U.S. Boiler Company 202E, Installation, Operating And Service Instructions

Page 1: ...ns 3 Pre installation 4 Removing Existing Boiler 5 Clearances 5 Venting 7 Water Piping 10 Gas Piping 13 Electrical 14 System Start Up and Checkout 17 Operation 21 Before Leaving Jobsite 25 Service and...

Page 2: ...erate injury WARNING Indicates a hazardous situation that if not avoided could result in death or serious injury DANGER Explosion Hazard DO NOT store or use gasoline or other flammable vapors or liqui...

Page 3: ...in Height in Supply NPT Return NPT Vent in Gas NPT Relief Valve NPT Drain NPT Maximum Allowable Working Pressure PSI 202E 2 27 14 32 1 1 4 1 1 4 3 1 2 3 4 3 4 50 203E 3 27 14 32 1 1 4 1 1 4 4 1 2 3 4...

Page 4: ...control replacement etc I Provide combustion and ventilation air in accordance with the section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or applicable prov...

Page 5: ...r Operating Instructions Adjust thermo stat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a matc...

Page 6: ...ood and vent connector Additional height required to maintain 6 clearance from all vent connector components Vent damper may be installed in vertical or horizontal section of vent connector within rea...

Page 7: ...s 4 Do not use CPVC PVC Polypropylene or any other non metallic vent pipe Do not use cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone 5 Do not cover non metallic vent pipe and...

Page 8: ...Gas Code ANSI Z223 1 NFPA 54 and allow vent downsizing when vent size determined by their Vent Sizing Tables is smaller than draft hood outlet vent damper These codes require all of following a Total...

Page 9: ...ons located at least 8 ft from vertical wall or similar obstruction termination shall extend above roof in accordance with Figure 5 3 3 For terminations located less than 8 ft from vertical wall or si...

Page 10: ...rance from hot water piping to combustible materials E If boiler is used in connection with refrigeration system See Appendix Combination Refrigeration Heating System F Use a system bypass if boiler i...

Page 11: ...ne Valve Controlled System System Circulator System Zone Valves Zone Circulators Full Port Isolation Valves Flow Check From System Full Port Isolation Valves Drain Valve Safety Relief Valve Pipe withi...

Page 12: ...e within 6 of floor or drain Drain Valve IWH Return IWH Supply Indirect Water Heater IWH Air Separator Air Vent Expansion Tank Backflow Preventer Fill Valve Cold Water Return Full Port Isolation Valve...

Page 13: ...ent i e water heater cooking equipment B Connect boiler to gas supply system 1 Use methods and materials in accordance with local plumbing codes and requirements of gas supplier In absence of such req...

Page 14: ...be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions Connect to black and white...

Page 15: ...15 SERIES 2E Installation Operating Service Manual 109443 02 12 19 Figure 8 1 Wiring Connection Diagram 8 Electrical continued...

Page 16: ...16 SERIES 2E Installation Operating Service Manual 109443 02 12 19 Figure 8 2 Schematic Ladder Diagram 8 Electrical continued...

Page 17: ...minate hose in five gallon bucket at a suitable floor drain or outdoor area 5 Starting with one circuit open zone valve or start circulator 6 Open drain valve 7 Open fill valve 8 Allow water to flow t...

Page 18: ...18 SERIES 2E Installation Operating Service Manual 109443 02 12 19 Figure 9 2 Operating Instructions 9 System Start Up and Checkout continued...

Page 19: ...MOSTAT to lowest setting 3 If limits are functioning properly LWCO Auxiliary limit flame rollout switch blocked vent switch damper boiler should spark If boiler does not spark see Section 14 Troublesh...

Page 20: ...listed on rating label 3 Turning regulator adjustment screw clockwise increases pressure 4 Turning regulator adjustment screw counterclockwise decreases pressure M Check gas input rate to boiler 1 Wh...

Page 21: ...required to be able to light off again Limit Open 15 There is a call for heat from thermostat but Limit is open Flame Present Out of Sequence 16 Flame signal is still present when expected to be 0 no...

Page 22: ...point HL High Limit Setpoint HdF High Limit Differential Setpoint tt Heat Request Status dh DHW Heat Request Status FLA Flame Current run Run Time Hours CYC Boiler Cycles Err Error Press I key on cont...

Page 23: ...ture is less than 140 F This feature helps save energy by satisfying home heating needs with residual boiler heat rather than cycling boiler 5 Start Temperature Amount of heat available is calculated...

Page 24: ...Water Demand dh IWH limit is wired to DHW terminal on control DHW circulator is wired to DHW Circulator on control wire harness Table 10 6 shows circulator status with different combinations of TT In...

Page 25: ...et pressure Checked gas manifold pressure Checked CO level in vent Checked vent damper operation Check ignition system safety shut off device Tested LWCO functionality Tested high limit operation Test...

Page 26: ...ed loose fitting clothing that is sufficiently tight around potential entry points for RCF dust 3 Gloves 4 Eye protection such as goggles safety glasses with side shields or full facepiece Take steps...

