UTICA BOILERS USC SERIES Manuel d'instructions

P/N 3771201, Rev. A [01/09]

USCSERIES

DirectVent

GasFiredHotWaterBoiler

INSTALLATION,OPERATION&

MAINTENANCEMANUAL

MEMBER: The Hydronics Institute

UTICA BOILERS

P.O. Box 4729

Utica, NY 13504-4729

www.uticaboilers.com

An ISO 9001-2000 Certified Company

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

TABLEOFCONTENTS

SAFETYSYMBOLS

SEALEDCOMBUSTION,GASFIRED,FORCEDHOTWATERBOILER

e following dened symbols are used throughout this

manual to notify the reader of potential hazards of varying risk

levels.

IMPORTANT: Read the following instructions COMPLETELY

before installing!

Tested for 100 lbs. ASME

Working Pressure

C.S.A. Certiﬁed for

Natural gas or Propane

NOTICE

KEEP THIS MANUAL NEAR BOILER AND

RETAIN FOR FUTURE REFERENCE.

DANGER

Indicates an imminently hazardous situation which,

if not avoided, WILL result in death, serious injury or

substantial property damage.

WARNING

Indicates an imminently hazardous situation which,

if not avoided, may result in death, serious injury or

substantial property damage.

WARNING

1. Keep boiler area clear and free from combustible

materials, gasoline and other ammable vapors and

liquids.

2. DO NOT obstruct air openings to the boiler room.

3. Modication, substitution or elimination of factory

equipped, supplied or specied components may

result in property damage, personal injury or the loss

of life.

4. To the owner: Installation and service of this boiler

must be performed by a qualied installer.

5. To the installer: Leave all instructions with the

boiler for future reference.

6. When this product is installed in the Common-

wealth of Massachusetts the installation must be per-

formed by a Licensed Plumber or Licensed Gas Fitter.

CAUTION

Indicates an imminently hazardous situation which, if

not avoided, may result in injury or property damage.

NOTICE

Indicates information which should be followed to

ensure proper installation and operation.

SafetySymbols........................................................................................................................................................2

Introduction............................................................................................................................................................3

BoilerRatings,Capacities&Dimensions..............................................................................................................4

ConnectingSupplyAndReturnPiping.................................................................................................................5

GeneralInformationGasVentsAndAppliances..................................................................................................8

VentPipeModiﬁcation...........................................................................................................................................9

ConnectGasService............................................................................................................................................ 10

ElectricalWiring................................................................................................................................................... 11

LightingInstructions........................................................................................................................................... 13

SequenceOfOperation....................................................................................................................................... 14

GeneralInstructionForSeasonalStartUpAndMaintenance.......................................................................... 15

VentingInstructions............................................................................................................................................ 20

ReplacementParts............................................................................................................................................... 40

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

INTRODUCTION

e installation must conform to the requirements of

the authority having jurisdiction or, in absence of such

requirements, to the latest revision of the National Fuel

Gas Code, ANSI Z223-1. (Available from the American

Gas Association, Pleasant Valley Road, Cleveland, Ohio

44134.) Reference should also be made to local gas utility

regulations and other codes in eect in the area in which

the installation is to be made.

Where required by the authority having jurisdiction, the

installation must conform to American Society of Me-

chanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME No.

CSD-1.

is boiler is classied as a Category I and II and vent

installation shall be in accordance with Part 7 of the latest

revision of the National Fuel Gas Code, ANSI Z223.1 or

applicable provisions of the local building codes.

LOCATE BOILER on level, solid base as near the outside

wall as possible and centrally located with respect to the

heat distribution system as practicable.

Allow 24 inches at the front and right side for servicing

and cleaning.

When installed in utility room, the door should be wide

enough to allow the largest boiler part to enter, or to

permit replacement of another appliance such as a water

heater.

e boiler shall be installed such that the gas ignition

system components are protected from water, (drip-

ping, spraying, rain, etc.), during appliance operation and

service, (circulator replacement, condensate trap, control

replacement, etc.).

6" (15.2 cm) MIN.

(22.9 cm)

MIN.

(7.6 cm)

MIN.

4" (10.2 cm)

MIN.

FRONT OF

BOILER

WARNING

Improper installation, adjustment, alteration, service

or maintenance can cause injury or property damage.

