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- U.S. Boiler Company
- Boiler
- 202
- Installation, Operating And Service Instructions
U.S. Boiler Company 202 Installation, Operating And Service Instructions
103698-04 - 10/14
Price - $5.00
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
Series 2
®
Gas - Fired Boiler
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9700609
9700609
Summary of 202
Page 1
103698-04 - 10/14 price - $5.00 installation, operating and service instructions for series 2 ® gas - fired boiler , r e li o b n o n o it a m r o f n i g n i k e e s n e h w . R o t c a r t n o c g n it a e h r u o y ll a c , r e li o b o t s r i a p e r r o e c i v r e s r o f .L e b a l g n it a ...
Page 2
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 boiler...
Page 3
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 ...
Page 4
4 table of contents i. Product description, specifications and dimensional data...................... 4 ii. Pre-installation & boiler mounting ............................................................ 6 iii. Gas piping..................................................................................
Page 5
5 i. Product description, specifications and dimensional data (continued) figure 1: line drawing boiler model number dimensions [inches] gas connection for automatic gas valve water content [gallons] recommended vent size [2] approx. Shipping weight [lb.] a b c d e f g 202 18-3/4 10-3/4 6-3/8 4 45-5...
Page 6
6 ii. Pre-installation and boiler mounting warning if you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. A. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our res...
Page 7
7 or 8.4 of natural gas and propane installation code, can/csa b149.1, or applicable provisions of local building codes. A. Closet installations (confined space) in a building of other than unusually tight construction (see definition below), provide combustion and ventilation air as shown in figure...
Page 8
8 iii. Gas piping a. Connect gas service from meter to gas control assembly in accordance with local piping codes and requirements of gas company. They may require piping of larger size than control assembly connection, especially if run from meter is long or includes several elbows. See figure 1 fo...
Page 9
9 a. Boiler water piping caution failure to properly pipe boiler may result in improper operation and damage to boiler or building. 1. Clearances - hot water pipes do not require clearance from combustible construction. 2. Install drain valve and safety relief valve as shown in figures 1 and 4. Note...
Page 10
10 iv . B oiler w ater p iping (continued ) figure 5: recommended w ater piping for zone v alve zoned heating systems.
Page 11
11 iv . B oiler w ater p iping (continued ) figure 6: recommended w ater piping for circulator zoned heating systems.
Page 12
12 iv. Boiler water piping (continued) there are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system leaks. B. Absorption through open tanks and fittings. C. Oxygen permeable materials in the distribution system. In order to insure long ...
Page 13
13 4. Piping and fittings required to install lwco are field supplied. 5. When constructing a piping tree to install lwco select fittings (tees, elbows etc) and nipples to have the same size (npt) as boiler supply connection. At minimum, 1-1/4” tee with ¾” branch outlet is required to connect the pr...
Page 14
14 figure 10: blocked vent switch installation diagram a. 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 g...
Page 15
15 figure 11: plug-in damper installation 1. The vent damper must be the same size as the outlet of the draft hood supplied with the boiler (see figure 1). Unpack the damper carefully - do not force it closed! Forcing the damper may damage the gear train and void the warranty. 2. Mount the vent damp...
Page 16
16 figure 12: typical vent installation 4. Do not connect into same leg of chimney serving an open fireplace. 5. Inspect chimney for obstructions or restrictions and remove. Clean chimney if necessary. 6. Vent pipe to chimney must not be smaller than outlet on draft hood or damper. Although single w...
Page 17
17 5. 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. 6. After it has been determined that each appliance remain ing connected to the common venting system properly vents when t...
Page 18
18 a. Install a room thermostat on an inside wall about four feet above floor. Never install thermostat on an outside wall or where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, rays of the sun or near a fireplace. Keep large furniture away from thermostat ...
Page 19
19 figure 13: connection wiring diagram, intelligent hydronic control vi. Electrical (continued).
Page 20
20 figure 14: ladder wiring diagram, intelligent hydronic control vi. Electrical (continued).
Page 21
21 figure 15: wiring schematic, zone valves figure 16: wiring schematic, zone circulators vi. Electrical (continued).
