U.S. Boiler Company Series 2 Installation, Operating And Service Instructions
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U.S. Boiler Company Series 2 Installation, Operating And Service Instructions

Series 2 (model b) gas - fired boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
Series 2
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103385-01 - 1/11
Gas - Fired Boiler
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Price - $5.00

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Summary of Contents for U.S. Boiler Company Series 2

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR (model B) Series 2 ® Gas - Fired Boiler 9700609 103385-01 - 1/11 Price - $5.00...

  • Page 2: Table Of Contents

    NOTE: The equipment shall be installed in accordance with those installation regulations in force in the area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
  • Page 3 WARNING READ THESE INSTRUCTIONS CAREFULLY BEFORE PROCEEDING WITH THE INSTALLATION OF BOILER. POST INSTRUCTIONS NEAR BOILER FOR REFERENCE BY OWNER AND SERVICE TECHNICIAN. MAINTAIN INSTRUCTIONS IN LEGIBLE CONDITION. Dimensions [Inches] Approx. Boiler Water Recommended Connection Shipping Model Content Vent Size For Automatic Weight Number...

  • Page 4: Installation Instructions

    I . Installation Instructions C. Save two of the wooden slats from the container INSPECT ShIPMENT carefully for any signs of sleeve for use in Steps D & E. damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon D.
  • Page 5 For boiler located in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. For boiler located in building of unusually tight construction, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely...
  • Page 6 Table 1: Maximum Capacity of Schedule 0 Pipe in CFH For Natural Gas Pressures of ½ psig or Less 0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop Length [Feet] ½ ¾ 1¼ ½ ¾ 1¼ 1,050 1,400 Table 2: Equivalent Length of Fittings Table 3: Specific Gravity Correction Factors for Natural Gas Nominal Pipe Size...
  • Page 7 Figure : Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems with flow control valves to prevent gravity circulation of boiler water during the operation of the cooling system. h. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be...
  • Page 8 Problems caused by oxygen contamination of boiler water are not covered by U.S. Boiler Company's standard warranty. There are many possible causes of oxygen contamination such as: 1.
  • Page 9 Install a cable clamp proceeding. around the flexible conduit and attach to the Jacket The automatic gas control valve supplied on each top panel. (See Figure 7). Series 2 boiler provides the redundancy referenced in ® the vent damper Installation Instructions. NOTICE...
  • Page 10 Category I, draft hood equipped appliances, such as remaining to it. this Series 2 boiler. Both standards prohibit the use ® At the time of removal of an existing boiler, the...
  • Page 11 l’espace où les appareils toujours raccordés au speed. Do not operate a summer exhaust fan. Close fireplace dampers. système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les D. Place in operation the appliance being inspected. sécheuses, tous les appareils non raccordés au Follow the Lighting (or Operating) Instructions.
  • Page 12 heat Anticipator in Thermostat should be set to match . vENT DAMPER SEQUENCE OF OPERATION. the requirements of the control to which it is connected. See Figure 9. See Table 4. If system tends to overheat above the A. The vent Damper is continuously powered at thermostat's temperature setting, reduce heat anticipator Terminal 1.
  • Page 13 Figure 11: Wiring Diagram,  Volt Standing Pilot and Intermittent Circulation 2. Blocked vent Switch SEQUENCE OF OPERATION In the event excessive blockage in the vent system is Normal Operation developed the blocked vent switch will open 1. When the thermostat call for heat, the vent damper interrupting power to the gas valve.
  • Page 14 Figure 1: Wiring Diagram, Electronic Ignition (EI), Intermittent Circulation SEQUENCE OF OPERATION NORMAL OPERATION 1. When the thermostat calls for heat, the relay is 2. Blocked vent Switch: Automatically interrupts energized. The circulator starts and the vent damper main burner operation when excessive vent system opens (see Paragraphs 17A through 17D).
  • Page 15 Figure 1: Wiring Diagram,  Volt Standing Pilot with Continuous or Gravity Circulation SEQUENCE OF OPERATION 2. Blocked vent Switch: In the event excessive blockage in the vent system is developed the NORMAL OPERATION blocked vent switch will open interrupting power to 1.
  • Page 16 Figure 1: Wiring Diagram, Electronic Ignition (EI), Continuous or Gravity Circulation SEQUENCE OF OPERATION NORMAL OPERATION 1. When the thermostat calls for heat the vent damper 2. Blocked vent Switch: Automatically interrupts opens (see Paragraphs 17A through 17D). When the main burner operation when excessive vent system damper blade reaches the fully open position, the blockage occurs.
  • Page 17 Figure 15: Wiring Schematic, Zone Valves Figure 1: Wiring Schematic, Zone Circulators...

