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

2 series gas - fired boiler
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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
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103698-04 - 10/14
Series 2
Gas - Fired Boiler
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Price - $5.00

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  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR Series 2 ® Gas - Fired Boiler 9700609 9700609 103698-04 - 10/14 Price - $5.00...
  • Page 2 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 This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Product Description, Specifications and Dimensional Data...... Pre-Installation & Boiler Mounting ............III. Gas Piping....................Boiler Water Piping..................Venting....................... 14 Electrical....................18 VII. System Start-up and Checkout..............22 VIII. Operation....................26 Service and Maintenance................30 Troubleshooting..................Repair Parts ..................... Appendix A - Figures.....................
  • Page 5 I. PRODUCT DESCRIPTION, SPECIFICATIONS AND DImENSIONAL DATA (CONTINUED) Table 1: Dimensions Dimensions [Inches] Approx. Boiler Water Recommended Connection Shipping Model Content Vent Size For Automatic Weight Number [gallons] Gas Valve [lb.] 18-3/4 10-3/4 6-3/8 45-5/8 8-1/2 10 [1] 3" dia. 202X 45-5/8 8-1/2...

  • Page 6: Pre-Installation & Boiler Mounting

    II. PRE-INSTALLATION AND BOILER mOUNTING CAUTION WARNING Avoid operating this boiler in an environment If you do not follow these instructions exactly, where saw dust, loose insulation fibers, dry wall a fire or explosion may result causing property dust, etc. are present. If boiler is operated under damage or personal injury.
  • Page 7 II. PRE-INSTALLATION AND BOILER mOUNTING (continued) • Walls and ceiling exposed to outside atmosphere have a continuous water vapor BOILER ‘W’ MODEL retarder with a rating of 1 perm or less with 10¾” (27.3cm) openings gasketed and sealed, and 202X 12”...

  • Page 8: Gas Piping

    III. GAS PIPING The boiler must be isolated from the gas supply piping CONNECT GAS SERvICE from Meter to gas control system by closing its individual manual shutoff valve assembly in accordance with Local Piping Codes and during any pressure testing of the gas supply piping requirements of Gas Company.

  • Page 9: Boiler Water Piping

    Install a pipe tee at the boiler return along with a Problems caused by oxygen contamination of boiler second tee in the supply piping as shown in Figures water are not covered by U.S. Boiler Company's 5 and 6. The bypass should be the same size as the standard warranty.
  • Page 12 IV. BOILER WATER PIPING (continued) OPTIONAL PROBE LWCO INSTALLATION 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.
  • Page 13 IV. BOILER WATER PIPING (continued) 4. Piping and fittings required to install LWCO are OPTIONAL AUxILIARY LIMIT INSTALLATION field supplied. 1. Some jurisdictions may require the use of an 5. When constructing a piping tree to install LWCO Auxiliary Limit control with a hot water boiler as a select fittings (tees, elbows etc) and nipples to have redundant safety control.

  • Page 14: Venting

    V. VENTING INSTALL dRAFT hOOd without modification on outlet of flue collector (See Figure 1). Secure with sheet metal screws. WARNING Do not alter boiler draft hood or place any obstruction or non-approved damper in the breeching or vent system. Flue gas spillage can occur.
  • Page 15 V. VENTING (continued) Figure 11: Plug-in Damper Installation 1. The vent damper must be the same size as the outlet INSTALL vENT CONNECTOR of the draft hood supplied with the boiler (see 1. Size 202 only - Install provided 4" x 3" vent reducer Figure 1).
  • Page 16 V. VENTING (continued) 9. Slope horizontal portions of vent pipe upwards not less than 1/4 in/ft (21 mm/m) from boiler to vent terminal. les chaudiêres de catégories I doivent présenter des tronçons horizontaux dont la pente montante est d'au moins 1/4 po par pied (21 mm/m) entre la chaudiêre et l'évent.
  • Page 17 V. VENTING (continued) 5. Test for spillage at the draft hood relief opening 3. dans la mesure du possible, fermer toutes les portes after 5 minutes of main burner operation. Use the et les fenêtres du bâtiment et toutes les portes entre flame of a match or candle, or smoke from a l’espace où...

  • Page 18: Electrical

    VI. ELECTRICAL INSTALL A ROOM ThERMOSTAT on an inside WARNING wall about four feet above floor. Never install thermostat on an outside wall or where it will be The combined boiler and circulator amperage influenced by drafts, hot or cold water pipes, lighting must not exceed 15 amps.
  • Page 19 VI. ELECTRICAL (continued) Figure 13: Connection Wiring Diagram, Intelligent Hydronic Control...
  • Page 20 VI. ELECTRICAL (continued) Figure 14: Ladder Wiring Diagram, Intelligent Hydronic Control...
  • Page 21 VI. ELECTRICAL (continued) Figure 15: Wiring Schematic, Zone Valves Figure 16: Wiring Schematic, Zone Circulators...