Figure1-Min.ClearancesToCombustibleMaterials

WARNING

All installations of boilers and venting should be done only by a qualied expert and in accordance with the appropriate

boiler manual. Installing or venting a boiler or any other gas appliance with improper methods or materials may result

in serious injury or death due to re or to asphyxiation from poisonous gases such as carbon monoxide which is odor-

less and invisible.

FOR INSTALLATION ON NON-COMBUSTIBLE

FLOORS ONLY. e boiler must not be installed on car-

peting (For installation on combustible ooring Special

Base Part NO.325-2-8.00 MUST BE USED). Minimum

clearances to combustible constructions are:

TOP 18 in. (46 cm)

FLUE CONNECTOR 2 in. (5 cm)

FRONT 6 in. (15 cm)

REAR 4 in. (10 cm)

RIGHT SIDE 9 in. (23 cm)

LEFT SIDE 3 in. (8 cm)

Refer to Figure 1. Greater clearances for access should super-

sede re protection clearances.

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

BOILERRATINGS,CAPACITIES&DIMENSIONS

Boiler

No.

A.G.A

Input

Btu/Hr.

Heating

Capacity

Btu/Hr.

I=B=R

Net Out-

put

Btu/Hr.

Natural

Gas

Inlet

Dimensions Supply &

Return

Tappings

No. Of

Burn-

ers

Water

Content

AFUE

Rat-

ings

A B C D

3 Sec-

tion

50,000

(14.7

KW)

44,000

(12.9 KW)

38,000

(11.1

KW)

1/2"

(1.27

cm)

15.1/8"

(38

cm)

3.1/2"

(9 cm)

3.1/2"

(9 cm)

(12.7

cm)

1.1/4"

(3.2 cm) 2

4.0 gals

(15.14

liters)

87%

4 Sec-

tion

100,000

(29.3

KW)

87,000

(25.5 KW)

76,000

(22.3

KW)

1/2"

(1.27

cm)

19"

(48

cm)

3.1/2"

(9 cm)

3.1/2"

(9 cm)

6.1/2"

(16.5

cm)

1.1/4"

(3.2 cm) 3

5.6 gals

(21.20

liters)

87%

5 Sec-

tion

140,000

(41.0

KW)

122,000

(35.7 KW)

107,000

(31.3

KW)

1/2"

(1.27

cm)

22.7/8"

(58

cm)

4.1/4"

(11

cm)

4.1/8"

(11

cm)

8.3/8"

(21.3

cm)

1.1/4"

(3.2 cm) 4

7.2 gals

(27.25

liters)

87%

NOTE: For altitudes above 2,000 . ratings should be reduced at the rate of 4% for each 1,000 . above sea level.

STANDARDEQUIPMENT:

Boiler Jacket, Cast Iron Boiler Battery, Limit Control, Remov-

able Transformers, Plug in Relay, eraltimeter Gauge, Cir-

culator (eld mounted), Main Gas Burners, Hot Surface Pilot;

A.S.M.E Relief Valve, Drain Cock, Induced DraFan, Safety

Pressure Switch, and Combination Intake/Exhaust Termina-

tion Kit.

All boilers are design certied for installation on non-combus-

tible oors. For installation on combustible oors, use combus-

tible oor kit.

is boiler is a Direct Vent Designed Certied appliance which

requires a special horizontal through the wall venting system.

Use ONLY the venting material products listed below:

HEAT-FAB® SAF-T-VENT™t

FLEX-L® STAR-34™t

ProTech™ FasNSeal®t

Z-FLEX® Z-VENT™t

Consult venting addendum for maximum vent lengths and

proper congurations.

Electrical service to be 120 Volts, 15 Amps, 60 Hz.

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

Connect supply and return piping as suggested in

Fig-

ure #2 below when the boiler is used in connection with

refrigerated systems:

e chilled medium MUST BE IN PARALLEL withA.

the boiler.

Use appropriate valves to prevent the chilled mediumB.

from entering the heating boiler.

During heating cycle open valves A and B. Closet

valves C and D.

During cooling cycle open valves C and D, close valvest

A and B.

Maintain a minimum clearance of 1 inch (2.54 cm) toC.

hot water pipes. In air handling units where they may

be exposed to refrigerated air circulation, the boiler

piping system MUST be supplied with ow control

valves or other automatic means to prevent grav-

ity circulation of the boiler water during the cooling

cycle.

