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- Installation, Operating And Service Instructions
U.S. Boiler Company B series 2 Installation, Operating And Service Instructions
103385-01 - 1/11
Price - $5.00
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
Series 2
®
(model B)
Gas - Fired Boiler
9700609
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Summary of B series 2
Page 1
103385-01 - 1/11 price - $5.00 installation, operating and service instructions for series 2 ® (model b) gas - fired boiler 9700609 , 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 ...
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 ...
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. Boiler model number dimensions [inches] gas connection for automatic gas valve water c...
Page 4
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 immediat...
Page 5
5 e. 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 thr...
Page 6
A. Allowable loss of pressure to assure a burner manifold pressure of 3½" (8.9cm) water for natural gas. B. Supply of gas to be provided in cubic feet. C. Length of piping and number of fittings. D. Specific gravity of gas. E. Correction factor for specific gravity. 9. Boiler piping caution failure ...
Page 7
Figure : recommended water piping for zone valve zoned heating systems figure : recommended piping for combination heating & cooling (refrigeration) 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 fre...
Page 8
Figure b. Pinch the black strain relief bushing installed in the jacket right side panel to dislodge it from the jacket and pull just enough of the black power cord out so the blocked vent switch will reach the near side of the draft hood skirt. Do not pull out more power cord than necessary. C. Pos...
Page 9
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. Re...
Page 10
10 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,...
Page 11
11 speed. Do not operate a summer exhaust fan. Close fireplace dampers. D. Place in operation the appliance being inspected. Follow the lighting (or operating) instructions. Adjust thermostat so appliance will operate continuously. E. Test for spillage at the draft hood relief opening after 5 minute...
Page 12
1 figure : vent damper schematic wiring diagram 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 sy...
Page 13
1 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. Where condensat...
Page 14
1 figure 1: 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 ful...
Page 15
15 figure 1: wiring diagram, 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 m...
Page 16
1 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 opens (see paragraphs 17a through 17d). When the damper blade reaches the fully open position, the ignition module is e...
Page 17
1 figure 15: wiring schematic, zone valves figure 1: wiring schematic, zone circulators.
Page 18
1 ii. Operating instructions 1. 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. 2. Initial start - a. Fill entire he...
Page 19
1 figure 0: operating instructions, vr0 and vr0 gas valves figure 1: top view of vr gas valves.
Page 20
0 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. ...
Page 21
1 table : green led flame codes green led flash code a indicates next system action recommended service action off no “call for heat” n/a none flash fast power up - internal check n/a none heartbeat normal startup - ignition sequence started (including prepurge) n/a none 4 seconds on then “x” flashe...
Page 22
Figure : lighting instructions.
Page 23
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 na...
Page 24
Figure : typical pilot flame, honeywell qa 6. 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 1" diameter burners. See figure 25. The pilot produces a single flame. The flame should be steady...
Page 25
5 figure : troubleshooting guide, honeywell electronic ignition (ei) iii. Trouble shooting honeywell electronic ignition troubleshooting guide "call for heat." power to module? (24 v nominal) no yes 30 second prepurge delay?(s8670 only) yes spark across ignitor/ sensor gap? Yes no check line voltage...
Page 26
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 ...
Page 27
Figure 0: burner cleaning and installation 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. 9. Brush top of burners with a soft bristle brush, see figure 30. Vacuum burners. Check orifices...
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, ...
Page 29
V. Repair parts section assembly and canopy group ............................30 base assembly ..................................................................32 manifold and main burners 1 inch main burners ..................................................34 40mm main burners ......................
Page 30
0 section assembly and canopy group key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 . Canopy group 2a canopy assembly (except for 206h) 61117022 1 --- --- --- --- --- --- --- --- --- 611170300 --- 1 --- --- --- --- --- --- --- --- 611170302 --- --- 1 --- --- --- --- --...
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Page 32
Base assembly key no. Description boiler size part no. Qty. . 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 1 209 618600991 1 210 618601091 1 3a...
Page 33
Key no. Description boiler size part no. Qty. . 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 burner tray (1" main burners) 202 7...
Page 34
Manifold and main burners (1 inch main burners).
Page 35
5 key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 . 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 --- --- --- --- --- --- --- --- --- 82...
Page 36
Manifold and main burners (0mm main burners) key no. Description part no. Quantity 202x 203 204 205 206 207 208 209 210 . 0 mm main burners only 4a main burner 8236135 1 1 2 3 4 5 6 7 8 b. 0 mm main burner, electronic ignition only 4b main burner with 48° pilot bracket 8236143 --- --- --- --- --- --...
Page 37
Key no. Description part no. Quantity 202x 203 204 205 206 207 208 209 210 . 0 mm main burners only (continued) c. 0mm main burner manifold 4c manifold 82260028 --- --- --- --- --- --- --- --- --- 82260038 1 1 --- --- --- --- --- --- --- 82260048 --- --- 1 --- --- --- --- --- --- 82260058 --- --- --...
Page 38
Key no. Description part no. Quantity 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) 5a pilot burner, honeywell q350a1321 8236065 1 1 1 1 1 1 *1 --- --- --- pilot burner, honeywell q327a1006 8236022 --- ---...
Page 39
Key no. Description 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 pilot burner, honeywell q327a1147 8236023 --- --- 1 1 1 1 1 1 1 1 pilot burner assembly, honeywell q350a (includes 5...
Page 40
0 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 compress...
Page 41
1 key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 . Jacket assembly, complete 6 jacket assembly, complete 604170254 1 --- --- --- --- --- --- --- --- --- 604170354 --- 1 1 --- --- --- --- --- --- --- 604170454 --- --- --- 1 --- --- --- --- --- --- 604170554 --- --- ---...
Page 43
Key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 . Jacket assembly (continued) 6b jacket vestibule panel 604170223 1 --- --- --- --- --- --- --- --- --- 604170323 --- 1 1 --- --- --- --- --- --- --- 604170423 --- --- --- 1 --- --- --- --- --- --- 604170523 --- --- --- -...
Page 44
Water trim.
Page 45
5 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 . Circulator, bell & gossett slc-0 option (intermittent and continuous circulation only) 8a circulator with gaskets, bell...
Page 46
Key no. Description part no. Quantity 12. Transformer/relay assembly (intermittent circulation only) 12a junction box, 4" x 4" x 1-1/2" 8136259 1 12b transformer/relay, honeywell r8285d5001 80160155u 1 12c relay, honeywell r8222u1006 80160096u 1 1. Transformer (continuous and gravity circulation onl...
Page 47
Key no. Description part no. Quantity 202 202x 203 204 205 206 207 208 209 210 1. Draft hood carton 16 draft hood 8116067 1 1 1 --- --- --- --- --- --- --- 8111702 --- --- --- 1 --- --- --- --- --- --- 8111703 --- --- --- --- 1 1 --- --- --- --- 8111704 --- --- --- --- --- --- 1 1 --- --- 8111705 --...
Page 48
Service record date service performed.
Page 49
Service record date service performed.
Page 50
50 service record date service performed.
Page 51
51 a 24 vac lwco is used primarily for gas fired boilers where a 24 volt control circuit exists within the boiler. However, a 24 vac lwco can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application. How to test shut off fuel s...
Page 52
5 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 (717) 397-4701 www.Usboiler.Burnham.Com.