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U.S. Boiler Company SERIES 3 Installation, Operating And Service Instructions

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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
9700609
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 Model Number
30__B
Heating Contractor
Address
103796-07 - 12/14
SERIES 3™
Gas - Fired Boiler
Boiler Serial Number
Installation Date
Phone Number
Price - $5.00

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Summary of Contents for U.S. Boiler Company SERIES 3

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 3™ Gas - Fired Boiler 9700609 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.
  • Page 2 WARNINGS FOR ThE hOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings DO NOT BLOCK OR OBSTRUCT flow of printed in this manual and posted on the boiler. combustion and ventilation air into or around the boiler. Insufficient air may cause the boiler to INSPECT THE BOILER ANNUALLY.
  • Page 3 WARNINGS FOR ThE INSTALLER READ THIS ENTIRE MANUAL before attempting ADHERE TO ALL LOCAL CODE REQUIREMENTS. installation, start-up, or service. Improper 1. Installation must conform to requirements installation, adjustment, alteration, service, or of authority having jurisdiction or in the maintenance may cause serious property damage, absence of such requirements, with the personal injury, or death.
  • Page 4 Congratulations on your purchase of a new Series 3 boiler—designed and constructed to provide you with years of reliable service. • Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger. • IQ Control™ – the most advanced and easiest to use control available.

  • Page 5: Specifications

    SPECIFICATIONS Ratings Series 3 Net AHRI Rating, Water Input (MBH) DOE Heating Capacity (MBH) AFUE (%) Boiler Model (MBH) 303B 84.0 304B 84.0 305B 84.0 306B 84.0 307B 84.0 308B 84.0 309B 84.0 Input ratings can be used for elevations up to 2000 ft (600 m). Refer to Appendix F for elevations 2000 ft (600 m) or higher.
  • Page 6 SPECIFICATIONS (continued) Weights and Volume Boiler Model Shipping Weight (lbs) Empty Weight (lbs) Water Content (gal) 303B 304B 305B 306B 307B 308B 309B Figure S-1: Minimum Clearances to Combustibles and Alcove Dimensions...

  • Page 7: Table Of Contents

    BOILER QUICk-START Installation: Unpack the crate ..................... 8 Position the boiler .................... 9 Provide combustion air .................. 10 Connect venting ..................... 10 Connect gas piping ..................11 Connect boiler water piping ................12 Connect electrical wiring ................14 Program the controls ..................15 Check for gas and water leaks ..............

  • Page 8: Unpack The Crate

    1. UNPACk ThE CRATE Tip the boiler and shimmy it off the skid THE BOILER IS TOP-HEAVY. Do not (Figure 1-b). allow it to tip over. Remove the sleeve. Remove the contents from the skid, except the boiler. Remove the four (4) hex-drive lag screws holding the boiler to the skid (Figure 1-a).

  • Page 9: Position The Boiler

    2. POSITION ThE BOILER WARNINGS OBSERVE MINIMUM CLEARANCES to CLEAN BURNERS DAILY if operating the boiler in combustible walls and ceilings to avoid potential a dusty environment. fire hazard. PROTECT IGNITION SYSTEM COMPONENTS DO NOT INSTALL ON CARPET. This may cause from sources of water that may spray, drip, or rain a fire.

  • Page 10: Provide Combustion Air

    Observe all general venting guidelines provided in Appendix B—Venting. Additionally: Install any of the following for this Series 3 Category I, draft hood equipped appliance: a. Type B or Type L gas vent. Install in accordance with listing and manufacturer's instructions.

  • Page 11: Connect Gas Piping

    4. CONNECT VENTING (continued) a. Do not modify either draft hood for vent damper. b. Maintain minimum 6" (152 mm) between vent damper and combustible construction. c. Position indicator must be visible following installation. Using sheetmetal screws, attach the vent connector between the vent damper and the vertical chimney (Figure 4-b).

  • Page 12: Connect Boiler Water Piping

    6. CONNECT BOILER WATER PIPING General system piping guidelines are included in Screw the relief valve into manifold tapping Appendix D—System Piping. “RV”. Additionally, for this particular boiler install piping This installation is not complete until the shown below (Figure 6-a). relief valve is installed.
  • Page 13 6. CONNECT BOILER WATER PIPING (continued) Item Description Part Number 1¼ x 1¼ x ½ Tee 806601021 Immersion Well, ½ NPT 80160456 1¼ x 6 Nipple 806600029 1¼ Tee 806601030 1¼ x ¾ Bushing 806600504 LWCO Sensor, ¾ NPT 102305-01 1¼...

