U.S. Boiler Company X-203, X-204, X-205, X-206, X-207 Installation, Operating And Service Manual
...
INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
X-2 ™ Series
Cast Iron Gas - Fired Boiler
9700609
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
Heating Contractor Phone Number
Address
106636-01 - 10/15
Boiler Serial Number Installation Date
Price - $5.00
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the X-2™ Series Boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval
Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas tter.
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 substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Table of Contents
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
I. Pre-Installation ....................................5
II. Unpack Boiler .....................................5
III. Water Piping and Trim ........................6
IV. Venting ................................................ 9
V. Gas Piping .........................................11
VI. Electrical ............................................12
2
VII. System Start-up and Checkout ..........16
VIII. Operation ..........................................20
IX. Service and Maintenance ...................24
X. Troubleshooting ................................27
XI. Repair Parts .......................................32
Table 1A: Dimensions and Connections
Boiler
Model
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 25 40 1¼ 1¼ 7 ¾ ¾ ¾
X-208 32 28 40 1¼ 1¼ 7 ¾ ¾ ¾
X-209 32 31 40 1¼ 1¼ 8 ¾ ¾ ¾
Depth Width Height
Supply NPT
(inch)
Return NPT
(inch)
Vent
(inch)
Gas NPT
(inch)
Relief Valve
NPT (inch)
Table 1B: Weights and Volume
Boiler
Model
X-203 70 254 180 2
X-204 105 304 231 3
X-205 140 357 284 4
X-206 175 405 332 5
X-207 210 462 382 6
X-208 245 518 438 7
X-209 280 564 484 8
Input (MBH)
(1)
Shipping Weight
(lbs)
Empty Weight
(lbs)
Water Content
(gal)
Drain
NPT (inch)
(1)
Input ratings can be used for elevations up to 2000 ft. Refer to System Start-up and Checkout Sections for elevations 2000 ft.
or higher.
Electrical Requirements: 120VAC, 60 Hz, 1-ph, Less than 12A
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valve.
3
Figure 1: Minimum Clearance to Combustible Materials and Alcove Dimensions
4
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 responsibility ceases upon delivery
of boiler to carrier in good condition. Any claim
for damage or shortage in shipment must be led
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
B. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas Code, ANSI Z223.1/NFPA 54.
C. Appliance is design certied for installation on
combustible ooring. The boiler must not be installed
on carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local re
ordinance. Refer to Figure 1 for minimum clearance
from combustible material for alcove installation.
Provide 1/2" clearance from water piping to
combustible materials.
F. Install on level oor. For basement installation provide
concrete base if oor is not level or if water may be
encountered on oor around boiler.
CAUTION
ASSURE THAT THE FRONT AIR DAM is in place
and undamaged. A damaged front air dam will
negatively affect the performance of this boiler,
which can cause serious property damage,
personal injury or death.
G. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
H. 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 provisions of local building codes.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
I. Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.
E. Provide practical service clearances. A minimum
of 24" from the left side and front jacket panels is
recommended for servicing but may be reduced to
minimums shown in Figure 1.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
F. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.
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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 makeup water, ttings, and
oxygen permeable materials in distribution system.
Eliminate oxygen contamination by repairing system
leaks, repairing ttings, and using non-permeable
materials in distribution system.
B. Install circulator with anges, gaskets and bolts
provided.
C. Install Safety Relief Valve. See Figure 2. Safety Relief
Valve must be installed with spindle in vertical position.
WARNING
Safety relief valve discharge piping must be piped
near oor to eliminate potential of severe burns.
Do not pipe in any area where freezing could
occur. Do not install any shut-off valves.
D. Connect system supply and return piping to boiler.
Refer to Figures 2, 4 and 5. Also consult Residential
Hydronic Heating Installation and Design I=B=R
Guide. Maintain minimum ½ inch clearance from hot
water piping to combustible materials.
E. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled medium
piped in parallel with the heating boiler using
appropriate valves to prevent chilled medium from
entering boiler. See Figure 3. Also consult Residential
Hydronic Heating Installation and Design I=B=R
Guide.
F. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
ow control valves or other automatic means to prevent
gravity circulation of boiler water during operation of
cooling system.
