U.S. Boiler Company X-203 Installation, Operating And Service Manual
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U.S. Boiler Company X-203 Installation, Operating And Service Manual

X-2 series
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
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
X-20
Heating Contractor
Address
106636-01 - 10/15
X-2 ™ Series
Cast Iron Gas - Fired Boiler
Boiler Serial Number
9700609
Installation Date
Phone Number
Price - $5.00

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Summary of Contents for U.S. Boiler Company X-203

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR X-2 ™ Series Cast Iron 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. Boiler Model Number Boiler Serial Number Installation Date...

  • Page 2: Table Of Contents

    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 X-2™ Series 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.
  • Page 3 Table 1A: Dimensions and Connections Boiler Supply NPT Return NPT Vent Gas NPT Relief Valve Drain Depth Width Height Model (inch) (inch) (inch) (inch) NPT (inch) NPT (inch) X-203 1¼ 1¼ ½ ¾ ¾ X-204 1¼ 1¼ ½ ¾ ¾ X-205 1¼ 1¼ ½...
  • Page 4 Figure 1: Minimum Clearance to Combustible Materials and Alcove Dimensions...

  • Page 5: Pre-Installation

    I. Pre-Installation Install on level floor. For basement installation provide WARNING concrete base if floor is not level or if water may be encountered on floor around boiler. Carefully read all instructions before installing boiler. Failure to follow all instructions in proper CAUTION order can cause personal injury or death.

  • Page 6: Water Piping And Trim

    III. Water Piping and Trim appropriate valves to prevent chilled medium from WARNING entering boiler. See Figure 3. Also consult Residential Hydronic Heating Installation and Design I=B=R Failure to properly pipe boiler may result in Guide. improper operation and damage to boiler or If boiler is connected to heating coils located in building.

  • Page 9: Venting

    IV. Venting Install Vent Damper OPEN THE VENT DAMPER CARTON and remove the Installation Instructions. READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding. The automatic gas control valve supplied on each X-2 Series boiler provides the redundancy referenced in the vent damper Installation Instructions. CAUTION Do not use one vent damper to control two heating appliances.
  • Page 10 IV. Venting (continued) building. Turn on clothes dryers and any appliance f. After it has been determined that each appliance not connected to the common venting system. remain ing connected to the common venting system Turn on any exhaust fans, such as range hoods and properly vents when tested as outlined above, return bathroom exhausts, so they will operate at maxi mum doors, win dows, exhaust fans, fireplace dampers and...

  • Page 11: Gas Piping

    V. Gas Piping Size gas piping. Design system to provide adequate gas 4. All above ground gas piping upstream from manual supply to boiler. Consider these factors: shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas 1.

  • Page 12: Electrical

    VI. Electrical General. Install wiring and electrically bond boiler to For installations using zone valves provide separate ground in accordance with requirements of authority transformer for zone valve wiring. Consult zone valve having jurisdiction, or in absence of such requirements, manufacturer for assistance.

  • Page 13: X-204

    VI. Electrical (continued) Figure 8: Wiring Connection Diagram...

  • Page 14: X-205

    VI. Electrical (continued) Figure 9: Schematic Ladder Diagram...

  • Page 15: X-206

    VI. Electrical (continued) Figure 10: Wiring Schematic, Zone Valves Figure 11: Wiring Schematic, Zone Circulators...

  • Page 16: System Start-Up And Checkout

    VII. System Start-up and Checkout . Main Burner Check - Check main burners to see that they were not dislodged during shipment. Rear of burners should be in the vertical slots in the rear of burner tray and the front of the burners should be seated completely on the orifices.

  • Page 17: X-208

    VII. System Start-up and Checkout (continued) Figure 14: Operating Instructions...

  • Page 18: X-209

    12,000 ft. See Table below. Input [Mbh] Boiler Rating 5000 ft. 7,000 ft. 10,000 ft. Model Figure 15: Main Burner Flame Label (1525 m) (2130 m) (3050 m) X-203 70.0 56.0 49.0 42.0 CAUTION X-204 105.0 84.0 73.5 63.0 X-205 140.0 112.0...
  • Page 19 VII. System Start-up and Checkout (continued) Combustion Chamber Burn-off 1. The mineral wool combustion chamber panels may contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation. 2. Ventilate the boiler room, set the high limit to its maximum setting, set the thermostat to call for heat.

