U.S. Boiler Company SERIES 3 Guide

WARNING: If the information in this
manual is not followed exactly, a re or
explosion may result causing property
damage, personal injury or loss of life.
-Do not store or use gasoline or other
ammable 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 re department.
-Installation and service must be
performed by a qualied installer,
service agency or the gas supplier.
103798-02 - 10/13
AVERTISSEMENT. Assurez-vous de
bien suivre les instructions données
dans cette notice pour réduire au
minimum le risque d'incendie ou
d'explosion ou pour éviter tout
dommage matériel, toute blessure ou
la mort.
- Ne pas entreposer ni utiliser
d'essence ni d'autres vapeurs
ou liquides inammables dans le
voisinage de cet appareil ou de tout
autre appareil.
- QUE FAIRE SI VOUS SENTEZ UNE
ODEUR DE GAZ:
• Ne pas tenter d'allumer d'appareils.
• Ne touchez à aucun interrupteur. Ne
pas vous servir des téléphones dans
le bâtiment où vous vous trouvez.
• Appelez immédiatement votre
fournisseur de gaz depuis un voisin.
Suivez les instructions du
fournisseur.
• Si vous ne pouvez rejoindre le
fournisseur de gaz, appelez le
service des incendies.
-L'installation et I'entretien doivent
être assurés par un installateur ou un
service d'entretien qualié ou par le
fournisseur de gaz.
USER'S INFORMATION MANUAL
Series 3™
GAS - FIRED BOILER

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The following terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
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,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
• If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.

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Basic Operation
A. General. This water boiler is equipped with controls
for proper operation. All controls must be in proper
working order. Contact a qualied service agency to
provide annual maintenance as specied in Installation,
Operating and Service Instructions.
1. Limit. See Figure 1. A device which automatically
interrupts boiler operation when the water
temperature exceeds the set point. Maximum
allowable temperature is 220°F.
Original equipment with this boiler is U.S. Boiler
Intelligent Boiler Control and Limit Rated Sensor
combination. The Intelligent Boiler Control shuts off
boiler main burners when boiler water temperature
exceeds pre-programmed Intelligent Boiler Control
water temperature set point. Boiler main burners
will re-light automatically, providing the call for
heat is present, when boiler water temperature falls
below pre-programmed control water temperature
set point less the set point differential.
2. Flame Rollout Switch. See Figure 1. A device
which automatically interrupts boiler operation
when ames or excessive heat are present in the
combustion area enclosure. The control is a single
use device. The control is located in the combustion
area enclosure. If the control was activated to
interrupt boiler operation, do not attempt to place
boiler in operation. Contact a qualied service
agency.
WARNING
Service on this boiler should be undertaken only
by trained and skilled personnel from a qualied
service agency.
WARNING
Do not reset Blocked Vent Switch unless a
qualied service agency has determined and
corrected the cause of any blockage in the vent
system or chimney.
3. Blocked Vent Switch See Figure 1. A device
which automatically interrupts boiler operation
when excessive vent system blockage occurs. If the
control was activated to interrupt boiler operation,
do not attempt to place boiler in operation. Contact
a qualied service agency.
4. Electronic Ignition System - see Figure 1. The
Electronic Ignition (EI) System consists of:
a. a solid state ignition control with integral
ignition module to initiate, monitor and stop
burner operation.
b. a combination gas valve to regulate gas ow to
the main burners.
c. a pilot burner to provide the ignition source for
the main burners.
B. Instructions to place the boiler in operation and to turn
off the boiler are shown on the Operating Instruction
Label posted on the left jacket panel of the boiler. The
Operating Instruction Label is shown in Figure 2.
C. The Sequence of Operation is shown in Figure 3.
CAUTION
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.
En cas de surchauffe ou si I'admission de gaz ne peut étre coupée, ne pas couper ni débrancher
l'alimentation électrique de la pompe. Fermer plutôt le robinet d'admission de gaz à l'extérieur de I'appareil.
Do not use this boiler if any part has been under water. Immediately call a qualied service technician to
inspect the boiler and to replace any part of the control system and any gas control which has been under
water.