  • Page 22: System Start-Up And Checkout

    VII. 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 slots in the rear of burner tray and the front of the burners should be seated completely on the orifices.
  • Page 23 VII. START-UP AND CHECkOUT (continued) Figure 19: Operating Instructions, VR8204 and VR8304 Gas Valves...
  • Page 24 VII. START-UP AND CHECkOUT (continued) volume of gas flow contact your utility for the ChECk GAS INPUT RATE TO BOILER first two items in order to utilize the formula NOTICE below. The gas meter should then be clocked for three (3) minutes with stop watch and substituting the appropriate values in the formula USA boilers built for installation at altitudes greater below, determine what the gas flow should be in...
  • Page 25 VII. START-UP AND CHECkOUT (continued) ChECk PILOT BURNER FLAME. ChECk hIGh LIMIT CONTROL. Jumper Thermostat connections in boiler wiring harness. Allow See Figure 22. burners to operate until shutdown by limit. REMOvE The pilot produces three (3) flames. The center flame JUMPER.

  • Page 26: Operation

    VIII. OPERATION BOILER SEQUENCE OF OPERATION Table 5: Sequence of Operation NORMAL OPERATION Status Codes displayed in STA Mode 1. The Series 2 Boilers are equipped with an Intelligent Status Description hydronic Control (control). This control replaces Standby the traditional separate ignition control, high limit (Burner off No call for heat detected switch and circulator relay and adds energy saving...
  • Page 27 VIII. OPERATION (continued) The STA (status) display code has the below listed values. This list is also available on the control cover. Status Code Displayed in STA mode Standby Prepurge Spark Flame Proving Running Figure 23: Intelligent Hydronic Control Retry/Recycle Delay Soft Lockout Hard Lockout Waiting for Limit to Close...
  • Page 28 VIII. OPERATION (continued) ChANGING ThE AdJUSTABLE PARAMETERS system piping and zone panel settings allow water flow to the priority zone after the call for heat ends. To adjust parameters such as high Limit Setpoint and The Circulator Overrun Time is adjustable between high Limit differential: 0 through 10 minutes.
  • Page 29 VIII. OPERATION (continued) system circulator. The Priority Time has a factory Table 8: DHW Terminal Function (dh_) setting of “On” and is field adjustable between “On” Selection = Domestic Hot Water Demand, and “Off” Refer to Table 8. (Parameter dh_ = dh) 7.

  • Page 30: 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 31 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 32 IX. SERVICE AND mAINTENANCE (continued) Table 10: Pilot Burner Location 1" Burner Pilot Burner Located Main Burner with Between Main Boiler Pilot Bracket * Burners * Model 1 Inch 40mm 1 Inch 40mm 1 & 2 202X 1 & 2 1 &...
  • Page 33 IX. SERVICE AND mAINTENANCE (continued) b. disconnect pilot piping. LUBRICATION c. disconnect all other leads to pilot. There are no parts requiring lubrication on the part of d. Select pilot assembly with identical model the service technician or the User. Circulator bearings number, reconnect leads and pilot tubing - re- are water lubricated.

  • Page 34: Troubleshooting

    X. TROUBLESHOOTING BEFORE TROUBLEShOOTING 120 vac power polarity is correct and that the boiler is properly grounded. Further, ensure that the control The following pages contain trouble shooting tables for power supply is 24 vAC (minimum 18 vAC to use in diagnosing control problems. When using these maximum 30 vAC) and polarity is correct.
  • Page 35 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 36 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 37 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 38 X. TROUBLESHOOTING (continued) 6. Circulator is On, Damper is Open But Boiler Fails to Start (continued) Recommended Corrective Action Display / Status 1. No Spark a. Can you hear sparking while STA 6 is displayed? - If there is no spark noise replace the control. b.

  • Page 39: Repair Parts

    All Series 2® 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: Section Assembly And Canopy Group

    XI. REPAIR PARTS (continued) Section Assembly and Canopy Group...
  • Page 41 XI. REPAIR PARTS (continued) Quantity Description Part No. 202X 1. Section Assembly 103918-02 103918-03 103918-04 103918-05 Section Assembly, Complete 103918-06 103918-07 103918-08 103918-09 103918-10 Quantity Description Part No. 202X 2. Canopy Group 61117022 611170300 611170302 611170402 611170502 Canopy Assembly 611170602 611170702 611170802 611170902...