  • Page 20: Operation

    VIII. Operation BOILER FAULT BOILER SEQUENCE OF OPERATION In the event the boiler fails to start, the control provides NORMAL OPERATION status information to help determine the cause of the 1. The X-2 Series Boilers are equipped with an problem. Table 3 provides a list of boiler status codes Intelligent Hydronic Control (control).
  • Page 21 VIII. Operation (continued) USING DISPLAY Status Code Displayed in STA Mode The control is located inside the boiler front door. Standby (Figure 17). Prepurge Spark Flame Proving Running Retry/Recycle Delay Soft Lockout Hard Lockout Waiting for Limit to Close Flame Present Out of Sequence Self Test Waiting for Damper to Open Figure 17: Intelligent Hydronic Control...
  • Page 22 VIII. Operation (continued) 3. Press the Up  and Down  keys to adjust the Table 4: Circulator Pre-purge Time example, displayed item to the desired value. (PP_ = 2 minutes) 4. To return to the normal operating mode from Call for the Adjustment Mode, when the "bAc”...
  • Page 23 VIII. Operation (continued) Table 5: DHW Terminal Function (dh_) When there is a DHW call for heat, the System Selection = Domestic Hot Water Demand, Circulator is “forced off”, the DHW Circulator (Parameter dh_ = dh) terminal is energized and the circulator pre-purge time delay control logic is bypassed to allow Call for Heat Circulator Status...

  • Page 24: Service And Maintenance

    IX. Service and Maintenance Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 25 IX. Service and Maintenance (continued) WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.
  • Page 26 IX. Service and Maintenance (continued) Lubrication. There are no parts requiring lubrication by service technician or owner. Circulator bearings are water lubricated.

  • Page 27: Troubleshooting

    X. Troubleshooting is properly grounded. Further, ensure that the control BEFORE TROUBLESHOOTING power supply is 24 VAC (minimum 18 VAC to The following pages contain trouble shooting tables for maximum 30 VAC) and polarity is correct. use in diagnosing control problems. When using these tables the following should be kept in mind: 4.
  • Page 28 X. 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 Paragraph C: Display Status Recommended Corrective Action...
  • Page 29 X. 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 30 X. 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 31 X. Troubleshooting (continued) 6. Circulator is On, Damper is Open But Boiler Fails to Start (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.

  • Page 32: Repair Parts

    All X-2 Series 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. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 33 XI. Repair Parts (continued) [Quantity] Part Number Description X-203 X-204 X-205 X-206 X-207 X-208 X-209 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...
  • Page 34 XI. Repair Parts (continued) [Quantity] Part Number Description X-203 X-204 X-205 X-206 X-207 X-208 X-209 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...
  • Page 35 XI. Repair Parts (continued) [Quantity] Part Number Description X-203 X-204 X-205 X-206 X-207 X-208 X-209 Control 103660-01 Transformer 102516-01 Temperature Sensor 103195-01 Temperature Sensor/LWCO (if equipped) 106495-02 Temperature Sensor Spring Clip (not shown) 102422-01...
  • Page 36 XI. Repair Parts (continued) [Quantity] Part Number Description X-203 X-204 X-205 X-206 X-207 X-208 X-209 Jacket Wrap-around Jacket 106357-03 106357-04 106357-05 106357-06 106357-07 106357-08 106357-09 Panel Jacket Vestibule Panel 106358-03 106358-04 106358-05 106358-06 106358-07 106358-08 106358-09 Jacket Rear Discharge 102549-03...
  • Page 37 XI. Repair Parts (continued) [Quantity] Part Number Description X-203 X-204 X-205 X-206 X-207 X-208 X-209 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 Taco 007 (not shown)
  • Page 40 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...

This manual is also suitable for:

X-204X-205X-206X-207X-208X-209

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