Page 22
22 vii. Start-up and checkout a. 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. B. Initial start - 1. Fill entire h...
Page 23
23 figure 19: operating instructions, vr8204 and vr8304 gas valves vii. Start-up and checkout (continued).
Page 24
24 c. 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 ap...
Page 25
25 vii. Start-up and checkout (continued) e. Check pilot burner flame. See figure 22. The pilot produces three (3) flames. The center flame should be steady, medium hard blue enveloping 3/8 to a ½ inch of sensing probe. F. Check thermostat operation. Raise and lower temperature setting as required t...
Page 26
26 viii. Operation a. Boiler sequence of operation normal operation 1. The series 2 boilers are equipped with an intelligent hydronic control (control). This control replaces the traditional separate ignition control, high limit switch and circulator relay and adds energy saving thermal purge featur...
Page 27
27 viii. Operation (continued) d. Viewing the operating mode options in operating mode the user may view (but not change) boiler operating status, settings and troubleshooting information. To view control display information: 1. Press and release the “ i ” key on the control to change from one param...
Page 28
28 viii. Operation (continued) e. Changing the adjustable parameters to adjust parameters such as high limit setpoint and high limit differential: 1. Access the adjustment mode by pressing and holding the up ñ, down ò, and “ i ” keys simultaneously for three (3) seconds. This procedure is intended t...
Page 29
29 viii. Operation (continued) system circulator. The priority time has a factory setting of “on” and is field adjustable between “on” and “off” refer to table 8. 7. Domestic hot water (dhw) terminal function (dh_) the control allows configuration of the dhw circulator output functionality to help t...
Page 30
30 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 a...
Page 31
31 a. 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 ca...
Page 32
32 1. To remove burners for cleaning, changing orifice plugs, or repairs. A. Remove the jacket front panel. B. Disconnect pilot tubing at the gas valve. See figure 17. C. Disconnect 3-wire plug at the gas valve. D. 40mm burners only. Remove injection shield assembly, where used. See figure 26. E. Re...
Page 33
33 ix. Service and maintenance (continued) b. Disconnect pilot piping. C. Disconnect all other leads to pilot. D. Select pilot assembly with identical model number, reconnect leads and pilot tubing - re- secure to pilot bracket. 3. To adjust or check spark gap between electrode and hood on honeywell...
Page 34
34 x. Troubleshooting a. Before troubleshooting the following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1. This information is only meant to be used by a professional heating technician as an aid in dia...
Page 35
35 x. Troubleshooting (continued) display status recommended corrective action blank boiler or control is not powered no 120 vac power at boiler, check breaker and wiring between breaker panel and boiler err 4 flame current lower than threshold check pilot assembly. Refer to troubleshooting section,...
Page 36
36 c. 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: x. Troubleshooting (continued) 2. Circulator is on, but boiler is off display / status recommended corrective action sta1 circu...
Page 37
37 x. Troubleshooting (continued) 6. Circulator is on, damper is open but boiler fails to start display / status description sta 10 retry / recycle delay the boiler is in “retry delay”: - the burner failed to light (no flame signal). After a 5 minute delay, control will attempt to light the burner a...
Page 38
38 display / status recommended corrective action sta 10 retry / recycle delay sta 13 soft lockout 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...
Page 39
39 xi. Repair parts section assembly and canopy group ............................40 base assembly ..................................................................42 manifold and main burners 1 inch main burners ..................................................44 40mm main burners ..................
Page 40
40 section assembly and canopy group xi. Repair parts (continued).
Page 41
41 key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 1. Section assembly 1 section assembly, complete 103918-02 1 --- --- --- --- --- --- --- --- --- 103918-03 --- 1 1 --- --- --- --- --- --- --- 103918-04 --- --- --- 1 --- --- --- --- --- --- 103918-05 --- --- --- --- 1...
Page 42
42 xi. Repair parts (continued) base assembly key no. Description boiler size part no. Qty. 3. Base assembly 3 base assembly (complete) available for 1 inch burners only 202 618600291 1 202x 618600391 1 203 618600391 1 204 618600491 1 205 618600591 1 206 618600691 1 207 618600791 1 208 618600891 1 2...