  • Page 14: Connect Electrical Wiring

    7. CONNECT ELECTRICAL WIRING DISCONNECT ELECTRICAL POWER to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock electrical boxes to prevent someone from inadvertently restoring power before the heating system is safe to operate. NEVER DEFEAT OR JUMP OUT safety devices.

  • Page 15: Program The Controls

    8. PROGRAM ThE CONTROLS Using Intelligent Hydronic Control Display . Press and release the “I” key on the control to change from one parameter to The Intelligent Hydronic Control (control) is located the next. Each setting will alternately flash inside the boiler front door, just above the IQ between the relevant display code and its Option Panel (Figure 8-a).
  • Page 16 8. PROGRAM ThE CONTROLS (continued) Please note that in operating mode to hold the The Outdoor Reset IQ Option Card reduces display on the value the user can press and hold the Operating Setpoint to regulate heat either the Up ñ or Down ò keys and the value delivery, increase home comfort and will be continuously shown.
  • Page 17 8. PROGRAM ThE CONTROLS (continued) Table 8a: Circulator Pre-purge Time example, Domestic Hot Water (DHW) Terminal (PP_ = 2 minutes) Function (dh_) The control allows configuration of the Call for Boiler DHW Circulator output functionality to help Heat Terminal Burner Status Temperature the Boiler integrate into each installation Source...

  • Page 18: Check For Gas And Water Leaks

    8. PROGRAM ThE CONTROLS (continued) b. When dh_ is set equal to Second Heating Using the IQ Option Panel Zone (tt2) IQ Option Cards are available from U.S. Boiler When there is no IWH the “DHW Company distributors and are the simplest way Circulator”...

  • Page 19: Perform Startup Checks And Adjustments

    10. PERFORM STARTUP ChECkS AND ADjUSTMENTS FAILURE TO PERFORM THESE CHECKS of the boiler's combustion and safety systems may result in serious property damage, injury, or death. IF YOU SMELL GAS, STOP and repair the leak. Lighting the boiler when gas is leaking may cause explosion or fire.

  • Page 20: Annual Maintenance Checklist

    10. PERFORM STARTUP ChECkS AND ADjUSTMENTS (continued) Return high limit to the desired setting (see Check combustion in the vent stack and "Programming High Limit" in Section 8). record results in the spaces provided below. _____ CO (less than 7%) Check draft.
  • Page 21 ANNUAL MAINTENANCE ChECkLIST (continued) Equipment you will need: Hold burner at throat. Lift front of burner to clear orifice (Figure AM-1). The q Soft bristle brush burner that holds the pilot can only be q Bristle flue brush removed by first lifting the burner q Vacuum with brush attachment adjacent to its right.
  • Page 22 ANNUAL MAINTENANCE ChECkLIST (continued) AM-2 Operating Instructions, VR8204 and VR8304 Gas Valves...

  • Page 23: Troubleshooting

    TROUBLEShOOTING Before troubleshooting wiring diagram in Figures IW-1 and IW-2. Ensure that incoming 120 Vac power polarity The following pages contain trouble shooting is correct and that the boiler is properly tables for use in diagnosing control problems. grounded. Further, ensure that the control When using these tables the following should power supply is 24 VAC (minimum 18 VAC be kept in mind:...
  • Page 24 TROUBLEShOOTING (continued) Use Control Display ERR (error) Number To Direct Troubleshooting Efforts If the control detects an error it will flash “Err” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below. If there is no Err display proceed to next Section: Display Status...
  • Page 25 TROUBLEShOOTING (continued) Use STA (status) Number To Guide Troubleshooting The control will flash “STA” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator Off Display / Status Recommended Corrective Action The boiler has not detected a call for heat (tt = off and dh = off).
  • Page 26 TROUBLEShOOTING (continued) 5. Circulator is On But Damper is Not Open Display / Status Recommended Corrective Action The control is waiting for the damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless the damper blade is in the fully open position. Check the following: - During status “STA18"...
  • Page 27 TROUBLEShOOTING (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while STA 6 is displayed? - If there is no spark noise replace the control. b. If you can hear spark noise check the following: - Loose connection in ignition cable or ground wire - Continuity of ignition cable - Break in ignition cable insulation...
  • Page 28 TROUBLEShOOTING (continued) If Control Shows Status Code “STA 15": The control is “Waiting for Limit to Close” and the display on the IQ Option Panel should be the first place to check. The IQ Option Panel display (lower display) will show one of the following status codes: IQ Option Panel Display Shows “ERR"...

