U.S. Boiler Company B series 2 Guide

USER'S INFORMATION MANUAL
CAST IRON GAS-FIREDCAST IRON GAS-FIRED
HOT WATER AND STEAM BOILERSHOT WATER AND STEAM BOILERS
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WARNING
This boiler has parts containing refractory ceramic fibers (RCF). After the boiler has been fired, RCF
may change into crystalline silica, a known carcinogen. See the safety information in the
Installation, Operating, and Service Instructions before attempting service or repair.
!
WARNING
• If the information in these instructions are not followed exactly, a fire or explosion may result causing
property damage, personal injury or death.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliance.
• WHAT TO DO IF YOU SMELL GAS
‐ Do not try to light any appliance.
‐ Do not touch any electrical switch;
do not use any phone in your
building.
‐ Immediately call your gas supplier
from a neighbor's phone. Follow the
gas supplier's instructions.
‐ If you cannot reach your gas supplier,
call the fire department.
• Installation and service must be
performed by a qualified installer, service agency or the gas supplier.
!
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.
WARNING
THERE ARE NO USER SERVICEABLE PARTS ON THIS BOILER. ATTEMPTS TO SERVICE THIS BOILER
BY SOMEONE OTHER THAN A QUALIFIED HEATING INSTALLER, SERVICE AGENCY OR GAS SUPPLIER
COULD VOID WARRANTY, CAUSE SEVERE PERSONAL INJURY, DEATH OR SUBSTANTIAL PROPERTY
DAMAGE.
!
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate
or minor injury or property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property
damage.
!!

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1. Instructions to safely light and shut down this boiler is shown on page 5, as well as on a label affixed to the
boiler. When the boiler is working properly, this boiler will light and shut down automatically in response to the
building thermostats(s). If it does not, the boiler must be inspected by a qualified installer, service agency or
gas supplier.
2. All boilers are equipped with a means of preventing the boiler from firing if there is an excessive blockage in the
vent system. Boilers designed for chimney venting are equipped with a blocked vent switch located as shown in
Figure 1 or 2, depending on the specific boiler design. If this switch opens, the boiler will not fire. Call a qualified
installer, service agency or gas supplier to diagnose and the problem and reset this switch if necessary.
3. All boilers are equipped with a flame rollout switch located as shown in Figure 3 or 4, depending on specific
boiler design. This switch will shut the burners down in the event that flames exit the burner compartment
through the front opening. If this happens, the flame rollout switch must be replaced. If the boiler fails to fire, call
a qualified installer, service agency or gas supplier to diagnose and correct the problem.
Basic Operation
WARNING
• A shutdown of the burners due to the blocked vent switch is an indication that there is a problem with
the vent system, such as a blockage, or the combustion air supply. The blocked vent switch should
only be reset after a qualified installer, service agency or gas supplier has diagnosed and corrected the
venting/combustion air problem that caused the blocked vent switch to open.
•In the event that the flame rollout switch opens, the cause of the flame rollout must be diagnosed and
corrected by a qualified gas service technician before the boiler is restarted.
• A “tripped” flame rollout switch must be replaced by an identical switch having the same
temperature setting.
• Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical
supply to the pump. Instead, shut off the gas supply at a location external to the appliance.
• Do not use this boiler if any part has been under water. Immediately call a qualified installer, service
agency or gas supplier to inspect the boiler and to replace any part of the control system and any gas
control which has been under water.
• This boiler is equipped with safety devices, which could cause it to shutdown, requiring service to
restore normal operation. Where such a shutdown could result in damage from low temperatures (such
as frozen pipes), do not leave the heating system unattended during cold weather unless alarms or
other safeguards are in place to prevent damage.
!

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WARNING
The following should be done on a continuous basis:
• Safe reliable operation of this boiler depends on proper periodic service by a qualified installer, service
agency or gas supplier.
• Proper air is essential for safe boiler operation. Do not block any fresh air opening.
• Keep area around boiler free of objects which are flammable or which could obstruct flow of air into
and around the boiler.
• Do not store or use sources of halogens such as bleaches, fabric softeners, paints, cleaners,
refrigerants and cat boxes near the boiler. Traces of these chemicals can be drawn into the boiler
causing severe corrosion damage to boiler and/or objectionable odors.
• Any damage caused by improper fuels, fuel additives or contaminated combustion air that may cause
fireside corrosion and/or clogging of burners or heat exchanger is not covered by the product warranty.
• Do not expose boiler to large amounts of dust such as generated by dry wall construction, fiberglass
insulation or woodworking.
1. A qualified installer, service agency or gas supplier must perform maintenance procedures shown in the
Installation, Operating, and Service Instructions on an annual basis.
2. Owner should visually inspect venting system on a monthly basis. If any of the following conditions are found,
the boiler should be shut down and a qualified installer, service agency or gas supplier called to correct the
problem before boiler is placed back in service:
• Loose joints, corrosion or other deterioration
• Condensate leakage
• Sags in horizontal runs of vent pipe
• (Chimney vent boilers only) Blocked vent switch not surely attached as shown in Figure 1 or 2, as
applicable
3. Owner should also perform a monthly visual inspection of boiler and surrounding system piping. To do this,
remove boiler jacket door. If any of the following are found, a qualified installer, service agency or gas supplier
should be consulted immediately:
• Deterioration of the visible controls, wiring, and sheet metal components
• Heating system water leaks
• Black carbon (“soot”) in or near the burner compartment area. See Figure 3 or 4
4. Steam Boilers – Steam boilers require occasional additions of makeup water to replace the small amount of
water lost through radiator and system vents. If an automatic water feeder is installed, this device should add
enough water on its own for boiler to operate. If there is no feeder and boiler needs more water, the red or yellow
"Low Water" light will be illuminated on the low water cut-off located on side of boiler. Wait at least 15 minutes
for all water in system to return to boiler and then open manual feed valve to add water. Stop adding water
when water level in gage glass reaches Boiler's Nominal Water Level (NWL). Consult Installation, Operating and
Service Instructions for NWL. Consult a qualified installer, service agency or gas supplier if you are not sure of
the location of the manual feed valve or cannot see the water level in the glass.
5. Auxiliary Controls – Many boilers are installed with equipment not supplied with the boiler, but which is critical for
safe, reliable operation of the boiler. Some examples of this type of equipment include zone controls and boiler
feed pumps. Make sure that this equipment is maintained in accordance with its manufacturer’s instructions.
Maintenance
WARNING
Black carbon (“soot”) in or near the burner compartment area is an indication of a potential carbon
monoxide hazard. If carbon is found, the boiler should be shut down immediately and inspected by
a qualified installer, service agency or gas supplier. The cause of the sooting should be found and
corrected before the boiler is restarted.
CAUTION
If it is necessary to either manually or automatically add water to a boiler more than once a month, a
qualified installer, service agency or gas supplier should inspect the system for leaks or defective vents.
Frequent additions of fresh water can result in severe damage to boiler.
!
!
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Figure 3: Burner Compartment Area
Figure 2: Boilers with Vertical Relief Opening
Figure 1: Boilers with Rear Relief Opening
Figure 4: Burner Compartment Area with Radiation
Shield Omitted

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LIGHTING AND SHUTDOWN INSTRUCTIONS
(Boilers Equipped with Honeywell VR8204 and VR8304 Gas Valves)
POSITION INDICATOR

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SERVICE RECORD
SERVICE PERFORMED
DATE