IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR S E R IE S 2 ® ( m o d e l B ) GA S - F I R E D BOI L E R F o r s e r vi c e o r r e p a i r s t o b o i le r, c a ll yo ur he a t i ng c o nt r a c t o r. W he n s e e k i ng i nf o r m a t i o n o n b o i le r, p r o vi d e B o i l e r M o d e l N u m b e r a n d S e r i a l N u m b e r a s s h o w n o n R a t i n g L a b e l .
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.
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] Gas Approx. Water Recommended Connection Shipping Content Vent Size For Automatic Weight [gallons] [1] [2] Gas Valve [lb.] Boiler Model Number A B C D E F G 202 18-3/4 10-3/4 6-3/8 4 45-5/8 8-1/2 10 [3] 1/2 2.5 3" dia. x 15 ft.
I . Installation Instructions 1. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of Boiler to the carrier in good condition. Any claims for damage or shortage in shipment must be filed immediately against the carrier by the consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within sixty (60) days after receipt of equipment. 2.
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. f. 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 communicating with the outdoors. Locate one opening within 12 inches (30.5cm) of top of space.
Table 1: Maximum Capacity of Schedule 40 Pipe in CFH For Natural Gas Pressures of ½ psig or Less Length [Feet] 0.3 Inch w.c. Pressure Drop 0.5 Inch w.c.
Figure 4: Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems Figure 3: Recommended Water Piping for Zone Valve Zoned Heating Systems WARNING Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns. Do not pipe in any area where freezing could occur. Do not install any shut-off valves. D. Install circulator with flanges, gaskets and bolts provided. Five foot long circulator harness allows circulator to be mounted on supply or return.
To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air. K. Oxygen Corrosion: Oxygen contamination of the boiler water will cause corrosion of the iron and steel boiler components, which can lead to failure.
Figure 7: Plug-in Damper Installation WARNING Failure to properly install and use this Blocked Vent Switch may result in property damage, personal injury or loss of life. 12. TO MEET FEDERALLY MANDATED EFFICIENCIES, THIS BOILER MUST BE EQUIPPED WITH A VENT DAMPER. OPEN the VENT DAMPER CARTON and remove the Installation Instructions. READ THE INSTALLATION INSTRUCTIONS THOROUGHLY before proceeding.
Figure 8: Typical Vent Installation DANGER Inspect existing chimney before installing boiler. Failure to clean or replace perforated pipe or tile lining will cause severe injury or death. A. Vent installation shall be in accordance with local building codes; or the local authority having jurisdiction; or the National Fuel Gas Code, ANSI Z223.1/NFPA 54; or the Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances, ANSI/NFPA 211. Both of the aforementioned standards, ANSI Z223.
D. E. F. G. A. B. C. speed. Do not operate a summer exhaust fan. Close fireplace dampers. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate continuously. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
Heat Anticipator in Thermostat should be set to match the requirements of the control to which it is connected. See Table 4. If system tends to overheat above the thermostat's temperature setting, reduce heat anticipator setting by .1 or .2 amps. If system tends to short cycle without reaching desired room temperature, increase heat anticipator setting by .1 or .2 amps. 17. Vent Damper Sequence of Operation. 16.
Figure 11: Wiring Diagram, 24 Volt Standing Pilot and Intermittent Circulation Sequence of Operation Normal Operation 1. When the thermostat call for heat, the vent damper will open (see paragraphs 17A through 17D). The circulator is started through a relay and at the same time the gas valve is energized allowing main gas flow and ignition of main burners. 2.
Figure 12: Wiring Diagram, Electronic Ignition (EI), Intermittent Circulation SEQUENCE OF OPERATION Normal Operation 1. When the thermostat calls for heat, the relay is energized. The circulator starts and the vent damper opens (see Paragraphs 17A through 17D). When the damper blade reaches the fully open position, the ignition module is energized opening the pilot valve and energizing the igniter to ignite the pilot burner. 2. Sensor proves presence of pilot flame. Main valve opens to ignite main burners.
Figure 13: Wiring Diagram, 24 Volt Standing Pilot with Continuous or Gravity Circulation Sequence of Operation Normal Operation 1. When the thermostat call for heat, the vent damper will open (see paragraphs 17A through 17D). The gas valve is energized allowing main gas to flow and operation of the main burners. 2.
Figure 14: Wiring Diagram, Electronic Ignition (EI), Continuous or Gravity Circulation SEQUENCE OF OPERATION NORMAL OPERATION 1. When the thermostat calls for heat the vent damper opens (see Paragraphs 17A through 17D). When the damper blade reaches the fully open position, the ignition module is energized opening the pilot valve and energizing the igniter to ignite the pilot burner. 2. Sensor proves presence of pilot flame. Main valve opens to ignite main burners. 3.
Figure 15: Wiring Schematic, Zone Valves Figure 16: Wiring Schematic, Zone Circulators 17
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. 1. Main burner check - Check main burners to see that they were not dislodged during shipment.
Figure 19: Top View of VR Gas Valves Figure 20: Operating Instructions, VR8204 and VR8304 Gas Valves 19
e. 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): a. Turn "ON" electric switch serving boiler. b. Open Manual Shut-off Valve upstream of Combination Gas Valve. c. Loosen or remove Inlet Pressure Tap Plug in Combination Gas Valve and when purging is complete, tighten or replace plug. See Figure 19. d.
Table 7: Green LED Status Codes Green LED Flash Code (X + Y)a Next System Action Recommended Service Action No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None OFF 5 minute Retry DelayPilot flame not detected during trial for ignition Initiate new trial for ignition after retry delay completed.