Page 27: ...and there are no openings into chimney 3 Remove soot accumulations with wire brush and vacuum 4 Repair or replace deteriorated vent pipe and vent accessories 5 Inspect piping to determine that it is a...

Page 28: ...ner Access Panel Connect Flame Rollout Switch wires E Inspect Water Piping 1 Check all system piping for leaks 2 Repair any leaks before placing back into service 12 Service and Maintenance continued...

Page 29: ...up and Checkout Check LWCO Functionality S Check High Limit Control See Start up and Checkout Check High Limit Control T Check Thermostat Operation See Start up and Checkout Check Thermostat Operation...

Page 30: ...module indicates boiler status and returns error codes if applicable See Troubleshooting for guidance with error codes 2 Transformer Control transformer reduces line voltage to 24 volts for gas valve...

Page 31: ...31 SERIES 2E Installation Operating Service Manual 109443 02 12 19 9 3 4 5 7 6 2 1 8 13 How It Works continued...

Page 32: ...serious and potentially dangerous condition In the event the IDL 1200 detects a low water condition the system must be inspected by a qualified service technician before the boiler is returned to serv...

Page 33: ...in If 24Vac is present unplug vent damper harness from control With wire harness unplugged check for 24Vac between P6 5 on Control and ground If voltage present replace control If voltage not present...

Page 34: ...poor draft Always follow recommended clearances combustion air requirements and venting requirements Check Flame Rollout Switch in event of excessive blockage of boiler section flue passageways is de...

Page 35: ...ommended corrective action Flame sensed during post purge before gas valve signaled open Check gas valve for proper operation Replace gas valve if problem persists Hard Lockout When a hard lockout occ...

Page 36: ...y tubes of air b If no gas flow check 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 across contr...

Page 37: ...py 109608 02 1 109608 03 1 109608 04 1 109608 05 1 109608 06 1 109608 07 1 109608 08 1 109608 09 1 1C 1B 1A All Series 2E Service Parts may be obtained through your local U S Boiler Company Wholesale...

Page 38: ...1 109613 04 1 109613 05 1 109613 06 1 109613 07 1 109613 08 1 109613 09 1 2B Base Tray 2C Burner Tray 2D Base Side Insulation 2E Base Rear Insulation 2F Base Front Insulation 2G Drip Shields 2H Manifo...

Page 39: ...04 1 109731 05 1 109731 06 1 N A Gas Manifold N A 109731 07 1 109731 08 1 109731 09 1 3C Orifice Natural Gas 46 109732 01 1 47 109733 01 1 Orifices LP Gas 1 25mm 109735 01 1 1 20 mm 109734 01 1 3D Pil...

Page 40: ...perating Service Manual 109443 02 12 19 Key No Description Part Number Quantity 202E 203E 204E 205E 206E 207E 208E 209E 4A Control 103966 02 1 4B Transformer 106034 01 1 4C LWCO High Limit 106495 02 1...

Page 41: ...202E 203E 204E 205E 206E 207E 208E 209E 5A Wrap around Jacket Panel Not available 5B Jacket Vestibule Panel 109612 03 1 109612 04 1 109612 05 1 109612 06 1 109612 07 1 109612 08 1 109612 09 1 5C Top...

Page 42: ...1 6C 30 PSI Safety Relief Valve 109038 01 1 6D Drain Valve Obtain Locally 3 4 NPT boiler connection 6E Vent Damper 109634 01 1 109634 02 1 109634 03 1 109634 04 1 109634 05 1 6F Draft Hood 109730 01 1...

Page 43: ...er Quantity 202E 203E 204E 205E 206E 207E 208E 209E 7A Power Supply Harness 109639 01 1 7B Main Control Harness 109640 01 1 7A 7B Key No Description Part Number Quantity 202E 203E 204E 205E 206E 207E...

Page 44: ...Guide Appendix Combination Refrigeration Heating System Water Chiller Shut off valves Shut off valves Expansion Tank Circulator Supply main to combined heating cooling system Return main from combine...

Page 45: ...thority having jurisdiction Failure to follow instructions could result in serious injury or property damage The qualified agency performing this work assumes responsibility for this conversion As wit...

Page 46: ...m condensing during these heating season shoulders is unlikely to cause problems Larger volume systems during the shoulder heating seasons or systems with aggressive set back or low temperature system...

Page 47: ...ons A strap on temperature sensor measures boiler inlet temperatures This temperature signal is sent to a variable speed pump that will ensure boiler inlet temperatures are always greater than the fac...

Page 48: ...48 SERIES 2E Installation Operating Service Manual 109443 02 12 19 Wiring Schematic Zone Valves Wiring Schematic Zone Circulators Appendix Wiring Schematics...

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Page 52: ...52 SERIES 2E Installation Operating Service Manual 109443 02 12 19 U S Boiler Company Inc P O Box 3020 Lancaster PA 17604 1 888 432 8887 www usboiler net...