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U.S. Boiler Company SERIES 3, Installation, Operating And Service Instructions

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U.S. Boiler Company SERIES 3 Installation, Operating And Service Instructions Download Page 1

103796-04 - 3/13

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

     

 30__B

Boiler Serial Number

Installation Date

Heating Contractor

Phone Number

Address

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

SERIES 3™

Gas - Fired Boiler

Summary of Contents for SERIES 3

Page 1: ...tor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number 30__B Boiler Serial Number Installation Date Heating Contractor Phone...

Page 2: ...stem is cool and free of pressure and that your clothing will protect you from a release of hot water or steam Do not rely solely on the boiler s temperature and pressure gage when making this judgmen...

Page 3: ...ure Gage NPT 100282 01 q Circulator Mounting Hardware Kit 1 1 4 NPT 6056007 q Drain Valve NPT 102802 01 q Pressure Relief Valve 30 psi 81660363 q Water Manifold for Pressure Relief Temp Gage 80607001...

Page 4: ...imensions and Connections Electrical Requirements 120VAC 60 hz 1 ph 15A Maximum Allowable Working Pressure 50 psi Boiler shipped from factory with a 30 psi relief valved Boiler Model Allowable Supply...

Page 5: ...5 Figure S 1 Minimum Clearances to Combustibles and Alcove Dimensions SPECIFICATIONS continued...

Page 6: ...9 Check for gas and water leaks 16 10 Perform startup checks and adjustments 17 Annual Maintenance Checklist 18 Troubleshooting 19 Repair Parts List 25 Internal Wiring 31 Appendices A Combustion Air...

Page 7: ...e contents from the skid except the boiler 3 Remove the four 4 hex drive lag screws holding the boiler to the skid Figure 1 a DO NOT DAMAGE front air dam It is required for proper operation of the boi...

Page 8: ...y cause fire or explosion CLEAN BURNERS DAILY if operating the boiler in a dusty environment PROTECT IGNITION SYSTEM COMPONENTS from sources of water that may spray drip or rain on them during install...

Page 9: ...lop a positive flow adequate to convey flue or vent gases to the outdoors while ensuring that flue gases do not cool prematurely Observe all general venting guidelines provided in Appendix B Venting A...

Page 10: ...S PIPING MUST BE GAS TIGHT Use gas rated thread compound on all threaded joints to avoid leaks which may result in fire or explosion SIZE GAS PIPING regulators valves and meters so as to provide an ad...

Page 11: ...6 CONNECT BOILER WATER PIPING continued 9 See Figure 6b for suggested near boiler piping of IQ Options 6 b Item Description Part Number 1 1 x 1 x Tee 806601021 2 Immersion Well NPT 80160456 3 1 x 6 Ni...

Page 12: ...arked circulator WIRE AN ADDITIONAL SAFETY LIMIT such as a low water cutoff or temperature limit device other than an IQ Control device in series with the 120V circuit used to power the boiler Do not...

Page 13: ...next Each setting will alternately flash between the relevant display code and its corresponding value Operating Mode Options StA Status bt Boiler Temperature SP Operating Setpoint Outdoor Reset HL H...

Page 14: ...The Outdoor Reset IQ Option Card reduces the Operating Setpoint to regulate heat delivery increase home comfort and save energy Refer to the Appendix I for additional information The High Limit Setpo...

Page 15: ...r heat does not force off the system circulator The Priority Time has a factory setting of On and is field adjustable between On and Off Refer to Table 8b 7 Domestic Hot Water DHW Terminal Function dh...

Page 16: ...o add functionality safety and efficiency to your heating system The IQ Option Panel provides an easy and convenient means to plug in an Auxiliary High Limit Low Water Cut off and or Outdoor Reset fun...

Page 17: ...an and blue 6 Disconnect pilot lead wires from gas valve Figure 10 b q Boiler shuts off 7 Reconnect pilot lead wires to gas valve q Boiler restarts 8 Adjust zone thermostat to minimum setting q Boiler...

Page 18: ...Clean low water cutoff probe if applicable 2 Inspect vent for obstruction and signs of condensation distortion overheating or gas leakage 3 Clean vent terminal and air intake screens 4 Inspect boiler...

Page 19: ...ve control or component is generally the least likely cause Before replacing a component try to rule out all other possible causes 5 When checking voltage across wiring harness pins be careful not to...

Page 20: ...If problem persists replace control eRR 35 Duplicate Zone Alarm Refer to IQ Zone Panel Instructions Err 55 Damper Failed to Open Atmospheric Damper End Switch failed to close end switch contacts stuck...

Page 21: ...ain on until the thermostat is turned off The source of blockage must be corrected by trained and skilled personnel from a qualified service agency before resetting switch Blocked Vents are caused by...

Page 22: ...nded corrective action Err 23 Flame sensed during post purge before gas valve signaled open Check the gas valve for proper operation Replace gas valve is problem persists STA 14 Hard Lockout When a ha...

Page 23: ...ot supply tubes of air b If no gas flow check the following 24 volts across PV and MV PV at gas valve if voltage ok replace defective gas valve Check for break in wiring harness to gas valve 24 volts...

Page 24: ...l are not causing the open limit IQ Option Panel Display Shows ERR Display Status Boiler Control Action s Err 1 Low Input Voltage AC voltage is too low Err 2 card IQ Option Card Type Change without Re...

