UTICA BOILERS USC SERIES Document technique

INSTINST

INSTALLAALLA

ALLAALLA

ALLATION MANUTION MANU

TION MANUTION MANU

TION MANUALAL

ALAL

AL AND OPERAAND OPERA

AND OPERAAND OPERA

AND OPERATING INSTRTING INSTR

TING INSTRTING INSTR

TING INSTRUCTIONSUCTIONS

UCTIONSUCTIONS

UCTIONS

USCUSC

USC

DIRECT VENT GAS FIRED BOILERS

FOR FORCED HOT WATER

Utica Boilers, Inc. • P.O. Box 4729 • Utica, NY 13504

SEALED

OMBUSTION

TABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

Safety Symbols & Warnings................................................................................. Page 1

Installation Procedure .......................................................................................... Page 2

Connecting Supply and Return Piping .......................................................... Pages 3 - 5

General Information: Gas Vents and Appliances .................................................. Page 5

Vent Pipe Modification ......................................................................................... Page 6

Connect Gas Service ........................................................................................... Page 7

Electrical Wiring............................................................................................. Pages 8 - 9

Thermostat Installation....................................................................................... Page 10

Lighting Instructions ................................................................................. Pages 10 - 11

Sequence of Operation ...................................................................................... Page 12

General Instructions .................................................................................. Pages 13 - 15

Check Venter Static Pressure ............................................................................ Page 16

Checking Gas Input Rate to Boiler..................................................................... Page 17

Replacement Parts List ............................................................................. Pages 17 - 25

Ratings, Data and Dimensions...................................................................... Back Cover

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

SERIES USC

CAST IRON

GAS FIRED BOILERS

INSTALLATION MANUAL AND

OPERATING INSTRUCTIONS

Published September 2004

Printed in USA

Made in USA

PAGE 1

Safety SymbolsSafety Symbols

Safety Symbols

The following defined symbols are used throughout this manual to notify the

reader of potential hazards of varying risk levels.

DANGERDANGER

DANGER

DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL

result in death or serious injury.

WARNINGARNING

ARNINGARNING

ARNING

WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD

result in death or serious injury

CAUTIONCAUTION

CAUTION

CAUTION - Indicates a potentially hazardous situation which, if not avoided, MAY

result in minor or moderate injury. It may also be used to alert against unsafe practices.

IMPORIMPOR

IMPORTT

TANT!ANT!

ANT!ANT!

ANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.

WARNING:WARNING:

WARNING:

1.Keepboilerareaclearandfreefromcombustiblematerials,gasolineandotherflammable

vaporsandliquids.

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

3.Modification,substitutionoreliminationoffactoryequipped,suppliedorspecifiedcompo

nents 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 qualified

installer.

5.To the installer: Leave all instructions with the boiler for future reference.

6.WhenthisproductisinstalledintheCommonwealthofMassachusetts,theinstallationmust

be performed by a licensed Plumber or Licensed Gas Fitter.

WARNING:WARNING:

WARNING: ALL INSTALLATIONS OF BOILERS ANDALL INSTALLATIONS OF BOILERS AND

ALL INSTALLATIONS OF BOILERS ANDALL INSTALLATIONS OF BOILERS AND

ALL INSTALLATIONS OF BOILERS AND

VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT ANDVENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND

VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND

IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS, INC.IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS, INC.

IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS, INC.

MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHERMANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER

MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER

GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAYGAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY

GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY

RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TORESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO

RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO

ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBONASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON

ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON

MONOXIDE WHICH IS ODORLESS AND INVISIBLE.MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

INSTINST

INSTALLAALLA

ALLAALLA

ALLATION PRTION PR

TION PRTION PR

TION PROCEDUREOCEDURE

OCEDUREOCEDURE

OCEDURE

WARNING: Improper installation, adjustment, alteration, service or

maintenance can cause injury or property damage.

1. The installation must conform to the requirements of the authority having jurisdiction or,

in absence of such requirements to one of the following:

When installed in the United States: 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 effect in the area in which the installation is to be made.