  • Page 29: Repair Parts List

    REPAIR PARTS LIST All Series 3™ Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S.
  • Page 30 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 Base Tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091...
  • Page 31 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Gas Valve (Natural Gas), 81660282 Honeywell VR8204P1171 Gas Valve (Natural Gas), 81660283 Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell 81660146 VR8204C3015 Gas Valve (LP Gas), Honeywell 81660160 VR8304P4314 ½"...
  • Page 32 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Control 103660-01 IQ Option Panel 102291-01 Transformer 102516-01 Temperature Sensor 102411-01 Temperature Sensor Spring Clip (not shown) 102422-01...
  • Page 33 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Jacket Left Side Panel 102566-01 Jacket Right Side Panel 102567-01 Jacket Rear Panel 102569-03 102569-04 102569-05 102569-06 102569-07 102569-08 102569-09 Jacket Vestibule Panel 102565-03 102565-04 102565-05 102565-06 102565-07...
  • Page 34 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Supply Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 30 PSI Relief Valve 81660363 Drain Valve 102802-01 Vent Damper 102284-01 102284-02 102284-03 102284-04 102284-05 Circulator (not shown): Taco 007-2 8056170 Grundfos UP-15...

  • Page 35: Internal Wiring

    INTERNAL WIRING Figure IW-1: Wiring Diagram...
  • Page 36 INTERNAL WIRING (continued) Figure IW-2: Wiring Schematic...
  • Page 37 INTERNAL WIRING (continued) Figure IW-3: Multiple Zone System with Zone Circulators Figure IW-4: Multiple Zone System with Zone Valves...
  • Page 38 INTERNAL WIRING (continued) Figure IW-5: Multiple Zone System with Zone Circulator Panel DHW AQUASTAT (L4006, L4080) POWER (SUPPLIED BY OTHERS) SUPPLY 120/60/1 THERMOSTAT THERMOSTAT THERMOSTAT TRANSFORMER DOMESTIC HOT WATER PRIORITY IS SELECTED USING ZONE PANEL SWITCH MODE ZONE 4 PRIORITY NORMAL RESET IQ OPTION PANEL POWER IN...

  • Page 39: Appendices: A - Combustion Air

    APPENDIX A – COMBUSTION AIR If the Floorspace from Step 1 is less than the PROVIDE ENOUGH AIR to ventilate the Minimum Floorspace from Step 3, then you boiler room, dilute the flue gases, and must provide outdoor air to the boiler room. sustain combustion.

  • Page 40: B - Venting

    APPENDIX B – VENTING VENT THIS BOILER according to the instructions. Failure to do so may cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Install this boiler according to this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA 54, the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
  • Page 41 APPENDIX B – Venting (continued) Au moment du retrait d’une chaudière Une fois qu’il a été déterminé, selon existante, les mesures suivantes doivent la méthode indiquée ci-dessus, que être prises pour chaque appareil toujours chaque appareil raccordé au système raccordé au système d’evacuation d’évacuation est mis à...
  • Page 42 APPENDIX B1 – ATMOSPhERIC VENTING GENERAL WARNINGS FOR ATMOSPhERIC VENTING SYSTEMS USE ATMOSPHERIC VENTING only with Exception: National Fuel Gas Code, boilers approved for atmospheric venting as ANSI Z223.1/NFPA 54, and Natural Gas noted in the Specifications Section of this and Propane Installation Code, CAN/ manual.
  • Page 43 APPENDIX B1 – ATMOSPhERIC VENTING (continued) Install vent and vent connector (Figure B-1). Vent installation shall be in accordance with "Venting of Equipment," of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or "Venting systems and Air Supply for Appliances," of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

  • Page 44: C - Gas Piping

    APPENDIX C – GAS PIPING Table C-3: Specific Gravity Correction Factors For ASSURE GAS PIPING IS LEAK FREE Natural Gas AND OF PROPER SIZE and type for the connected load. Specific Correction Specific Correction Gravity Factor Gravity Factor SHUT OFF MAIN GAS SUPPLY prior to installing or servicing boiler gas piping.

