Table of Contents
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Installation, Operating and Service Instructions for
X-2
Models:
• X-202
• X-203
• X-204
• X-205
• X-206
• X-207
• X-208
• X-209
Manual Contents
Dimensional and Physical Data . . . . . . . . . . . . 3
Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing Existing Boiler . . . . . . . . . . . . . . . . . 6
Unpack Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System Start-Up and Checkout . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Before Leaving Jobsite . . . . . . . . . . . . . . . . . . 27
Service and Maintenance . . . . . . . . . . . . . . . . 28
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 34
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
Provide model number and serial number when
seeking information and support.
TO THE CONSUMER:
Retain these instructions for future reference.
Contact heating contractor for all issues and support.
Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, consult a qualified installer, service agency or gas
supplier. Read these instructions carefully before installing.
106636-02 - 12/19
TM
Page
9700609
!
WARNING
• Water Boiler
• Cast Iron
• Chimney Vent
• Gas Fired
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Table of Contents
Related Manuals for U.S. Boiler Company X-2 X-202
Summary of Contents for U.S. Boiler Company X-2 X-202
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Page 1: Table Of Contents
Installation, Operating and Service Instructions for • Water Boiler • Cast Iron • Chimney Vent • Gas Fired Models: • X-202 • X-203 • X-204 • X-205 • X-206 • X-207 • X-208 • X-209 Manual Contents Page Dimensional and Physical Data . . . . . . . . . . . . 3 Pre-Installation . - Page 2 Installation, Operating & Service Manual 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 listed the X-2 Series Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, https://licensing .reg .state .ma .us/pubLic/pl_products/pb_product .asp for the latest Approval Code or ask your local Sales Representative.
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Page 3: Dimensional And Physical Data
Installation, Operating & Service Manual Dimensional and Physical Data Table 1-1: 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-202 1¼ 1¼ ½... - Page 4 Installation, Operating & Service Manual Dimensional and Physical Data (continued) Model "W" X-202 14" X-203 14" X-204 16" X-205 19" X-206 22" X-207 25" X-208 28" Figure 1-3: Minimum Closet Clearances Model "W" X-209 31" Figure 1-4: Minimum Alcove Clearances Minimum radial clearance around vent pipe and breeching for single-wall metal pipe vent connector.
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Page 5: Pre-Installation
Installation, Operating & Service Manual Pre-Installation Install on level floor. For basement installation WARNING provide 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 WARNING order can cause personal injury or death. -
Page 6: Removing Existing Boiler
Installation, Operating & Service Manual Removing Existing Boiler A. If an Existing Boiler is Removed: 4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) When an existing boiler is removed from a Instructions. Adjust thermo stat so appliance common venting system, the common venting will operate continuously. -
Page 7: Venting
Installation, Operating & Service Manual Venting A. Inspect chimney and remove any obstructions 1. Type B or Type L gas vent. Install in or restric tions. Clean chimney if previously used accordance with listing and manufacturer's for solid or liquid fuel-burning appliances or instructions. - Page 8 Installation, Operating & Service Manual Venting (continued) 4. Vent pipe to chimney must not be smaller than outlet on draft hood or vent damper. Arrange venting system so boiler is served by vent damper device. Exception: National Fuel Gas Code, ANSI Z223.1/NFPA 54, and allow vent downsizing when vent size determined by their Vent Sizing...
- Page 9 Installation, Operating & Service Manual Venting (continued) Install vent termination (Masonry chimney and 2. For terminations located at least 8 ft. from single wall metal pipe) vertical wall or similar obstruction, termination shall extend above roof in accordance with 1. Termination shall extend at least 5 ft. Figure 5-3.
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Page 10: Water Piping
Installation, Operating & Service Manual Water Piping WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or building. 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, fittings, and oxygen permeable materials in distribution system. - Page 11 Installation, Operating & Service Manual Water Piping (continued) 106636-02 - 12/19...
- Page 12 Installation, Operating & Service Manual Water Piping (continued) 106636-02 - 12/19...
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Page 13: Gas Piping
Installation, Operating & Service Manual 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. Minimum gas valve inlet pressure is listed on rating label. -
Page 14: Electrical
Installation, Operating & Service Manual Electrical D. For installations using zone valves, provide WARNING separate transformer for zone valve wiring. Electrical Shock Hazard . Wiring errors can Consult zone valve manufacturer for assistance. cause improper or dangerous operation. Verify See Figure 8-3. proper operation after installation. - Page 15 Installation, Operating & Service Manual Electrical (continued) Figure 8-1: Wiring Connection Diagram 106636-02 - 12/19...
- Page 16 Installation, Operating & Service Manual Electrical (continued) Figure 8-2: Schematic Ladder Diagram 106636-02 - 12/19...