Figure 22: Lighting Instructions
B. See Figure 22 for continuous ignition system (standing pilot). 4. CHECK GAS INPUT RATE TO BOILER NOTICE USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers' orifice sizing is indicated on the rating label.
Figure 25: Typical Pilot Flame, Honeywell Q350 The pilot produces a single flame. The flame should be steady, medium hard blue enveloping 3/8 to a 1/2 inch of thermocouple. B. Continuous Ignition (Standing Pilot) Natural gas Models 207 with 40mm (1-9/16") diameter burners and 208 through 210. See Figure 26. LP gas Models 203 through 210. See Figure 26. The pilot produces three (3) flames. The center flame should be steady, medium hard blue enveloping 3/8 to a 1/2 inch of thermocouple.
III.
IV. Service 1. Inspection should be conducted annually. Service as frequently as specified in paragraphs below. While service or maintenance is being done, Electrical Power and all Gas Supply to the Boiler must be "off". CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. ATTENTION. Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher.
8. Hold burner at throat. Lift front of burner to clear orifice. Burner which holds pilot can only be removed by lifting the burner adjacent to its right first. 1" Burner 40mm Burner If pilot assembly, thermocouple or pilot orifice need 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.
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. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
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......................................................
Key Description No. Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 2.
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Base Assembly Key Description No. Boiler Size Part No. Qty. 3 3A 32 Base Tray Boiler Size Part No. Qty. 3. Base Assembly Continued 3. Base Assembly Base Assembly (Complete) Available for 1 Inch Burners Only Key Description No.
Key Description No. Boiler Size Part No. Qty. 3C Base Front Panel Assembly Burner Tray (1" Main Burners) 3D Burner Tray (40mm Main Burners) Boiler Size Part No. Qty. 3. Base Assembly Continued 3. Base Assembly Continued 202 Key Description No.
Manifold and Main Burners (1 Inch Main Burners) 34
Key Description No. Part No. Quantity 202 202X 203 2 2 204 205 206 207 208 209 210 4.
Manifold and Main Burners (40mm Main Burners) Key No. Description Part No. Quantity 202X 203 204 205 206 207 208 209 210 4. 40 MM Main Burners Only 4A Main Burner 8236135 1 1 2 3 4 5 6 7 8 4B. 40 MM Main Burner, Electronic Ignition Only 4B Main Burner with 48° Pilot Bracket 8236143 --- --- --- --- --- --- --- --- --- Main Burner with 41° Pilot Bracket 8236136 1 1 1 1 1 1 1 1 1 4B.
Key No. Description Part No. Quantity 202X 203 204 205 206 207 208 209 210 4. 40 MM Main Burners Only (Continued) 4C.
* 1" Burner Only ** 40mm Burner Only Key Description No. Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas Valve, 24-volt Continuous Ignition, Natural Gas (1 Inch and 40mm Main Burners) 5A 5B 5C 5D 5E 5F 38 Pilot Burner, Honeywell Q350A1321 8236065 1 1 1 1 1 1 *1 Pilot Burner, Honeywell Q327A1006 8236022 --- --- --- --- --- --- **1 1 1 1 1 1 1 1 1 --- --- --- --- Pilot Orifice, Honeywell 388146AG .
Key Description No. Part No. Quantity 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) 5A 5B 5C 5D 5E 5F Pilot Burner, Honeywell Q327A1147 8236023 --- --- 1 1 1 1 1 1 1 1 Pilot Burner Assembly, Honeywell Q350A (Includes 5B & 5F) 8236105 1 1 --- --- --- --- --- --- --- --- --- --- 1 1 1 1 1 1 1 1 Pilot Orifice, Honeywell 390686-23 (.
Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 5. Pilot Burner and Gas Valve, Electronic Ignition (EI), Natural Gas 5A Pilot Burner, Honeywell Q348A1002 8236072 1 1 1 1 1 1 1 1 1 1 5B Pilot Orifice, Honeywell 388146NE Included with 5A 1 1 1 1 1 1 1 1 1 1 5C Compression Nut/Fitting, 1/4" OD x 1/4 C.C.
Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 6.
Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 6.
Water Trim 44
Key No. 7 Description Part No. Quantity Safety Relief Valve, 30 psi, 3/4 NPT, Conbraco 10-408-05 81660319 1 Safety Relief Valve, 50 psi, 3/4 NPT, Conbraco 10-303-10 101662-01 1 8. Circulator, Bell & Gossett SLC-30 Option (Intermittent and Continuous Circulation Only) 8A Circulator with Gaskets, Bell & Gossett NRF-22 8B Gasket, Bell & Gossett NRF-22 8056174 1 806602029 2 8.
Key No. Description Part No. Quantity 8136259 1 12. Transformer/Relay Assembly (Intermittent Circulation Only) 12A Junction Box, 4" x 4" x 1-1/2" 12B Transformer/Relay, Honeywell R8285D5001 80160155U 1 12C Relay, Honeywell R8222U1006 80160096U 1 12. Transformer (Continuous and Gravity Circulation Only) 12A Junction Box, 4" x 4" x 1-1/2" 8136259 1 12D Transformer, 40VA, Honeywell AT140D1012 or AT72D1188 80160039 1 13.
Key No. Description Part No. Quantity 202 202X 203 204 205 206 207 208 209 210 16.
SERVICE RECORD DATE 48 SERVICE PERFORMED
SERVICE RECORD DATE SERVICE PERFORMED 49
SERVICE RECORD DATE 50 SERVICE PERFORMED
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 A low water cutoff is required to protect a hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same floor level as the boiler).
Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS Subject to the terms and conditions set forth below, U.S. Boiler Co., Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1,1991: ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER BOILERS U.S. Boiler Co., Inc.