  • Page 18: Operating Instructions

    II. Operating Instructions Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in American National Standard for Gas-Fired Low-Pressure Steam and Hot Water Boilers, ANSI Z21.13b-1994.
  • Page 19 Figure 1: Top View of VR Gas Valves Figure 0: Operating Instructions, VR0 and VR0 Gas Valves...
  • Page 20 Reconnect pilot tubing and check pipe and fittings from meter to combination Gas valve for leaks using soap solution or other approved method. 2. Electronic Ignition Models (Suffix I): Turn "ON" electric switch serving boiler. Open Manual Shut-off valve upstream of Combination Gas valve.
  • Page 21 The minimum steady pilot flame signal counterclockwise to increase pilot flame. must be 1 μAmp (microampere) DC (direct Always reinstall pilot adjustment screw current). cover and tighten securely upon completion to assure proper gas valve For reliable operation the flame current operation.
  • Page 22 Figure : Lighting Instructions...
  • Page 23 B. See Figure 22 for continuous ignition system first two items in order to utilize the formula (standing pilot). below. The gas meter should then be clocked for three (3) minutes with stop watch and ChECK GAS INPUT RATE TO BOILER substituting the appropriate values in the formula below, determine what the gas flow should be in NOTICE...
  • Page 24 Figure 5: Typical Pilot Flame, Honeywell Q50 ChECK PILOT BURNER FLAME. A. Continuous Ignition (Standing Pilot) LP gas Models 202 and 202x. See Figure 25. Natural gas Models 202 through 206 and 207 with Figure : Typical Pilot Flame, Honeywell QA 1"...

  • Page 25: Trouble Shooting

    III. Trouble Shooting Honeywell Electronic Ignition Troubleshooting Guide "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.

  • Page 26: Service

    IV. Service Reinstall Jacket Top Panel, draft hood, blocked vent Inspection should be conducted annually. Service as switch, damper (if boiler is so equipped), and vent frequently as specified in paragraphs below. While pipe. service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be "off".
  • Page 27 If pilot assembly, thermocouple or pilot orifice need 1" Burner replacing, remove main burner with pilot using procedure described in paragraph 4. A. To replace orifice: 1. Disconnect pilot tubing. The honeywell Q350 pilot orifices are insert type retained by the compression fitting.
  • Page 28 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 about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.

  • Page 29: Repair Part

    V. Repair Parts Section Assembly and Canopy Group ......30 Base Assembly ..............32 Manifold and Main Burners 1 Inch Main Burners ..........34 40mm Main Burners ..........36 Pilot Burner and Gas Valve Continuous Ignition (Standing Pilot) .......38 Electronic Ignition .............40 Jacket Assembly ...............41 Water Trim ...............44 Controls ................46 Draft Hood and Vent Damper .........47...

  • Page 30: Section Assembly And Canopy Group

    Quantity Description Part No. 202 202X 203 206 207 208 209 210 . Canopy Group 61117022 611170300 611170302 611170402 611170502 Canopy Assembly (except for 206H) 611170602 611170702 611170802 611170902 611171002 Canopy Assembly 206H 6111706010 Carriage Bolt, 1/4-20 x 1" 80860115 Flat Washer, 1/4"...
  • Page 31 THIS PAGE LEFT INTENTIONALLY BLANK...

  • Page 32: Base Assembly

    Base Assembly Boiler Boiler Description Part No. Qty. Description Part No. Qty. Size Size . Base Assembly Continued . Base Assembly 718600211 618600291 202X 718600311 202X 618600391 718600311 618600391 718600411 618600491 Base Assembly 718600511 618600591 (Complete) Base Wrapper Available for 1 Inch 718600611 618600691 Burners Only...
  • Page 33 Boiler Boiler Description Part No. Qty. Description Part No. Qty. Size Size . Base Assembly Continued . Base Assembly Continued Base Leg Assembly 6186001 618600241 Base Leg 71860021 202X 618600341 Nylon Glide 8186006 618600341 718600261 618600441 202X 718600361 618600541 Base Front Panel 718600361 Assembly 618600641...

