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

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Series 3
Installation, Operating and Service Instructions for
Manual Contents
Qualified Installer, Service Agency or Gas Supplier Read
Before Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1 .
Locating Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 . Preparing Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3 . Provide Combustion Air . . . . . . . . . . . . . . . . . . . . . .10
4 . Connect Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5 . Connect Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . .12
6 . Connect Boiler Water Piping . . . . . . . . . . . . . . . . . .13
7 .
Connect Electrical Wiring . . . . . . . . . . . . . . . . . . . . .15
8 . Program the Controls . . . . . . . . . . . . . . . . . . . . . . . .16
9 . Check for Gas and Water Leaks . . . . . . . . . . . . . . . .19
11 . Service and Maintenance . . . . . . . . . . . . . . . . . . . . .23
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Internal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Appendicies:
A Combustion Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
B Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
C Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
D System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
E Filling System and Checking for Leaks . . . . . . . . . . .54
F High Altitude Installations . . . . . . . . . . . . . . . . . . . . . .55
G Checking Draft and Combustion . . . . . . . . . . . . . . . .56
H Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
I IQ Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
!
Attention Installer - Affix these instructions
adjacent to boiler. Provide model number and serial
number when seeking information and support.
Attention Building Owner - Retain these
instructions for future reference. Contact a qualified
installer, service agency or gas supplier for all issues
and support.
Read these instructions carefully before installing . This boiler must only be installed, serviced, or repaired
by a qualified installer, service agency or gas supplier. Improper installation, adjustment, alteration, service,
or maintenance can cause severe personal injury, death, or substantial property damage. For assistance or
additional information, consult a qualified installer, service agency or gas supplier.
103796-09 - 3/24
WARNING
TM
Page
9700609
!
WARNING

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  • Page 1: Table Of Contents

    Series 3 Installation, Operating and Service Instructions for Manual Contents Page Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 User/Homeowner Read Before Proceeding .
  • Page 2 Series 3 Installation, Operating & Service Instructions 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 Series 3 Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, https://licensing .reg .state .ma .us/pubLic/pl_products/pb_pre_form .asp for the latest Approval Code or ask your local Sales Representative.

  • Page 3: Before Proceeding

    Series 3 Installation, Operating & Service Instructions Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding NOTICE: DANGER 1. Size boiler properly. A grossly oversized boiler Asphyxiation Hazard, Burn Hazard, Electrical will cycle excessively leading to premature Shock Hazard . failure of boiler and its components.

  • Page 4: User/Homeowner Read Before Proceeding

    Series 3 Installation, Operating & Service Instructions User/Homeowner Read Before Proceeding WARNING CAUTION Asphyxiation Hazard . Fire Hazard . Burn Hazard . • A qualified installer, service agency or gas Keep children and pets away from hot surfaces supplier should annually inspect boiler. of the boiler including boiler piping, vent piping, and vent terminals.
  • Page 5 Series 3 Installation, Operating & Service Instructions 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.

  • Page 6: Specifications

    Series 3 Installation, Operating & Service Instructions Specifications Ratings Series 3 Net AHRI Rating, Water Boiler Model Input (MBH) DOE Heating Capacity (MBH) AFUE (%) (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).
  • Page 7 Series 3 Installation, Operating & Service Instructions 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 103796-09 - 3/24...

  • Page 8: Locating Boiler

    Series 3 Installation, Operating & Service Instructions Locating Boiler NOTICE: Flue side corrosion caused by 1. If replacing an existing boiler, check for and contaminants is not covered by warranty. correct common system problems including: A. System leaks resulting in premature heat Table 1-a: Corrosive Combustion Contaminants exchanger failure from oxygen corrosion or and Sources...

  • Page 9: Preparing Boiler

    Series 3 Installation, Operating & Service Instructions Preparing Boiler Unpack Crate 4 . Tip the boiler and shimmy it off the skid (Figure 2-b). DANGER Use precautions and appropriate rigging apparatus when moving heavy objects. CAUTION Do not drop boiler. Do not bump boiler jacket against floor.

  • Page 10: Provide Combustion Air

    Series 3 Installation, Operating & Service Instructions Preparing Boiler Provide Combustion Air (continued) Position Bioler WARNING INSUFFICIENT COMBUSTION AIR 1 . Slide the boiler into desired location. SUPPLY may result in the production and release of deadly carbon monoxide (CO) into 2 .

