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  5. Installation, Operating And Service Manual

U.S. Boiler Company X-203 Installation, Operating And Service Manual

Manual is about: X-2 Series

Summary of X-203

  • Page 1

    106636-01 - 10/15 9700609 price - $5.00 for service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide boiler model number and serial number as shown on rating label. Boiler model number x-20 boiler serial number installation date heating contractor phone...

  • Page 2

    2 the following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. Danger indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substanti...

  • Page 3

    3 table 1a: dimensions and connections boiler model depth width height supply npt (inch) return npt (inch) vent (inch) gas npt (inch) relief valve npt (inch) drain npt (inch) x-203 32 14 40 1¼ 1¼ 4 ½ ¾ ¾ x-204 32 16 40 1¼ 1¼ 5 ½ ¾ ¾ x-205 32 19 40 1¼ 1¼ 6 ½ ¾ ¾ x-206 32 22 40 1¼ 1¼ 6 ½ ¾ ¾ x-207 32 ...

  • Page 4

    4 figure 1: minimum clearance to combustible materials and alcove dimensions.

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    5 i. Pre-installation warning carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. A . Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our re...

  • Page 6

    6 iii. Water piping and trim warning failure to properly pipe boiler may result in improper operation and damage to boiler or building. A. Design and install boiler and system piping to prevent oxygen contamination of boiler water. Oxygen contamination sources are system leaks requiring addition of ...

  • Page 7

    7 figure 4: recommended w ater piping for zone v alve zoned heating systems iii. W ater piping and t rim (continued).

  • Page 8

    8 figure 5: recommended w ater piping for circulator zoned heating systems iii. W ater piping and t rim (continued).

  • Page 9

    9 iv. Venting a. Install vent damper open the vent damper carton and remove the installation instructions. Read the installation instructions thoroughly before proceeding. The automatic gas control valve supplied on each x-2 series boiler provides the redundancy referenced in the vent damper install...

  • Page 10

    10 building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maxi mum speed. Do not operate a summer exhaust fan. Close fireplace dampers. D. Place in operation the appli...

  • Page 11

    11 a. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional informat...

  • Page 12

    12 vi. Electrical a. General. Install wiring and electrically bond boiler to ground in accordance with requirements of authority having jurisdiction, or in absence of such requirements, with the national electrical code , ansi/nfpa 70. B. Install thermostat. Locate on inside wall approximately 4 fee...

  • Page 13

    13 figure 8: wiring connection diagram vi. Electrical (continued).

  • Page 14

    14 figure 9: schematic ladder diagram vi. Electrical (continued).

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    15 vi. Electrical (continued) figure 10: wiring schematic, zone valves figure 11: wiring schematic, zone circulators.

  • Page 16

    16 vii. System 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 vertical slots in the rear of burner tray and the front of the burners should be seated completely on the orifices. B. Initial start -...

  • Page 17

    17 figure 14: operating instructions vii. System start-up and checkout (continued).

  • Page 18

    18 vii. System start-up and checkout (continued) caution 11. Test gas piping and connections between combination gas valve and manifold, orifices, and pilot piping for leaks after boiler is operating. Use soap solution or other approved method. C. Check gas input to boiler 1. Input rate and maximum ...

  • Page 19

    19 vii. System start-up and checkout (continued) figure 16: pilot burner flame j . Combustion chamber burn-off 1. The mineral wool combustion chamber panels may contain a cornstarch based binder that must be burned out at installation to prevent odors during subsequent boiler operation. 2. Ventilate...

  • Page 20

    20 viii. Operation status codes displayed in sta mode status sta description standby (burner off circulator off) 1 no call for heat detected circulator pre-purge (burner off circulator on) 1 either condition is true: a. Call for heat detected and boiler temperature higher than operating setpoint. B....

  • Page 21

    21 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 , down , and “ i ” keys simultaneously for three (3) seconds. This procedure is intended to discourage unauthorized chan...

  • Page 22

    22 viii. Operation (continued) 3. Press the up and down keys to adjust the displayed item to the desired value. 4. To return to the normal operating mode from the adjustment mode, when the " bac ” option is displayed, press either the up or down key. If no keys are pressed, after five (5) minutes th...

  • Page 23

    23 viii. Operation (continued) table 5: dhw terminal function ( dh_ ) selection = domestic hot water demand, (parameter dh_ = dh) call for heat circulator status t-t input dhw input priority time ( pt_ ) system circulator output dhw circulator output on off on on off on on on off on off on on off on...

  • Page 24

    24 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 ...

  • Page 25

    25 a. General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions to turn off gas to appliance. See figure 14. Caution label all wires prior to disconnection when servicing controls. Wiring errors...

  • Page 26

    26 ix. Service and maintenance (continued) g. Lubrication. There are no parts requiring lubrication by service technician or owner. Circulator bearings are water lubricated..

  • Page 27

    27 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 28

    28 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 29

    29 x. Troubleshooting (continued) 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: 2. Circulator is on, but boiler is off display / status recommended corrective action sta1 cir...

  • Page 30

    30 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 31

    31 x. Troubleshooting (continued) 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: - loo...

  • Page 32

    32 xi. Repair parts key no. Description [quantity] part number x-203 x-204 x-205 x-206 x-207 x-208 x-209 1a block assembly 102287-03 102287-04 102287-05 102287-06 102287-07 102287-08 102287-09 1b canopy gasket kit 6206001 1c canopy assembly 102554-03 102554-04 102554-05 102554-06 102554-07 103860-08...

  • Page 33

    33 xi. Repair parts (continued) key no. Description [quantity] part number x-203 x-204 x-205 x-206 x-207 x-208 x-209 2a base wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 2b base tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 2c burner tray assemb...

  • Page 34

    34 xi. Repair parts (continued) key no. Description [quantity] part number x-203 x-204 x-205 x-206 x-207 x-208 x-209 3a gas valve (natural gas), honeywell vr8204p1171 81660282 n/a gas valve (natural gas), honeywell vr8304p4496 n/a 81660283 gas valve (lp gas), honeywell vr8204c3015 81660146 n/a gas v...

  • Page 35

    35 xi. Repair parts (continued) key no. Description [quantity] part number x-203 x-204 x-205 x-206 x-207 x-208 x-209 4a control 103660-01 4b transformer 102516-01 4c temperature sensor 103195-01 4d temperature sensor/lwco (if equipped) 106495-02 temperature sensor spring clip (not shown) 102422-01.

  • Page 36

    36 xi. Repair parts (continued) key no. Description [quantity] part number x-203 x-204 x-205 x-206 x-207 x-208 x-209 5a jacket wrap-around jacket panel 106357-03 106357-04 106357-05 106357-06 106357-07 106357-08 106357-09 5b jacket vestibule panel 106358-03 106358-04 106358-05 106358-06 106358-07 10...

  • Page 37

    37 xi. Repair parts (continued) key no. Description [quantity] part number x-203 x-204 x-205 x-206 x-207 x-208 x-209 6a supply water manifold 80607001 6b temperature/pressure gauge 100282-01 6c 30 psi relief valve 81660363 6d drain valve 102802-01 6e vent damper 102284-01 102284-02 102284-03 102284-...

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  • Page 40

    40 u.S. Boiler company, inc. P.O. Box 3020 lancaster, pa 17604 1-888-432-8887 www.Usboiler.Net.