  • Page 34: Manifold And Main Burners 1 Inch Main Burners

    Manifold and Main Burners (1 Inch Main Burners)

  • Page 35: Electronic Ignition

    Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 . Manifold and Main Burners (1 Inch Main Burners Only) Main Burner 8236099 Main Burner with Pilot Bracket ----- See Table Below 82260023 82260033 82260043 82260053 Manifold 82260063 82260073...
  • Page 36 Manifold and Main Burners (0mm Main Burners) Quantity Description Part No. 202X 203 204 205 206 207 208 209 210 . 0 MM Main Burners Only Main Burner 8236135 B. 0 MM Main Burner, Electronic Ignition Only Main Burner with 48° Pilot Bracket 8236143 Main Burner with 41°...
  • Page 37 Quantity Description Part No. 202X 203 204 205 206 207 208 209 210 . 0 MM Main Burners Only (Continued) C. 0MM Main Burner Manifold 82260028 82260038 82260048 82260058 Manifold 82260068 82260078 82260088 82260098 82260108 4D. 40 MM Main Burner Orifices Natural Gas, 2001-5000 Ft. USA Only 822713 822727 822720...
  • Page 38 * 1" Burner Only ** 0mm Burner Only Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas Valve, -volt Continuous Ignition, Natural Gas (1 Inch and 0mm Main Burners) Pilot Burner, Honeywell Q350A1321 8236065 Pilot Burner, Honeywell Q327A1006 8236022...
  • Page 39 Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, LP/Propane (1 Inch and 40mm Main Burners) Pilot Burner, Honeywell Q327A1147 8236023 Pilot Burner Assembly, Honeywell Q350A 8236105 (Includes 5B &...
  • Page 40 Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas Valve, Electronic Ignition (EI), Natural Gas Pilot Burner, Honeywell Q348A1002 8236072 Included Pilot Orifice, Honeywell 388146NE with 5A Compression Nut/Fitting, 1/4" OD x 1/4 C.C. 8236109 (Included with 5A and 5E) Pilot Tubing, 1/4"...

  • Page 41: Jacket Assembly

    Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 . Jacket Assembly, Complete 604170254 604170354 604170454 604170554 Jacket Assembly, Complete 604170654 604170754 604170854 604170954 604171054 . Jacket Assembly 604170215 604170315 604170415 604170515 Jacket Wrap-Around Panel 604170615 604170715 604170815...
  • Page 43 Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 . Jacket Assembly (Continued) 604170223 604170323 604170423 604170523 Jacket Vestibule Panel 604170623 604170723 604170823 604170923 604171023 604170233 604170333 604170433 604170533 Jacket Top Panel 604170633 604170733 604170833 604170933 604171033 604170242...

  • Page 44: Water Trim

    Water Trim...
  • Page 45 Description Part No. Quantity Safety Relief Valve, 30 psi, 3/4 NPT, Conbraco 10-408-05 81660319 Safety Relief Valve, 50 psi, 3/4 NPT, Conbraco 10-303-10 101662-01 . Circulator, Bell & Gossett SLC-0 Option (Intermittent and Continuous Circulation Only) Circulator with Gaskets, Bell & Gossett NRF-22 8056174 Gasket, Bell &...
  • Page 46 Description Part No. Quantity 12. Transformer/Relay Assembly (Intermittent Circulation Only) Junction Box, 4" x 4" x 1-1/2" 8136259 Transformer/Relay, Honeywell R8285D5001 80160155U Relay, Honeywell R8222U1006 80160096U 1. Transformer (Continuous and Gravity Circulation Only) Junction Box, 4" x 4" x 1-1/2" 8136259 Transformer, 40VA, Honeywell AT140D1012 or AT72D1188 80160039...
  • Page 47 Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 1. Draft Hood Carton 8116067 8111702 Draft Hood 8111703 8111704 8111705 1. Vent Damper 4" 8116321 5" 8116322 6" 8116323 7" 8116324 8" 8116325 1. Vent Reducer Reducer, 4"...

  • Page 48: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 49 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 50 SERVICE RECORD DATE SERVICE PERFORMED...

  • Page 51: Low Water Cut Off

    VI. Low Water Cut Off (LWCO) WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. When manufacturers recommend an annual inspection of the probe.
  • Page 52 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 (717) 397-4701 www.usboiler.burnham.com...

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