CONNECTINGSUPPLYANDRETURNPIPING

EXPANSION

TANK

CHECK

VALVE

CIRCULATOR

FROM HEATING

AND COOLING

ELEMENT

SUPPLY PIPING

TO HEATING

AND COOLING

ELEMENT

WATER

CHILLER

RETURN PIPING

FEED

WATER

NOTICE

* Reduced pressure back ow preventer must be used

under provisions required by the Environmental Pro-

tection Agency, (EPA).

Hot water boilers installed above radiation level must be

provided with a low water cut-odevice at the time of

boiler installation.

When a boiler is connected to a heating system that

utilizes multiple zoned circulators, each circulator must

be supplied with a ow control valve to prevent gravity

circulation.

Figure1-NearBoilerSupply&ReturnPiping

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

CONNECTINGSUPPLYANDRETURNPIPING

Bypass piping is an option which

gives the ability to adjust the supply

boiler water temperature to t the

system or condition of the installa-

tion. is method of piping is not

typically required for baseboard

heating systems.

is method is used to protectA.

boilers from condensate forming

due to low temperature return

water. Generally noticed in large

converted gravity systems or

other large water volume sys-

tems. See Figure #3.

ese methods are used to pro-B.

tect systems using radiant panels

and the material they are encased

in from high temperature supply

water from the boiler and protect

the boiler from condensation.

See Figures #4 & #5.

NOTE:

When using bypass piping,

adjust valves A and B, in Figures #3

& #5, until desired system tempera-

ture is obtained.

NOTE:

When using a 4-way mixing

valve, set control knob until desired

temperatures are met. See instruction

supplied with valve.

Bypass loop piping must be the same

size piping as the supply and the

return.

Typical installation using circulators

is shown in Figure #6 on following

page.

Typical installation using zone

valves is shown in Figure #7 on fol-

lowing page.

For further piping information refer

10.

to the I=B=R installation and piping

guide.

ZONE

CIR.

VALVE

FLOW

VALVE

EXPANSION

TANK

VALVE

SYSTEM

TEMPERATURE

GAUGE

RETURN

SUPPLY

"A"

"B"

WATER

FEED

ZONE

CIR.

EXPANSION

TANK

SYSTEM

TEMPERATURE

GAUGE

RETURN

SUPPLY

4 WAY MIXING

VALVE

WATER

FEED

Figure3-BypassPiping

Figure3-MixingValvePiping

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

CONNECTINGSUPPLYANDRETURNPIPING

CIRCULATOR

VALVE

EXPANSION

TANK

VALVE

RETURN

SUPPLY

(31 cm)

MAX.

CIRCULATOR

FLOW

VALVE

SYSTEM

TEMPERATURE

GAUGE

"B"

"A"

SYSTEM

PRIMARY

12"

FEED

WATER

TANK

CIRCULATOR

SYSTEM

CIR.

REDUCED PRESSURE

BACKFLOW PREVENTER

FEED

WATER

SYSTEM

RETURN

COLD WATER

PUMP CONTROL

THERMOSTAT/

WIRING FOR

TRAP

THERMAL

OUTLET

HOT WATER

DRAIN

COCK

RELIEF VALVE

FLOW CONTROL

INLET

OR CHECK VALVE

GATE VALVE

PRESSURE

REDUCING

VALVE

Figure5-PrimarySecondaryPipingwithBypass

Figure6

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

By Federal Codes, gas appliances are categorized by the pres-

sure and temperature of the ue gas vented from the appliance.

Category I and II appliances are natural dra(drahood)

vented, with high ue gas temperatures (Category I), or low

ue gas temperatures (Category II).

Category III and IV appliances are fan forced vents with high

temperature (Category III) or low temperature (Category IV)

ue gasses. Appliance eciency is directly related to ue gas

temperature. Higher eciency appliances remove more heat

from the gas, so they will have lower temperature ue prod-

ucts.

When ue gas temperatures are lowered, corrosive condensates

may form in the gas vent or in the appliance. Condensates may

form in Category II, III, IV appliance vents, so special corro-

sive resistant venting systems are required for higher eciency

appliances.

CONNECTINGSUPPLYANDRETURNPIPING

GENERALINFORMATIONGASVENTSANDAPPLIANCES

TANK ZONE

VALVE

SYSTEM ZONE

VALVE

CIR.