- Page 17 Installation, Operating & Service Manual Electrical (continued) Figure 8-3: Wiring Schematic, Zone Valves Figure 8-4: Wiring Schematic, Zone Circulators 106636-02 - 12/19...
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Page 18: System Start-Up And Checkout
Installation, Operating & Service Manual System Start-up and Checkout A. Visual Main Burner Check D. Purge Air from System Inspect burners for dislodgement during 1. Fill entire heating system with water and shipment. Rear of burners should be in vertical vent air from boiler, radiators and system, slots in rear of burner tray and front of burners one zone at a time. - Page 19 Installation, Operating & Service Manual System Start-up and Checkout (continued) Figure 9-2: Operating Instructions 106636-02 - 12/19...
- Page 20 Installation, Operating & Service Manual System Start-up and Checkout (continued) E. Perform gas leak test upstream of boiler shutoff 3. Locate and address leaks using listed valve. combustible gas detector,a non corrosive leak detection fluid or other listed leak 1. Protect boiler gas valve. detection method.
- Page 21 Installation, Operating & Service Manual System Start-up and Checkout (continued) J. Check Main Burner Flame (see Figure 9-6) valve can prevent pressure surge that blows out manometer fluid. 1. NORMAL FLAME: 2. Adjust regulator on gas valve so manifold a. Clearly defined inner cone with no yellow pressure matches values listed on rating label.
- Page 22 Installation, Operating & Service Manual System Start-up and Checkout (continued) P. Check ignition system safety shut-off device. After control has finished sparking, remove ignitor/ flame sense wire from control. Burners will shut down. Q. Test LWCO functionality Press "TEST" button on IDL 1200. See Figure 9-1. Boiler should shut down.
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Page 23: Operation
Installation, Operating & Service Manual Operation Table 10-1: Sequence of Operation A. Boiler Sequence of Operation (See Table 10-1) 1. When thermostat calls for heat, control starts Status Codes displayed in STA Mode system circulator. Status Description Standby 2. If thermostat is not satisfied with residual (Burner off No call for heat detected heat in boiler, or boiler water temperature is... - Page 24 Installation, Operating & Service Manual Operation (continued) Viewing the Operating Mode Options Table 10-3 In operating mode, user may view (but Adjustable Parameters not change) boiler operating status, settings and Default Range Description troubleshooting information. 180oF 140-220°F Adjust High Limit Setting For example, when “I”...
- Page 25 Installation, Operating & Service Manual Operation (continued) Table 10-5: Circulator Pre-purge Time example, More Information About Adjustable Parameters (PP_ = 2 minutes) 1. High Limit (HL_) Call for Burner turns "off" when boiler water Boiler Heat Terminal Burner Status temperature (bt) is above this value. Temperature Source Selection...
- Page 26 Installation, Operating & Service Manual Operation (continued) 7. Domestic Hot Water (DHW) Terminal Function (dh_) b. Second heating zone (dh_ is set to second heating zone (tt2)) DHW Circulator output can be connected to a domestic hot water circulator or a second Helpful when home uses only two heating heating zone circulator.
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Page 27: Before Leaving Jobsite
Installation, Operating & Service Manual Before Leaving Jobsite Before Leaving Jobsite: Boiler and system filled with water Performed gas leak test Checked pilot burner flame Checked main burner flames Checked gas input rate Checked gas inlet pressure ... -
Page 28: Service And Maintenance
Installation, Operating & Service Manual Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen. - Page 29 Installation, Operating & Service Manual 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.
- Page 30 Installation, Operating & Service Manual Service and Maintenance (continued) 1. Water temperature needle should move with D. Clean Main Burners and Firebox. variation in water temperature. 1. To remove burners for cleaning, changing 2. Pressure needle should move with variation in orifices, or repairs: pressure.
- Page 31 Installation, Operating & Service Manual Service and Maintenance (continued) Q. Test Vent Damper Operation Vent damper must be in open position when main burners are operating. R. Test Functionality of LWCO See "Start-up and Checkout - Check LWCO Functionality. S. Check High Limit Control See "...
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Page 32: How It Works
Installation, Operating & Service Manual How It Works X-2 boilers are equipped with an Intelligent Hydronic Control. This control combines features such as ignition control, high limit switch, and circulator relays. Energy is saved by using a thermal purge feature that starts the circulator and delays burner start when residual heat is available in boiler. - Page 33 Installation, Operating & Service Manual How It Works (continued) Rear of Boiler (On rear of boiler) UNLESS OTHERWISE NOTE ALL DIMENSIONS IN INCH TOLERANCES: X.X ±.1 X.XXX ±.005 X.XX ±.03 ANGLE ±1° PROPER U.S. Boiler Co LANCAST THIS DOCUMENT CONTAINS CO AND ITS CONTENTS ARE THE SO COMPANY, INC.