Page 43
43 xi. Repair parts (continued) key no. Description boiler size part no. Qty. 3. Base assembly continued 3c base front panel assembly 202 618600241 1 202x 618600341 1 203 618600341 1 204 618600441 1 205 618600541 1 206 618600641 1 207 618600741 1 208 618600841 1 209 618600941 1 210 618601041 1 3d bu...
Page 44
44 manifold and main burners (1 inch main burners) xi. Repair parts (continued).
Page 45
45 xi. Repair parts (continued) key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 4. Manifold and main burners (1 inch main burners only) 4a main burner 8236099 1 2 2 4 6 8 11 13 15 17 4b main burner with pilot bracket ----- see table below 4c manifold 82260023 1 --- ---...
Page 46
46 manifold and main burners (40mm main burners) xi. Repair parts (continued) key no. Description part no. Quantity 203 202x 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 with pilot bracket 4b main burner with 41° pilot bracket ...
Page 47
47 xi. Repair parts (continued) key no. Description part no. Quantity 202x 203 204 205 206 207 208 209 210 4. 40 mm main burners only (continued) 4c. 40mm main burner manifold 4c manifold 82260038 1 1 --- --- --- --- --- --- --- 82260048 --- --- 1 --- --- --- --- --- --- 82260058 --- --- --- 1 --- -...
Page 48
48 xi. Repair parts (continued) key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 5. Pilot burner and gas valve, natural gas 5a pilot burner, honeywell q3481b1206 with fiberglass insulated integral 36" lg. Igniter/ sensor cable 103704-01 1 1 1 1 1 1 1 1 1 1 5b pilot burn...
Page 49
49 xi. Repair parts (continued) key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 6. Jacket assembly, complete 6 jacket assembly, complete 604170254 1 --- --- --- --- --- --- --- --- --- 604170354 --- 1 1 --- --- --- --- --- --- --- 604170454 --- --- --- 1 --- --- --- --...
Page 50
50 xi. R ep air p arts (continued ) jacket assembly.
Page 51
51 xi. Repair parts (continued) key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 6. Jacket assembly (continued) 6b jacket vestibule panel 604170223 1 --- --- --- --- --- --- --- --- --- 604170323 --- 1 1 --- --- --- --- --- --- --- 604170423 --- --- --- 1 --- --- --- --...
Page 52
52 water trim xi. Repair parts (continued).
Page 53
53 xi. Repair parts (continued) key no. Description part no. Quantity 7 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 8a circulator with gaskets, bell & gossett nrf-...
Page 54
54 key no. Description part no. Quantity 12. Transformer/j-box/controls 12a junction box, 4" x 4" x 1-1/2" 8136259 1 12b junction box cover 8136027 1 13a flame rollout switch 80160044 1 13b flame rollout switch mounting bracket (all models except 202) 7186018 1 14 blocked vent switch replacement ass...
Page 55
55 xi. Repair parts (continued) draft hood key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 16. Draft hood carton 16 draft hood 8116067 1 1 1 --- --- --- --- --- --- --- 8111702 --- --- --- 1 --- --- --- --- --- --- 8111703 --- --- --- --- 1 1 --- --- --- --- 8111704 --...
Page 56
56 figure number page number description section i - product description, specifications & dimensional data figure 1 5 line drawing section ii - pre-installation & boiler mounting figure 2 7 minimum clearances section iii - gas piping figure 3 8 recommended gas piping section iv - boiler water pipin...
Page 57
57 appendix a - figures (continued) figure number page number description section xi - repair parts n/a 40 section assembly & canopy group n/a 42 base assembly n/a 44 maniflold & main burners (1 inch main burners) n/a 46 manifold & main burners (40mm main burners) n/a 48 pilot burner & gas valve n/a...
Page 58
58 n/atable nun/ amber page number description section iii - gas piping table 1 5 dimensions table 2 8 maximum capacity of schedule 40 pipe in cfh for natural gas pressures of ½ psig or less table 3 8 equivalent length of fittings table 4 8 specific gravity correction factors for natural gas section...
Page 59
59.
Page 60
60 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.