When installed in Canada: The latest revision of the CAN1-B149.1 and/or B149.2

Installation Codes for Gas-Burning Equipment and/or local codes.

2. Where required by the authority having jurisdiction, the installation must conform to

American Society of Mechanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME No. CSD-1.

3. This boiler is classified as a Direct Vent and vent installation shall be in accordance with

Part 7 of the latest revision of the National Fuel Gas Code, ANSI Z223.1 when installed

in the United States. In Canada refer to the CAN1-B149.1 and/or B149.2 Installation

Codes for Gas-Burning Equipment. Also refer to applicable provisions of the local

building codes.

4. 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.

5. 24 inches (61 cm) of clearance is recommended at the front and right side for servicing

and cleaning.

6. 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.

7. The boiler shall be installed such that the gas ignition system components are protected

fromwater(dripping,spraying,rain,etc.)

during appliance operation and service,

(circulatorreplacement,condensatetrap,

control replacement, etc.).

8. THIS BOILER IS DESIGN CERTIFIED

FOR INSTALLATION ON NON-

COMBUSTIBLE FLOORS ONLY. FOR

INSTALLATION ON COMBUSTIBLE

FLOORING SPECIAL BASE PART

NUMBER 325-2-8.00 MUST BE USED.

The boiler must NEVER be installed on

carpeting. 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)

(SEE FIGURE 1 AT RIGHT)

NOTE : GREATER CLEARANCES FOR

ACCESS SHOULD SUPERSEDE FIRE

PROTECTION CLEARANCE. PAGE 2

FIGURE 1

CLEARANCE TO COMBUSTIBLE MATERIAL

PAGE 3

FIGURE 2 FIGURE 3

BYPASS PIPING

CONNECTING SUPPLCONNECTING SUPPL

CONNECTING SUPPLYY

Y AND RETURN PIPINGAND RETURN PIPING

AND RETURN PIPINGAND RETURN PIPING

AND RETURN PIPING

IMPORTANT: Circulators in the following illustrations are mounted on the system supply

side, but mounting on the system return side is also acceptable practice.

B.Useappropriatevalvestopreventthechilledmediumfromenteringtheheatingboiler.

1.DuringheatingcycleopenvalvesAand B. Close valves C and D.

2.Duringcoolingcycle open valves C andD,closevalves A and B.

C.Maintainaminimumclearanceof1inch(2.54cm)tohotwaterpipes.Inairhandlingunits

where they may be exposed to refrigerated air circulation, the boiler piping system

MUSTbesuppliedwithflowcontrolvalvesorotherautomaticmeanstopreventgravity

circulationoftheboilerwaterduringthecoolingcycle.

2.Hotwaterboilersinstalledaboveradiationlevelmustbeprovidedwithalowwatercut-off

deviceatthetimeofboilerinstallation.

3.Whenaboilerisconnectedtoaheatingsystemthatutilizesmultiplezonedcirculators,each

circulatormustbesuppliedwithaflowcontrolvalvetopreventgravitycirculation.

*Reducedpressureback flowpreventermustbeusedunder provisionsrequiredbythe

EnvironmentalProtectionAgency,(EPA).

4. Bypass piping is an option which gives the ability to adjust the supply boiler water

temperaturetofitthesystemorconditionoftheinstallation.Thismethodofpipingisnot

typicallyrequiredforbaseboardheatingsystems.

A.Thismethodisusedtoprotectboilersfromcondensateformingduetolowtemperature

returnwater.Generallynoticedinlargeconvertedgravitysystemsorotherlargewater

volumesystems.Seefigure3above.

B.Thesemethodsareusedtoprotectsystemsusingradiantpanelsandthematerial

theyareencasedinfromhightemperaturesupplywaterfromtheboilerandprotect

the boiler from condensation. See figures 4 & 5 below.

5.Note:Whenusingbypasspiping,adjustvalvesAandB,infigures3and5,untildesired

systemtemperatureisobtained.

1.Connectsupplyandreturnpipingassuggestedinfigure2belowwhentheboilerisusedin

connectionwithrefrigeratedsystems:

A.ThechilledmediumMUSTBE INPARALLELwiththeboiler.