G. Use a boiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).
Remove circulator and install pipe tee between
circulator and boiler return along with second tee in
supply piping as shown in Figures 4 and 5. Bypass
should be same size as the supply and return lines with
valves located in bypass and supply outlet as illustrated
in Figures 4 and 5 in order to regulate water ow to
maintain higher boiler water temperatures.
Set by-pass and boiler supply valves to half throttle
position to start. Operate boiler until system water
temperature reaches normal operating range.
Adjust valves to provide 180° to 200°F supply water
temperature. Opening the boiler supply valve will raise
system temperature, while opening by-pass valve will
lower system supply temperature.
H. If it is required to perform a long term pressure
test of the hydronic system, the boiler should rst be
isolated to avoid a pressure loss due to the escape of air
trapped in the boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must rst be removed from the
boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained
trapped air.
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Figure 2: Near Boiler Piping
Figure 3: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
III. Water Piping and Trim (continued)
Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems
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III. Water Piping and Trim (continued)
8
Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems
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 Installation Instructions.
CAUTION
Do not use one vent damper to control two heating
appliances.
1. The vent damper must be the same size as the outlet
of the Draft Hood supplied with the boiler (see
Table 1A). Unpack the damper carefully - DO NOT
FORCE IT CLOSED! Forcing the damper may
damage the gear train and void the warranty.
2. Mount the vent damper assembly onto the canopy/
diverter. (Refer to Figure 6 and to instructions
packed with the vent damper for specic
instructions). Do not modify either the draft hood or
vent damper.
NOTICE
Provide adequate clearance for servicing.
3. Locate vent damper position indicating means to be
visible following installation.
WARNING
Provide 6" minimum clearance between damper
and combustible construction.
4. Plug the factory harness vent damper connector into
damper motor polarized receptacle.
DANGER
Inspect existing chimney before installing boiler.
Failure to clean or replace perforated pipe or tile
lining will cause severe injury or death.
B. Inspect chimney and remove any obstructions or
restric tions. Clean chimney if previously used for solid
or liquid fuel-burning appliances or replaces.
C. Install vent system in accordance with "Venting of
Equipment" of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of local
building codes. The X-2 Series boiler is a Category I,
draft hood equipped appliance.
Figure 6: Vent Damper Installation
WARNING
D. If an Existing Boiler is Removed:
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the appliances
remaining connected to it.
At the time of removal of an existing boiler, the
following steps shall be followed with each appliance
remaining connected to the common venting system
placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation:
a. Seal any unused openings in the common venting
system.
b. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deciencies which could cause an unsafe condition.
c. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
9
IV. Venting (continued)
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
replace dampers.
d. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermo stat so appliance will operate
continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the ame
of a match or candle, or smoke from a cigarette,
cigar or pipe.
f. After it has been determined that each appliance
remain ing connected to the common venting system
properly vents when tested as outlined above, return
doors, win dows, exhaust fans, replace dampers and
any other gas-burning appliance to their previous
condition of use.
g. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. When resizing any portion of
the common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Chapter 13 of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
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V. Gas Piping
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 information.
Minimum gas valve inlet pressure is listed on rating
label.
2. Maximum gas demand. Consider existing and
expected future gas utilization equipment (i.e. water
heater, cooking equipment).
B. Connect boiler gas valve to gas supply system.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liqueed petroleum gas.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve.
See Figure 7.
4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, ANSI/NFPA 70.
C. Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonammable
solution. Do not use matches, candles, open ames,
or other ignition source.
Figure 7: Pilot and Gas Piping
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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 feet above oor. Do not install on
outside wall, near replace, or where inuenced by
drafts or restricted air ow, hot or cold water pipes,
lighting xtures, television, or sunlight. Allow free air
movement by avoiding placement of furniture near
thermostat.
C. Wire boiler. Boiler is rated for 120 VAC, 60 hertz,
less than 12 amperes. A separate electrical circuit
must 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 wires
and green ground screw. See Figures 8 and 9.
D. For installations using zone valves provide separate
transformer for zone valve wiring. Consult zone valve
manufacturer for assistance. See Figure 10.
CAUTION
This boiler contains controls which may cause
the boiler to shut down and not restart without
service. If damage due to frozen pipes is a
possibility, the heating system should not be
left unattended in cold weather; or appropriate
safeguards and alarms should be installed on the
heating system to prevent damage if the boiler is
inoperative.
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