurrentinserieswiththe
wiring will not yield the accurate reading.
d. The minimum steady pilot ame signal must
be 1 μAmp (microampere) DC (direct current).
e. For reliable operationtheamecurrentshould
be 2 μAmp or greater.
f. To ensure adequate ame current:
i. Turn off boiler power at circuit breaker or
fuse box
ii. Cleantheamerodwithemeryclothif
required
iii. Make sure electrical connections are clean
and tight, and wiring not damaged, repair/
replace as needed
iv. Check for igniter/sensor cracked ceramic
insulator, replace if needed
Figure 17B: Measuring Pilot Flame Current with Micro-ammeter
v. Checkthepilotame.Itmustbeblue,
steadyandenveloptheamesensingrod
3/8” to ½”.
vi. Ifneeded,adjustpilotamebyturningthe
gas valve pilot adjustment screw clockwise
to decrease or counterclockwise to increase
pilotame.Alwaysreinstallpilotadjustment
screw cover and tighten securely upon
completion to assure proper gas valve
operation.
g. Reconnect MV lead wire to the module upon
satisfactorycompletionofpilotamecurrent
measurement.
h. Check the pilot burner operation/ignition
sequence during ignition cycle:
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
v. If main burners do not light or if main
burners light but system locks out, check the
module ground wire and gas control as
described in Figure 18 “ Honeywell
Electronic Ignition Troubleshooting Guide”
VII. System Start-up (continued)

20
Honeywell Electronic Ignition Troubleshooting Guide
Figure 18: Troubleshooting Guide
"CALL FOR HEAT."
POWER TO
MODULE? (24 V
NOMINAL)
NO
YES
30 SECOND
PREPURGE
DELAY?(S8670
ONLY)
YES
SPARK
ACROSS IGNITOR/
SENSOR
GAP?
YES
NO
CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO,
CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED)
IS MADE.
REPLACE S8670
PULL IGNITION LEAD AND
CHECK SPARK AT MODULE. SPARK OK? NO
YES
CHECK IGNITION CABLE, GROUND WIRING, CERAMIC INSULATOR, AND SPARK GAP AND CORRECT.
CHECK BOOT OF THE IGNITION CABLE FOR SIGNS OF MELTING OR BUCKLING. TAKE PROTECTIVE ACTION TO SHIELD CABLE
AND BOOT FROM EXCESSIVE TEMPERATURES.
REPLACE MODULE
NO
TURN GAS SUPPLY ON AND
RECYCLE "CALL FOR HEAT."
PILOT BURNER
LIGHTS?
YES
NO
SPARK
STOPS WHEN
PILOT IS
LIT?
YES
NO
MAIN BURNER
LIGHTS?
YES
NO
SYSTEM
RUNS UNTIL "CALL
FOR HEAT"
ENDS?
YES
NO
CHECK THAT ALL MANUAL GAS VALVES ARE OPEN, SUPPLY TUBING AND PRESSURES ARE GOOD, AND PILOT BURNER
ORIFICE IS NOT BLOCKED (PILOT GAS FLOWING).
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND PILOT OPERATOR ON GAS CONTROL.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE, IF VOLTAGE IS OK, REPLACE GAS CONTROL. IF NOT,
REPLACE MODULE.
NOTE: IT MAY BE NECESSARY 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 GROUND WIRE.
CLEAN FLAME ROD.
CHECK ELECTRICAL CONNECTIONS BETWEEN FLAME ROD AND MODULE.
CHECK FOR CRACKED CERAMIC FLAME ROD INSULATOR.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE.
ADJUST PILOT FLAME.
IF PROBLEM PERSISTS, REPLACE MODULE.
CHECK FOR 24 VAC ACROSS PV-MV/PV TERMINALS ON MODULE. IF NO VOLTAGE, REPLACE MODULE.
CHECK ELECTRICAL CONNECTIONS BETWEEN MODULE AND GAS CONTROL INCLUDING SAFETY CONTROLS WIRED IN THE CIRCUIT. IF
OKAY, REPLACE GAS CONTROL.
NOTE: IF CONTROL GOES INTO LOCKOUT OR RETRY DELAY, RESET THE "CALL FOR HEAT."
CHECK CONTINUITY OF IGNITION CABLE AND GROUND WIRE.
NOTE: IF GROUND IS POOR OR ERRATIC, SHUTDOWNS MAY OCCUR OCCASIONALLY EVEN THOUGH OPERATION IS NORMAL
AT THE TIME OF CHECKOUT.
CHECK THAT PILOT FLAME COVERS FLAME ROD AND IS STEADY AND BLUE. PILOT FLAME MUST NOT BE MOVING AROUND DUE TO
OUTSIDE AIR FLOWS, ETC.
ADJUST PILOT FLAME. CHECK GAS PRESSURE MEETS APPLIANCE SPECIFICATIONS WHILE APPLIANCE MAIN BURNER IS ON AND ALL
OTHER GAS APPLIANCES ON THE SUPPLY ARE OPERATING AT FULL RATE.
IF CHECKS ARE OKAY, REPLACE MODULE.
"CALL FOR HEAT" ENDS
SYSTEM
SHUTS OFF? NO
CHECK FOR PROPER THERMOSTAT (CONTROLLER) OPERATION.
REMOVE MV LEAD AT MODULE. IF VALVE CLOSES, RECHECK TEMPERATURE CONTROLLER AND WIRING. IF NOT, REPLACE
GAS CONTROL.
VII. System Start-up (continued)