PAGE 4

FIGURE 4 FIGURE 5

FIGURE 6

MIXING-VALVE PIPING PRIMARY SECONDARY PIPING

WITH BYPASS

6.Note:Whenusinga4-waymixingvalve,setcontrolknobuntildesiredtemperaturesare

met.Seeinstructionsuppliedwithvalve.

7.Bypasslooppipingmustbethesamesizepipingasthesupplyandthereturn.

8.Typicalinstallationusingcirculatorsisshowninfigure6onpage 4.

9.Typicalinstallationusingzonevalvesisshowninfigure7,below.

10.ForfurtherpipinginformationrefertotheI=B=Rinstallationandpipingguide.

FIGURE 7

GENERAL INFORMAGENERAL INFORMA

GENERAL INFORMATIONTION

TIONTION

TION

GAS VENTS AND APPLIANCESGAS VENTS AND APPLIANCES

GAS VENTS AND APPLIANCES

By Federal Codes, gas appliances are categorized by the pressure and temperature of

thefluegas vented from theappliance. Category I and II appliancesare natural draft (draft

hood) vented, with high flue gas temperatures (Category I), or low flue gas temperatures

(Category II). Category III and IV appliances are fan forced vents with high temperature

(CategoryIII)orlowtemperature(CategoryIV)fluegasses. Applianceefficiencyisdirectly

related to flue gas temperature. Higher efficiency appliances remove more heat from the

gas, so they will have lower temperature flue products. When flue gas temperatures are

lowered,corrosivecondensatesmayforminthegasventorintheappliance. Condensates

may form in Category II, III, IV appliance vents, so special corrosive resistant venting

systems are required for higher efficiency appliances.

WARNING:ARNING:

ARNING:ARNING:

ARNING: VentsforCategoryIappliancesmaynotbesuitableforusewith

Category II, III, or IV appliances because condensate may corrode the vent.

WARNING:ARNING:

ARNING:ARNING:

ARNING: Vents for Category III appliances may not be suitable for use

with Category I appliances because flue gas temperatures may be too high.

Properoperationoftheventsystemandapplianceisdependentupontheuseofallparts

specified by the manufacturer for use in the particular installation. Appliance and vent

system performance may be affected by improper assembly.

PAGE 5

PAGE 6

VENT PIPE MODIFICAVENT PIPE MODIFICA

VENT PIPE MODIFICATIONTION

TIONTION

TION

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 SYSTEMREMOVAL OF BOILER FROM VENTING SYSTEM

REMOVAL OF BOILER FROM VENTING SYSTEM

Atthetimeofremovalofanexistingboiler,thefollowingstepsshallbefollowedwitheach

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.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine

thereisnoblockageorrestriction,leakage,corrosionandotherdeficiencieswhichcould

cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the

spaceinwhich the appliances remainingconnected to the commonventing 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

hoodsand bathroom exhausts, sothey will operate atmaximum speed. Do notoperate

a summer exhaust fan. Close fireplace dampers.

4.Place in operation the appliance being inspected. Follow the lighting instructions. Adjust

thermostat so appliance will operate continuously.

5.Testforspillageat thedrafthoodreliefopeningafter5 minutesofmainburneroperation.

Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to a common

venting system properly vents when tested as outlined above, return doors, windows,

exhaust fans, fireplace dampers and any other gas burning appliance to their previous

conditions of use.

7. Any improper operation of the common venting system should be corrected so the

installationconformswitheitherthelatestrevisionofthe NationalFuelGasCode,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

resizinganyportionofthecommonventingsystem,thecommonventingsystemshould

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.

CONNECT GAS SERCONNECT GAS SER

CONNECT GAS SERVICEVICE

VICEVICE

VICE

Connect gas service meter to control

assembly in accordance with the latest

revision of ANSI Z223.1 and local codes or

utility.Agroundjointunionshouldbeinstalled

foreasyremovalofgascontrolfor servicing.

Adriportrap must be installed at thebottom

ofaverticalsectionofpipingattheinlettothe

boiler. A pipe compound resistant to the

action of liquefied petroleum gases must be

usedonallthreadedpipeconnections.Check

with the local utility for location of manual

shutoff valve if required. (See figure 8 at

right.)