WATER

FEED

INLET

COLD WATER

HOT WATER

OUTLET

PUMP CONTROL

WIRING FOR

THERMOSTAT/

TRAP

TERMAL

RELIEF VALVE

DRAIN COCK

RETURN

SYSTEM

PRESSURE

REDUCING

VALVE

BACKFLOW PREVENTER

REDUCED PRESSURE

GATE VALVE

WARNING

Vents for Category I appliances may not be suitable

for use with Category II, III, or IV appliances because

condensate may corrode the vent.

Vents for Category III appliances may not be suitable

for use with Category I appliances because ue gas

temperatures may be too high.

Proper operation of the vent system and appliance is depen-

dent upon the use of all parts specied by the manufacturer for

use in the particular installation. Appliance and vent system

performance may be aected by improper assembly.

Figure7

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

VENTPIPEMODIFICATION

When an existing boiler is removed from a common venting

system, the common venting system is likely to be too large for

the proper venting of the appliances remaining connected to

it. If this situation occurs, the following test procedure must be

followed:

REMOVALOFBOILERFROMVENTINGSYSTEM

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.

Seal any unused openings in the common venting system.

Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion and other deciencies which

could cause an unsafe condition.

Insofar as is practical, close all building doors and win-

dows and all doors between the space in which the ap-

pliances remaining connected to the common venting

system are located and other spaces of the 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 oper-

ate at maximum speed. Do not operate a summer exhaust

fan. Close replace dampers.

Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance

will operate continuously.

Test for spillage at the drahood relief opening aer 5

minutes of main burner operation. Use the ame of a

match or candle, or smoke from a cigarette, cigar or pipe.

Aer it has been determined that each appliance remain-

ing connected to a common venting system properly vents

when tested as outlined above, return doors, windows,

exhaust fans, replace dampers and any other gas burning

appliance to their previous conditions of use.

Any improper operation of the common venting system

should be corrected so the installation conforms with

either the latest revision of the National Fuel Gas Code,

ANSI Z223.1, (when installed in the United States) or the

CAN1-B149.1 and/or B149.2 Installation Codes for Gas-

Burning Equipment, (when installed in Canada). 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 appendix G in the latest revision of the National

Fuel Gas Code, ANSI Z223.1 or the CAN1-B149.1 and/or

B149.2 Installation Codes for Gas-Burning Equipment.

National Excelsior Company

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Subject to change without notice.

CONNECTGASSERVICE

ZONE I

TANK CIR.

SYSTEM

CIR.

TANK

CONTROL

BRASS TEE

P-T RELIEF

VALVE, LONG

ELEMENT

DRAIN

BRASS

TEE

PREFERRED METHOD

FOR THERMAL TRAP

COLD WATER

INLET

HOT WATER

OUTLET

RETURN

PIPING

SYSTEM

COCK

CONTROL

VALVES

FLOW

Connect gas service meter to control assembly in accordance

with the latest revision of ANSI Z223.1 and local codes or util-

ity. A ground joint union should be installed for easy removal

of gas control for servicing. A drip or trap must be installed

at the bottom of a vertical section of piping at the inlet to the

boiler. A pipe compound resistant to the action of liqueed pe-

troleum gases must be used on all threaded pipe connections.

Check with the local utility for location of manual shutovalve

if required. (See Figure #8)

e gas line should be of adequate size to prevent undue

pressure drop and never smaller than the pipe size of the

main gas control valve. See chart below.

To check for leaks in gas piping, use a soap and water

solution or other approved method.

WARNING

DO NOT USE AN OPEN FLAME.

NOTICE

For additional information refer to Part 10, table 10-2

of the National Fuel Gas Code Handbook, latest revi-

sion, or in Canada, the CAN1-B149.1 and/or B149.2

Installation Codes for Gas-Burning Equipment.

Figure8

e boiler and its individual shutovalve must be discon-

nected from the gas supply piping system during any pres-

sure testing of that system at test pressures in excess of ½

psig (3.5 kPa).

e boiler must be isolated from the gas supply piping sys-

tem by closing its individual manual shutovalve during

any pressure testing of the gas supply piping system at test

pressures equal to or less than ½psig (3.5 kPa).

National Excelsior Company

www.excelsiorhvac.com

Subject to change without notice.

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