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Page 34: Troubleshooting
Installation, Operating & Service Manual Troubleshooting A. Before Troubleshooting B. IDL 1200 LWCO: Amber "LOW WATER" LED indicates the boiler is not sensing water in boiler. When using troubleshooting tables, keep in mind: 1. If AMBER LED is ON and boiler is filled with 1. - Page 35 Installation, Operating & Service Manual Troubleshooting (continued) C. Use Control Display ERR (ERROR) Number To Direct TroubleShooting Efforts If control detects an error it will flash “Err” (ERROR) followed by a number. Use this number to identify boiler problem and corrective action in table below. If there is no Err display, proceed to Troubleshooting Section D: Display Status Recommended Corrective Action...
- Page 36 Installation, Operating & Service Manual Troubleshooting (continued) D. 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 table below: 1 . Boiler and Circulator Off Display / Status Recommended Corrective Action Boiler has not detected a call for heat (tt = ff and dh = ff).
- Page 37 Installation, Operating & Service Manual Troubleshooting (continued) 5 . Circulator is On But Damper is Not Open Display / Status Recommended Corrective Action Control is waiting for damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless damper blade is in the fully open position.
- Page 38 Installation, Operating & Service Manual 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.
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Page 39: Service 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 40 Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description X-202 X-203 X-204 X-205 X-206 X-207 X-208 X-209 Base Wrapper Base Tray Burner Tray Base Side Insulation Base Rear Insulation Base Front Insulation Drip Shields Manifold Support 109613-02 109613-03 109613-04 109613-05...
- Page 41 Installation, Operating & Service Manual Service Parts (continued) Natural Gas Only Part Number [Quantity] Description X-202 X-203 X-204 X-205 X-206 X-207 X-208 X-209 Gas Valve (Natural Gas), 109620-01 [1] Honeywell VR8204C3007 Gas Valve (Natural Gas), 109622-01 [1] Honeywell VR8304P4496 Gas Valve (LP Gas), 109615-01 [1] Honeywell VR8204C3015 Gas Valve (LP Gas),...
- Page 42 Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Key No. Description X-202 X-203 X-204 X-205 X-206 X-207 X-208 X-209 Control 103966-02 [1] Transformer 106034-01 [1] Temperature Sensor/LWCO 106495-02 [1] Temperature Sensor (Models Not Shown 109645-01 [1] without LWCO) 106636-02 - 12/19...
- Page 43 Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description X-202 X-203 X-204 X-205 X-206 X-207 X-208 X-209 Jacket Wrap-around Jacket 106357-03 [1] 106357-04 [1] 106357-05 [1] 106357-06 [1] 106357-07 [1] 106357-08 [1] 106357-09 [1] Panel Jacket Vestibule Panel Jacket Rear Discharge Chute Jacket Top Panel 110126-02 [1]...
- Page 44 Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description X-202 X-203 X-204 X-205 X-206 X-207 X-208 X-209 Supply Water Manifold 109614-01 [1] Temperature/Pressure Gauge 105894-01 [1] 30 PSI Relief Valve 109038-01 [1] Drain Valve Obtain Locally (3/4" NPT boiler connection) Vent Damper 109634-01 [1] 109634-02 [1]...
- Page 45 Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Key No. Description X-202 X-203 X-204 X-205 X-206 X-207 X-208 X-209 Power Supply Harness 109639-01 [1] Main Control Harness 109640-01 [1] Accessories: Part Number [Quantity] Key No. Description X-202 X-203 X-204 X-205...
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Page 46: Appendix
Installation, Operating & Service Manual Appendix: Combination Refrigeration/ Heating System A. If boiler is used in connection with refrigeration B. If boiler is connected to heating coils located in systems, boiler must be installed with chilled air handling units where they may be exposed to medium piped in parallel with the heating boiler refrigerated air, boiler piping must be equipped using appropriate valves to prevent chilled... - Page 47 Installation, Operating & Service Manual Appendix: Low Return Water Temperatures Thermal Shock: Cast iron boilers are very robust. 110oF and below return water temperatures will not cause thermal shock to U.S. Boiler castings. Condensation is a different matter: Cast iron boilers will tolerate intermittent periods of condensation, but are not designed for extended condensation periods.
- Page 48 Installation, Operating & Service Manual Appendix: Low Return Water Temperatures (continued) Primary-Secondary Pumping: This is an improvement over simple by-pass piping to reduce condensation. Again this is a fixed system. It can not adapt to variations in temperature and flow. Best Alternative: U.S.
- Page 49 Installation, Operating & Service Manual SERVICE RECORD DATE SERVICE PERFORMED __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________...
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- Page 51 Installation, Operating & Service Manual SERVICE RECORD DATE SERVICE PERFORMED __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________ __________________________________________________________________________________________________...
- Page 52 Installation, Operating & Service Manual U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 106636-02 - 12/19...
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