PAGE 7

FIGURE 8

1. The 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.

Maximum Capacity of Pipe in Cubic Feet of Gas Per Hour (Cubic Meters per Hour)

(Gas pressure = 0.5 psig (3.45 kPa) or less pressure drop = .5 in.w/c(1.27 cm w/c))

Nominal Length of Pipe

Iron Pipe

Size 10' 20' 30' 40' 60' 80' 100'

(3.05m) (6.10m) (9.14m) (12.19m) (18.29m) (24.38m) (30.48m)

1/2" 175 120 97 82 66 57 50

(1.27 cm) (4.96) (3.40) (2.75) (2.32) (1.87) (1.61) (1.42)

3/4" 360 250 200 170 138 118 103

(1.91 cm) (10.20) (7.08) (5.66) (4.81) (3.91) (3.34) (2.92)

1" 680 465 375 320 260 220 195

(2.54 cm) (19.26) (13.17) (10.62) (9.06) (7.36) (6.23) (5.52)

1.1/4" 1400 950 770 660 530 460 400

(3.18 cm) (39.65) (26.90) (21.81) (18.69) (15.01) (13.03) (11.33)

For additional information refer to Part 10, table 10-2 of the National Fuel Gas Code

Handbook, or in Canada, the CAN1-B149.1 and/or B149.2 Installation Codes for Gas-

Burning Equipment.

2.Tocheckforleaksingaspiping,useasoapandwatersolutionorotherapprovedmethod.

WARNING:ARNING:

ARNING:ARNING:

ARNING: DO NOT USE AN OPEN FLAME.

3. The boiler and its individual shutoff valve must be disconnected from the gas supply

piping system during any pressure testing of that system at test pressures in excess of

1/2 psig (3.5 kPa).

4. The boiler must be isolated from the gas supply piping system by closing its individual

manualshutoffvalveduringanypressuretestingofthegassupplypipingsystemattest

pressures equal to or less than 1/2 psig (3.5 kPa).

NOT ALL COMPONENTS LISTED ARE USED IN ALL CONTROL SYSTEMS.

4. Honeywell hot water control and hot surface ignition wiring for USC series boilers.

See figure 9 on page 9.

NOTES:

•Switches are shown in position during the heating cycle.

•If any of the original wiring supplied with the boiler is replaced it must be

replaced with like wire size and type of insulation or equivalent.

5. WIRING CODE

LINE VOLTAGE BY FACTORY

LOW VOLTAGE BY FACTORY

LINE VOLTAGE BY INSTALLER

LOW VOLTAGE BY INSTALLER

1K2 Relay Contacts

LS Limit Switch

MS Manual Switch

CIR Circulator

ECO Energy Cut-Off

PSC Pilot Safety Coil

Wire Connection

LWCO Low Water Cut Off

EWF Electric Water Feeder

PG Power Generator

RSW Roll-OutSwitch

TH-1 Thermostat (millivolt)

TH-2 Thermostat (24 Volt)

TH-3 Thermostat (Line Voltage)

TR-1 Transformer(120V/24V40VA)

TR-2 Transformer(120V/24V50VA)

LGV 24 Volt Gas Valve

LGV-1 24 Volt Gas Valve

PS Pressure Switch

MR-PS Manual Reset Pressure Sw.

Control Terminal

1K Relay Coil

1K1 Relay Contacts

ELECTRICAL WIRINGELECTRICAL WIRING

ELECTRICAL WIRING

Electrical wiring must conform with National Electrical Code, ANSI/NFPA No. 70 when

installed in the United States, the CSA C22.1 Canadian Electrical Code, Part 1, when

installed in Canada, and/or the local authority having jurisdiction.

1. When an external electrical source is utilized, the boiler, when installed, MUST BE

electrically grounded in accordance with these requirements.

2. Install a fused disconnect switch between boiler and meter at a convenient location.

PAGE 8

3. COMPONENT CODING (SEE WIRING DIAGRAM ON PAGE 9)

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