  • Page 11: Connect Venting

    Series 3 Installation, Operating & Service Instructions Connect Venting 2 . Attach the vent damper with three sheetmetal DANGER screws around the perimeter of the flue collar • INSPECT EXISTING CHIMNEY before installing (Figure 4-a). The vent damper may also be boiler.

  • Page 12: Connect Gas Piping

    Series 3 Installation, Operating & Service Instructions Connect Gas Piping WARNING Explosion Hazard . • Failure to properly pipe gas supply to boiler could cause improper operation if leaks of flammable gas resulting in severe personal injury, death, or substantial property damage. •...

  • Page 13: Connect Boiler Water Piping

    Series 3 Installation, Operating & Service Instructions Connect Boiler Water Piping General system piping guidelines are included in DANGER Appendix D—System Piping. • Pipe relief valve discharge to a safe location. A boiler installed above radiation level or as required •...
  • Page 14 Series 3 Installation, Operating & Service Instructions Connect Boiler Water Piping (continued) Figure 6-b 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...

  • Page 15: Connect Electrical Wiring

    Series 3 Installation, Operating & Service Instructions Connect Electrical Wiring 7 . Insert vent damper harness to vent damper. DANGER 8 . Wire an additional safety limit such as a low Electrical Shock Hazard . water cutoff or temperature limit device, other •...

  • Page 16: Program The Controls

    Series 3 Installation, Operating & Service Instructions Program the Controls Using Intelligent Hydronic Control Display Operating Mode Options Status The Intelligent Hydronic Control (control) is located inside the boiler front door, just above the IQ Option Boiler Temperature Panel (Figure 8-a). Operating Setpoint (Outdoor Reset) High Limit Setting High Limit Differential...
  • Page 17 Series 3 Installation, Operating & Service Instructions Program the Controls (continued) 1 . Access the adjustment mode by pressing 3 . Circulator Overrun Time (OR_) and holding the Up ñ, Down ò, and “I ” The control is factory programmed with a keys simultaneously for three (3) seconds.
  • Page 18 Series 3 Installation, Operating & Service Instructions Program the Controls (continued) Table 8b: DHW Terminal Function (dh_) Table 8c: DHW Terminal Function (dh_) Selection = Domestic Hot Water Demand, Selection = Second Heating Zone, (Parameter dh_ = dh) (Parameter dh_ = tt2) Call for Heat Circulator Status Call for Heat...

  • Page 19: Check For Gas And Water Leaks

    Series 3 Installation, Operating & Service Instructions Program the Controls Perform Startup Checks and (continued) Adjustments b. When dh_ is set equal to Second Heating DANGER Zone (tt2) Explosion Hazard . When there is no IWH the “DHW Circulator” • FAILURE TO PERFORM THESE CHECKS of the output may be configured to control a second boiler's combustion and safety systems may result heating zone.
  • Page 20 Series 3 Installation, Operating & Service Instructions Perform Startup Checks and Adjustments (continued) Operating Instructions, VR8204 and VR8304 Gas Valves Figure 10-b 103796-09 - 3/24...
  • Page 21 Figure 10-f). f. Liquefied Petroleum Gases (LP/Propane). • Contact your U.S. Boiler Company wholesale Adjust gas valve pressure regulator to distributor for alternate main burner orifices if provide outlet pressure of 10 inches water outlet pressure is less than 3.2 inches water...
  • Page 22 Series 3 Installation, Operating & Service Instructions Perform Startup Checks and Adjustments (continued) CAUTION WARNING Avoid operating boiler in an environment where Explosion Hazard . saw dust, loose insulation fibers, dry wall dust, • The boiler and its gas connections must be leak etc.

  • Page 23: Service And Maintenance

    Series 3 Installation, Operating & Service Instructions 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 24 Series 3 Installation, Operating & Service Instructions Service and Maintenance (continued) WARNING This boiler should be serviced by a qualified installer, service agency, or gas supplier. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition. •...
  • Page 25 Series 3 Installation, Operating & Service Instructions Service and Maintenance (continued) 6. Inspect Temperature/Pressure Gauge. 4. Clean Main Burners and Combustion Chamber. A. Water temperature needle should move with A. To remove burners for cleaning, changing variation in water temperature. orifices, or repairs: B.