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Figure 1: Control Locations

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Figure 2: Operating Instructions
NOTE: YOUR BOILER IS EQUIPPED WITH A HONEYWELL VR8204 OR VR8304 GAS VALVE.
PLEASE FOLLOW THESE OPERATING INSTRUCTIONS:

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Figure 3: Sequence of Operation
Thermostat Calls
for Heat
Circulator Output
Energizes
Waiting For
Damper to Open
Ignition Source Energized
Pilot Gas On
Limits Closed Checked
Trial For Ignition
Ignition Source Off
Main Gas On
Pilot Flame
Proven
Pilot Flame
Not Proven
Call For Heat Ends
Standby
Intelligent Hydronic
Control can display
(typical)
Delay 60 Seconds
Ignition Source Off
Pilot Gas Off
Main Gas Off
Vent Damper De-Energized
Circulator Output De-Energized
Continuous
Retry
Standby
Vent Damper Energized
Self Testing

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User Maintenance
A.General Housekeeping (Continuous).
1. Keep boiler area clear and free of combustible
materials and obstructions to the free ow of
combustion and ventilation air to the boiler.
2. Do not store or use gasoline, other ammable
vapors, liquids or sources of hydrocarbons in the
vicinity of the boiler or any other appliance.
3. Do not store or use halogen-containing products
(bleaches, cleaners, fabric softeners, refrigerants,
chemicals, etc.) in the vicinity of the boiler.
B. Inspect Inlet Air and Vent System (Monthly). Check
the following. If corrective action is required contact
qualied service agency.
1. Blocked vent switch must be attached to the canopy.
2. Vent pipe must be full round shape, showing no
damage from impact or excessive temperature.
3. All vent pipe joints must be secure.
4. Horizontal runs must not sag.
5. The vent system must be free of corrosion and other
deterioration.
6. Supports must not be loose or broken.
C. Inspect Pilot and Main Burner Flames (Monthly).
1. Remove jacket front panel.
2. View ames through burner access panel. See
Figure 1.
3. Adjust thermostat to highest setting.
4. Check pilot ame. See Figure 4. The pilot produces
three (3) ames. The center ame should be steady,
medium hard blue enveloping 3/8to ½ inch of
sensing probe. If ame is yellow and lazy, follow
instructions TO TURN OFF GAS TO APPLIANCE
(see Figure 2), and contact qualied service agency.
5. Check main burner ames. See Figure 5. Flame
should have clearly dened inner cone with no
yellow tipping. Orange-yellow streaks caused
by dust should not be confused with true yellow
tipping. If yellow ames are observed, follow
instructions TO TURN OFF GAS TO APPLIANCE
(see Figure 2), and contact qualied service agency.
6. Adjust thermostat to normal setting.
D. Schedule Inspection by Qualied Service Agency
(Annual or at Beginning of Heating Season). For
continued safe operation a qualied service agency
must provide a more detailed inspection of burners, heat
exchanger and vent system, and provide maintenance
as specied in Installation, Operating and Service
Instructions.
WARNING
Service on this boiler should be undertaken only by trained and skilled personnel from a qualied service agency.
Inspections should be performed at intervals specied in Installation, Operating and Service Instructions and this
manual. Maintain manuals in a legible condition.
Keep boiler area clear and free of combustible materials, gasoline and other ammable vapors and liquids.
Do not place any obstructions in boiler room that will hinder ow of combustion and ventilation air.
Figure 4: Pilot Burner
Figure 5: Main Burner Flame

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All Series 3™ repair parts may be obtained through your local U.S. Boiler Company Wholesale distributor.
Should you require assistance in locating a U.S. Boiler Company distributor in your area, or have questions
regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company,
Inc. Customer Service at [phone] or Fax [phone].