  • Page 45: D - System Piping

    APPENDIX C – Gas Piping (continued) Bond all above-ground gas piping to a When testing at ½ psig (3.5 kPa) or less, grounding electrode and ensure the piping is isolate boiler from gas supply piping by electrically continuous. closing boiler’s individual manual shut- off valve.
  • Page 46 APPENDIX D – System Piping (continued) Overpressure boiler bypass, system bypass, or primary-secondary loop when needed to Install a properly sized expansion tank. maintain water temperatures and flows Do not exceed the boiler’s specific within the specified limits. requirements for maximum allowable (3) Do not allow chilled water to enter the working pressure.

  • Page 49: E - Filling The System And Checking For Leaks

    APPENDIX E – FILLING ThE SYSTEM AND ChECkING FOR LEAkS Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling. Close full port ball valve located between Open the zone valve or shut-off valve vertical hose bib and air scoop in boiler...

  • Page 50: F - Adjusting Gas Input Rate

    APPENDIX F – ADjUSTING GAS INPUT RATE Input ratings shown on boiler rating label can be used for elevations up to 2000 ft (600 m). United States. For elevations 2000 ft (600 m) or higher, reduce input rate 4 percent per 1000 ft (300 m) above sea level.
  • Page 51 APPENDIX F – Adjusting Gas Input Rate (continued) R echeck Main Burner Flame. Do not force the adjustment screw. Leak Test Gas Piping: The BoiLeR ANd iTS GAS Liquefied Petroleum Gases (LP/Propane). Adjust gas valve pressure regulator to CoNNeCTioNS must be leak tested and provide outlet pressure of 10 inches water leak free before placing boiler in operation. column. FoR LeAk TeSTiNG oveR ½ PSiG (3.5kPa), disconnect boiler and its Natural Gas. Adjust gas valve pressure individual shut-off valve from gas supply piping. regulator to provide outlet pressure of 3.5 inches water column. Check input rate by For testing at ½ psig (3.5 kPa) or less, clocking gas meter. isolate boiler from gas supply piping by • Adjust gas valve pressure regulator, if closing boiler’s individual manual shut-off necessary, to change input rate (turn valve. counterclockwise to decrease pressure Check for gas leaks in all piping joints, and decrease input rate, see Figure F-2).

  • Page 52: G - Checking Draft And Combustion

    APPENDIX G – ChECkING DRAFT AND COMBUSTION CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) After 5 minutes of main burner operation, Insofar as is practical, close all doors and test for spillage at the draft hood relief windows in the building. opening, using a lighted match, candle, Turn on all appliances not connected to the cigarette, etc.

  • Page 53: H - Operation

    APPENDIX h – OPERATION Boiler Sequence of Operation Table 4: Sequence of Operation NORMAL OPERATION Status Codes displayed in STA Mode The boiler is equipped with an Intelligent Status Description Hydronic Control (control). This control Standby replaces the traditional separate ignition (Burner off No call for heat detected control, high limit switch and circulator relay...

  • Page 54: I - Iq Control System

    APPENDIX I – IQ CONTROL SYSTEM • Ensures adequate heat and supply of IQ Control System Overview domestic hot water. The “IQ Control System” consists of a control and • UL / CSA Listed or Recognized and tested an IQ Option Panel with optional “plug in” cards: as part of a complete system.
  • Page 55 APPENDIX I – IQ Control System (continued) IQ Outdoor Reset Option Card: P/N 105648-01 Installing the IQ Outdoor Reset Option Card is the simplest way to maximize the efficiency of any boiler. The IQ Outdoor Reset Card is a microprocessor- based control that regulates the water temperature of the heating system based on the outdoor temperature.
  • Page 56 APPENDIX I – IQ Control System (continued) IQ Hi Limit Option Card (Auto Reset): P/N 102717-01 IQ Hi Limit Option Card (Manual Reset): P/N 102720-01 IQ High Limit Option Cards add auxiliary temperature limit-rated controls to boilers. High Limit Option Cards plug into the IQ Option Panel and connect to a system-mounted probe with a single Molex connection.
  • Page 57 APPENDIX I – IQ Control System (continued) stem Parts List Optional Components Part Number Item Description Outside Reset IQ Option Card, Domestic Hot Water Priority, for use with Option Control Panel, with Outside 105648-01 Air Temperature Sensor with 60 inch lead, Instructions, Unit Pack. No additional pipe fittings required. Contact Factory Outdoor Reset IQ Option Card, Domestic Hot Water Priority, for use with IQ Option Panel, less Sensor.
  • Page 60 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...

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