  • Page 26: Troubleshooting

    Series 3 Installation, Operating & Service Instructions Troubleshooting polarity is correct and that the boiler is properly Before troubleshooting grounded. Further, ensure that the control power The following pages contain trouble shooting tables supply is 24 VAC (minimum 18 VAC to maximum for use in diagnosing control problems.
  • Page 27 Series 3 Installation, Operating & Service Instructions 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 28 Series 3 Installation, Operating & Service Instructions 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: Boiler and Circulator Off Display / Status Recommended Corrective Action The boiler has not detected a call for heat (tt = off and dh = off).
  • Page 29 Series 3 Installation, Operating & Service Instructions 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.
  • Page 30 Series 3 Installation, Operating & Service Instructions 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 31 Series 3 Installation, Operating & Service Instructions 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 32: Service Parts

    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. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
  • Page 33 Series 3 Installation, Operating & Service Instructions Service Parts (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Base Wrapper Base Tray Burner Tray Assembly Base Front Panel Burner Access Panel Base Gasket Kit Base Side Insulation 109613-03 109613-04 109613-05...
  • Page 34 Series 3 Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Description 303B 304B 305B 306B 307B 308B 309B Gas Valve (Natural Gas), 109620-01 Honeywell VR8204C3007 Gas Valve (Natural Gas), 109622-01 Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell 109615-01 VR8204C3015 Gas Valve (LP Gas), Honeywell...
  • Page 35 Series 3 Installation, Operating & Service Instructions Service Parts (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Control 103966-02 IQ Option Panel 109647-01 Transformer 106034-01 Temperature Sensor 111455-01 103796-09 - 3/24...
  • Page 36 Series 3 Installation, Operating & Service Instructions Service Parts (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Jacket Left Side Panel 111451-01 Jacket Right Side Panel Jacket Rear Panel Jacket Vestibule Panel Jacket Top Panel 111450-03 111450-04 111450-05 111450-06...
  • Page 37 Series 3 Installation, Operating & Service Instructions Service Parts (continued) Part Number Description 303B 304B 305B 306B 307B 308B 309B Supply Water Manifold 109614-01 Temperature/Pressure Gauge 105894-01 30 PSI Relief Valve 109038-01 Drain Valve Obtain Locally Vent Damper 109634-01 109634-02 109634-03 109634-04 109634-05...
  • Page 38 Series 3 Installation, Operating & Service Instructions Service Parts (continued) Part Number [Quantity] Key No. Description 303B 304B 305B 306B 307B 308B 309B Power Supply Harness 109639-01 [1] Main Control Harness 111454-01 [1] Accessories: Part Number [Quantity] Key No. Description 303B 304B 305B...

  • Page 39: Internal Wiring

    Series 3 Installation, Operating & Service Instructions Internal Wiring Figure IW-1: Wiring Diagram 103796-09 - 3/24...
  • Page 40 Series 3 Installation, Operating & Service Instructions Internal Wiring (continued) Figure IW-2: Wiring Figure IW-2: Wiring Schematic 103796-09 - 3/24...
  • Page 41 Series 3 Installation, Operating & Service Instructions Internal Wiring (continued) Figure IW-3: Multiple Zone System with Zone Circulators Figure IW-3: Multiple Zone System with Zone Circulators Figure IW-4: Multiple Zone System with Zone Valves Figure IW-4: Multiple Zone System with Zone Valves 103796-09 - 3/24...
  • Page 42 Series 3 Installation, Operating & Service Instructions 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...

  • Page 43: A Combustion Air

    Series 3 Installation, Operating & Service Instructions Appendix A Combustion Air If the Floorspace from Step 1 is less than the WARNING Minimum Floorspace from Step 3, then you must PROVIDE ENOUGH AIR to ventilate the provide outdoor air to the boiler room. Proceed boiler room, dilute the flue gases, and to Step 6.

