Page 2 - Table of Contents
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 i...
Page 3 - WARNING; INSTRUCTIONS IN LEGIBLE CONDITION.; Figure 1
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...
Page 4 - Do not drop boiler. Do not bump boiler jacket; DANGER; Do not install boiler where gasoline or other; Adequate combustion and ventilation air must be
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 - Figure : Minimum Clearances
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 - CAUTION; Failure to properly pipe boiler may result in
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 8 - Figure; Do not alter boiler draft hood or place any
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 10 - Inspect existing chimney before installing boiler.; Figure : Typical Vent Installation
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 - Table : Wiring Diagrams and Heat Anticipator Settings; Ignition Type
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 - Figure : Vent Damper Schematic Wiring Diagram; the boiler is inoperative.; inspected daily to insure proper operation.
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 17 - Figure 1: Wiring Schematic, Zone Circulators
1 Figure 1: Wiring Schematic, Zone Valves Figure 1: Wiring Schematic, Zone Circulators
Page 18 - II. Operating Instructions; in
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 20 - Figure 1: LED Locations; Note; Table : Yellow LED Flame Codes
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 ...
Page 21 - Table : Green LED Status Codes; Green LED
1 Table : Green LED Status Codes Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None 2 5 minute Retry Delay- Pilot flame not detected during tr...
Page 22 - Figure : Lighting Instructions
Page 23 - NOTICE; Figure 3: 0mm Main Burner Flame
3 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...
Page 25 - III. Trouble Shooting; Honeywell Electronic Ignition Troubleshooting Guide
Figure : Troubleshooting Guide, Honeywell Electronic Ignition (EI) III. Trouble Shooting Honeywell Electronic Ignition Troubleshooting Guide
Page 28 - Warning; AVOID Breathing Fiber Particulates and Dust; Precautionary Measures
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 30 - Section Assembly and Canopy Group; Key
30 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 --- --- --- --- -...
Page 31 - THIS PAGE LEFT INTENTIONALLY BLANK
Page 34 - Manifold and Main Burners
Page 35 - B. Inch Main Burner with Pilot Bracket, Electronic Ignition Only
3 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 - . 0 MM Main Burners Only
3 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 - C. 0MM Main Burner Manifold
3 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 44 - Water Trim
Page 45 - Circulator with Gaskets, Grundfos UP 15-42F; Miscellaneous Trim; Temperature - Pressure Gauge
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-30 Option (Intermittent and Continuous Circulation Only) 8A Circulator with Gaskets, B...
Page 46 - Flame Rollout Switch; Blocked Vent Switch
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 Cir...
Page 47 - Draft Hood Carton
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
Page 51 - minimum
1 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 su...
Page 52 - Limited Warranty; FOR RESIDENTIAL CAST IRON WATER BOILERS
boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthorized modifica...