Page 25: ...305B 306B 307B 308B 309B 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 0...

Page 26: ...02705 03 102705 04 102705 05 102705 06 102705 07 102705 08 102705 09 2E Burner Access Panel 102707 03 102707 04 102707 05 102707 06 102707 07 102707 08 102707 09 2F Base Gasket Kit 6206002 2G Base Sid...

Page 27: ...old 82207031 82207041 82207051 82207061 N A Gas Manifold N A 82207071 82207081 82207091 3C Burner Orifices Natural Gas 47 4 822710 6 822710 8 822710 10 822710 12 822710 14 822710 16 822710 Burner Orif...

Page 28: ...ey No Description Quantity Part Number 303B 304B 305B 306B 307B 308B 309B 4A Control 103660 01 4B IQ Option Panel 102291 01 4C Transformer 102516 01 4D Temperature Sensor 102411 01 Temperature Sensor...

Page 29: ...2565 07 102565 08 102565 09 5E Jacket Top Panel 102568 03 102568 04 102568 05 102568 06 102568 07 102568 08 102568 09 5F Jacket Front Door 102576 03 102576 04 103717 05 103717 06 103717 07 103717 08 1...

Page 30: ...7B 308B 309B 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 04 1...

Page 31: ...31 INTERNAL WIRING Figure IW 1 Wiring Diagram...

Page 32: ...32 INTERNAL WIRING continued Figure IW 2 Wiring Schematic...

Page 33: ...33 INTERNAL WIRING continued Figure IW 3 Multiple Zone System with Zone Circulators Figure IW 4 Multiple Zone System with Zone Valves...

Page 34: ...N O COM N C ZONE 4 RELAY DHW CIRCULATOR SUPPLIED BY OTHERS JUMPER 3 4 2 WIRE ZONE VALVE NO END SWITCH 2 WIRE ZONE VALVE NO END SWITCH 1 4 WIRE ZONE VALVE POWER OPEN SELF CLOSING JUMPER 3 4 PRIORITY Z...

Page 35: ...s the boiler located in a building of unusually tight construction 5 If the answer to all of the three questions below is yes then you must provide outdoor air to the boiler room Do the walls and ceil...

Page 36: ...ing connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch and d...

Page 37: ...ture de d charge Utiliser la flamme d une allumette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe APPENDIX B Venting continued 6 Une fois qu il a t d termin selon la m thode...

Page 38: ...t be vented into the same chimney space as this boiler DO NOT REDUCE THE DIAMETER of the vent connector between the boiler and the chimney It must not be smaller than the outlet on the draft hood damp...

Page 39: ...manuel dans le code local et le National Fuel Gas Code ou CAN CSA B149 1 Les chemin es en ma onnerie rev tues int rieurement d argile ne respectent pas les exigences d vacuation de cet appareil NE PAS...

Page 40: ...1400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240...

Page 41: ...iler and provide many years of comfort to the building occupants Be sure to protect the boiler from the following problems 1 Corrosion 1 Comply with the boiler s specific water quality requirements Se...

Page 42: ...urn water and supply water temperature requirements Install a boiler bypass system bypass or primary secondary loop when needed to maintain water temperatures and flows within the specified limits 3 D...

Page 43: ...43 APPENDIX D System Piping continued Figure D W2 Recommended Water Piping for Zone Valve Zoned heating Systems...

Page 44: ...44 APPENDIX D System Piping continued Figure D W3 Recommended Water Piping for Circulator Zoned heating Systems...

Page 45: ...onvector and repeat procedure until all convectors in the loop are purged of air 10 Close the opened zone valve or shut off valve for the zone being purged of air 11 Open the zone valve or shut off va...

Page 46: ...djustment screw clockwise to increase manifold pressure or counterclockwise to decrease manifold pressure Figure F 2 Several turns may be required Do not force the adjustment screw DO NOT EXCEED the b...

Page 47: ...matches the required CO2 or O2 specified for the boiler If CO2 O2 or CO fall outside of the range specified for the boiler review the installation and startup instructions and make any necessary adjus...

Page 48: ...vides status information to help determine the cause of the problem Table 5 provides a list of boiler status codes that are reported Refer to the Troubleshooting Section for more information Status Co...

Page 49: ...outdoor temperature increases the Operating Setpoint temperature is reduced from the High Limit Setting to save energy while improving home comfort By better matching boiler heat supply to actual home...

Page 50: ...The Operating Setpoint is set to the DHW Setpoint when the Control or Outdoor Reset Option Card DHW input is energized This setpoint is set equal to the Indirect Water Heater manufacturer s recommende...

Page 51: ...t curve to save energy while the home is in a reduced room temperature mode Honeywell VisionPro IAQ Setback Thermostat Honeywell P N TH942lc1004 The Display Kit provides a 3 5 LCD multi color Touch Sc...

Page 52: ...nal pipe fittings are required 102717 01 Aquastat IQ Option Card 130 220 F 15 F Adjustable Differential Auto Reset for use with Option Control Panel Temperature Sensor with 36 inch lead Well Sensor Cl...

Page 53: ...53 SERVICE RECORD DATE SERVICE PERFORMED...

Page 54: ...54 SERVICE RECORD DATE SERVICE PERFORMED...

Page 55: ...55 SERVICE RECORD DATE SERVICE PERFORMED...

Page 56: ...56 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...

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