  • Page 44: B Venting

    Series 3 Installation, Operating & Service Instructions Appendix B Venting WARNING 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. NOTICE: 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 45 Series 3 Installation, Operating & Service Instructions Appendix B Venting (3) Dans la mesure du possible, fermer toutes les 3 . Horizontal portions of the venting system shall portes et les fenêtres du bâtiment et toutes be supported to prevent sagging. Follow venting les portes entre l’espace où...
  • Page 46 Series 3 Installation, Operating & Service Instructions Appendix B1 Atmospheric Venting WARNING Gerneral warnings for atmospheric venting systems: • USE ATMOSPHERIC VENTING only with boilers approved for atmospheric venting as noted in the Specifications Section of this manual. • INSPECT EXISTING CHIMNEY for obstructions and deterioration and repair or line the chimney prior to placing the boiler in service.
  • Page 47 Series 3 Installation, Operating & Service Instructions 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 48: C Gas Piping

    Series 3 Installation, Operating & Service Instructions Appendix C Gas Piping Table C-3: Specific Gravity Correction Factors For Natural Gas WARNING Specific Correction Specific Correction Explosion Hazard . Gravity Factor Gravity Factor • Failure to properly pipe gas supply to boiler 0.50 1.10 0.85...

  • Page 49: D System Piping

    Series 3 Installation, Operating & Service Instructions Appendix C Gas Piping (continued) 6 . Install sediment trap, ground-joint union and (3) Locate leaks using approved manual shut-off valve upstream of boiler gas combustible gas detector or control valve and outside jacket. nonflammable, non-corrosive leak detection solution.
  • Page 50 Series 3 Installation, Operating & Service Instructions Appendix D System Piping (continued) (2) Adhere to the boiler’s specific minimum return water and supply (2) Do not exceed the boiler’s specific water temperature requirements. requirements for maximum Install a boiler bypass, system allowable working pressure.
  • Page 51 Series 3 Installation, Operating & Service Instructions Appendix D System Piping (continued) 103796-09 - 3/24...
  • Page 52 Series 3 Installation, Operating & Service Instructions Appendix D System Piping (continued) 103796-09 - 3/24...
  • Page 53 Series 3 Installation, Operating & Service Instructions Appendix E Filling System & Check 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. 1 .

  • Page 54: F High Altitude Installations

    Series 3 Installation, Operating & Service Instructions Appendix F High Altitude Installations Conversion kits are required for installations above 5,400 ft. WARNING Asphyxiation Hazard . Proper operation of boiler depends upon use of correct burner orifice and blocked vent switch for fuel and altitude at which boiler is installed.
  • Page 55 Series 3 Installation, Operating & Service Instructions Appendix G Checking Draft & Combustion CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) 1 . Insofar as is practical, close all doors and 7 . Repeat this test for each appliance connected to windows in the building.
  • Page 56 Series 3 Installation, Operating & Service Instructions Appendix H Operation Boiler Sequence of Operation Table H-1: Sequence of Operation NORMAL OPERATION Status Codes displayed in STA Mode 1 . The boiler is equipped with an Intelligent Status Description Hydronic Control (control). This control replaces the traditional separate ignition control, high limit Standby (Burner off...

  • Page 57: I Iq Control System

    Series 3 Installation, Operating & Service Instructions Appendix I IQ Control System • UL / CSA Listed or Recognized and tested as IQ Control System Overview part of a complete system. The “IQ Control System” consists of a control and an IQ •...
  • Page 58 Series 3 Installation, Operating & Service Instructions 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 59 Series 3 Installation, Operating & Service Instructions 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.
  • Page 60 Series 3 Installation, Operating & Service Instructions 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.
  • Page 61 Series 3 Installation, Operating & Service Instructions SERVICE RECORD DATE SERVICE PERFORMED 103796-09 - 3/24...
  • Page 62 Series 3 Installation, Operating & Service Instructions SERVICE RECORD DATE SERVICE PERFORMED 103796-09 - 3/24...
  • Page 63 Series 3 Installation, Operating & Service Instructions SERVICE RECORD DATE SERVICE PERFORMED 103796-09 - 3/24...
  • Page 64 Series 3 Installation, Operating & Service Instructions U .S . Boiler Company, LLC P .O . Box 3020 Lancaster, PA 17604 1-888-432-8887 www .usboiler .net 103796-09 - 3/24...

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