  • Page 42: Base Assembly

    XI. REPAIR PARTS (continued) Base Assembly Boiler Description Part No. Qty. Boiler Size Description Part No. Qty. Size 3. Base Assembly Continued 3. Base Assembly 718600211 618600291 202X 718600311 202X 618600391 718600311 618600391 718600411 618600491 718600511 Base Assembly Base Wrapper 618600591 (Complete) 718600611...
  • Page 43 XI. REPAIR PARTS (continued) Boiler Boiler Description Part No. Qty. Description Part No. Qty. Size Size 3. Base Assembly Continued 3. Base Assembly Continued Base Leg Assembly 6186001 618600241 Base Leg 71860021 202X 618600341 Nylon Glide 8186006 618600341 718600261 618600441 202X 718600361 618600541...

  • Page 44: Manifold And Main Burners 1 Inch Main Burners

    XI. REPAIR PARTS (continued) manifold and main Burners (1 Inch main Burners)
  • Page 45 XI. REPAIR PARTS (continued) Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 4. manifold and main Burners (1 Inch main Burners Only) Main Burner 8236099 Main Burner with Pilot Bracket ----- See Table Below 82260023 82260033 82260043...

  • Page 46: 40Mm Main Burners

    XI. REPAIR PARTS (continued) manifold and main Burners (40mm main Burners) Quantity Description Part No. 202X 4. 40 mm main Burners Only Main Burner 8236135 4B. 40 mm main Burner with Pilot Bracket Main Burner with 41° Pilot Bracket 8236136...
  • Page 47 XI. REPAIR PARTS (continued) Quantity Description Part No. 202X 203 4. 40 mm main Burners Only (Continued) 4C. 40mm main Burner manifold 82260038 82260048 82260058 82260068 Manifold 82260078 82260088 82260098 82260108 4D. 40 MM Main Burner Orifices Natural Gas, 2001-5000 Ft. USA Only 822713 822727 822720...

  • Page 48: Pilot Burner And Gas Valve

    XI. REPAIR PARTS (continued) Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas Valve, Natural Gas Pilot Burner, Honeywell Q3481B1206 with Fiberglass Insulated Integral 36" lg. Igniter/ 103704-01 Sensor Cable Pilot Burner Orifice, Honeywell NE22, 0.022"...

  • Page 49: Jacket Assembly

    XI. REPAIR PARTS (continued) Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 6. Jacket Assembly, Complete 604170254 604170354 604170454 604170554 Jacket Assembly, Complete 604170654 604170754 604170854 604170954 604171054 6. Jacket Assembly 604170215 604170315 604170415 604170515 Jacket Wrap-Around Panel 604170615...
  • Page 51 XI. REPAIR PARTS (continued) Quantity Description Part No. 202 202X 203 204 205 206 207 208 209 210 6. 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...

  • Page 52: Water Trim

    XI. REPAIR PARTS (continued) Water Trim...
  • Page 53 XI. REPAIR PARTS (continued) 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 8. Circulator, Bell & Gossett SLC-30 Option Circulator with Gaskets, Bell & Gossett NRF-22 8056174 Gasket, Bell &...

  • Page 54: Controls

    XI. REPAIR PARTS (continued) Controls Description Part No. Quantity 12. Transformer/J-Box/Controls Junction Box, 4" x 4" x 1-1/2" 8136259 Junction Box Cover 8136027 Flame Rollout Switch 80160044 Flame Rollout Switch Mounting Bracket (All Models Except 202) 7186018 Blocked Vent Switch Replacement Assembly 6016058 Intelligent Hydronic Control, Honeywell S9361A2072 103660-01...

  • Page 55: Draft Hood And Vent Damper

    XI. REPAIR PARTS (continued) Draft Hood Quantity Description Part No. 202X 16. Draft Hood Carton 8116067 8111702 Draft Hood 8111703 8111704 8111705 17. Vent Damper 4" 102284-01 5" 102284-02 6" 102284-03 7" 102284-04 8" 102284-05 18. Vent Reducer Reducer, 4" x 3" 8116164...

  • Page 56: Appendix A - Figures

    APPENDIX A - FIGURES Figure Page Description Number Number Section I - Product Description, Specifications & Dimensional Data Figure 1 Line Drawing Section II - Pre-Installation & Boiler mounting Figure 2 Minimum Clearances Section III - Gas Piping Figure 3 Recommended Gas Piping Section IV - Boiler Water Piping Figure 4...
  • Page 57 APPENDIX A - FIGURES (continued) Figure Page Description Number Number Section XI - Repair Parts Section Assembly & Canopy Group Base Assembly Maniflold & Main Burners (1 inch Main Burners) Manifold & Main Burners (40mm Main Burners) Pilot Burner & Gas Valve Jacket Assembly Water Trim Controls...

  • Page 58: Appendix B - Tables

    APPENDIX B - TABLES N/ATable Page NuN/ Description Number Amber Section III - Gas Piping Table 1 Dimensions Table 2 Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of ½ psig or Less Table 3 Equivalent Length of Fittings Table 4 Specific Gravity Correction Factors for Natural Gas Section VIII - Operation...
  • 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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