UTICA BOILERS USC SERIES Installation, Operation & Maintenance Manual
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UTICA BOILERS USC SERIES Installation, Operation & Maintenance Manual

Direct vent gas fired hot water boiler
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USC SERIES

Direct Vent

Gas Fired Hot Water Boiler
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Utica BOiLERS
P.O. Box 4729
Utica, NY 13504-4729
www.uticaboilers.com
An ISO 9001-2000 Certified Company
R
MEMBER: The Hydronics Institute
3771201
P/N
, Rev. A [01/09]

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  • Page 1: Direct Vent

    USC SERIES Direct Vent Gas Fired Hot Water Boiler INSTALLATION, OPERATION & MAINTENANCE MANUAL Utica BOiLERS P.O. Box 4729 Utica, NY 13504-4729 www.uticaboilers.com An ISO 9001-2000 Certified Company MEMBER: The Hydronics Institute 3771201 , Rev. A [01/09]...

  • Page 2: Table Of Contents

    SEALED COmBUSTION, GAS FIRED, FORCED HOT WATER BOILER TABLE OF CONTENTS 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 ..............................

  • Page 3: Introduction

    INTRODUCTION FOR INSTALLATION ON NON-COMBUSTIBLE WARNING FLOORS ONLY. The boiler must not be installed on car- Improper installation, adjustment, alteration, service peting (For installation on combustible flooring Special or maintenance can cause injury or property damage. Base Part NO.325-2-8.00 MUST BE USED). Minimum clearances to combustible constructions are: The installation must conform to the requirements of the authority having jurisdiction or, in absence of such...

  • Page 4: Boiler Ratings, Capacities & Dimensions

    BOILER RATINGS, CAPACITIES & DImENSIONS I=B=R Dimensions A.G.A Heating Natural Supply & No. Of AFUE Boiler Net Out- Water Input Capacity Return Burn- Rat- Content Btu/Hr. Btu/Hr. Inlet Tappings ings Btu/Hr. 50,000 38,000 1/2" 15.1/8" 5" 4.0 gals 3 Sec- 44,000 3.1/2"...

  • Page 5: Connecting Supply And Return Piping

    CONNECTING SUPPLy AND RETURN PIPING fig- Connect supply and return piping as suggested in Hot water boilers installed above radiation level must be ure #2 below when the boiler is used in connection with provided with a low water cut-off device at the time of refrigerated systems: boiler installation.
  • Page 6 CONNECTING SUPPLy AND RETURN PIPING Figure 3 - Bypass Piping Bypass piping is an option which gives the ability to adjust the supply SUPPLY boiler water temperature to fit the SYSTEM system or condition of the installa- TEMPERATURE GAUGE tion. This method of piping is not typically required for baseboard FLOW VALVE...
  • Page 7 CONNECTING SUPPLy AND RETURN PIPING Figure 5 - Primary Secondary Piping with Bypass RETURN SYSTEM SYSTEM CIRCULATOR TEMPERATURE 12" GAUGE (31 cm) FLOW MAX. VALVE SUPPLY "A" VALVE PRIMARY CIRCULATOR "B" VALVE FEED EXPANSION WATER TANK Figure 6 GATE VALVE SYSTEM TANK CIR.

  • Page 8: General Information Gas Vents And Appliances

    CONNECTING SUPPLy AND RETURN PIPING Figure 7 SYSTEM ZONE VALVE GATE VALVE SYSTEM COLD WATER RETURN INLET REDUCED PRESSURE TANK ZONE BACKFLOW PREVENTER VALVE HOT WATER OUTLET CIR. PRESSURE REDUCING VALVE FEED WATER TERMAL TRAP RELIEF VALVE WIRING FOR THERMOSTAT/ PUMP CONTROL DRAIN COCK GENERAL INFORmATION GAS VENTS AND APPLIANCES...

  • Page 9: Vent Pipe Modification

    VENT PIPE mODIFICATION When an existing boiler is removed from a common venting Place in operation the appliance being inspected. Follow system, the common venting system is likely to be too large for the lighting instructions. Adjust thermostat so appliance the proper venting of the appliances remaining connected to will operate continuously.

  • Page 10: Connect Gas Service

    CONNECT GAS SERVICE Connect gas service meter to control assembly in accordance The boiler and its individual shutoff valve must be discon- with the latest revision of ANSI Z223.1 and local codes or util- nected from the gas supply piping system during any pres- ity.

  • Page 11: Electrical Wiring

    ELECTRICAL WIRING Electrical wiring must conform with National Electrical Code, COMPONENT KEy CODING ANSI/NFPA No. 70 when installed in the United States, the CSA C22.1 Canadian Electrical Code, Part 1, when installed Thermostat (24 Volt) TH-2 in Canada, and/or the local authority having jurisdiction. (See Transformer (120V/24V 40VA) TR-1 figure #8)
  • Page 12 HOT WATER CONTROL AND HOT SURFACE PILOT WIRING Q3450B INDUCED DRAFT L4080B BLOWER 120V GREEN 60HZ SUPPLY WHITE ORANGE GREEN ORANGE CONTROL IGNITION Honeywell SV9501H TH-2 TR-1 TR-2 R8222C Q3450B 120V L4080B 60HZ INDUCED SUPPLY DRAFT BLOWER GREEN WHITE GREEN CONTROL IGNITION Honeywell...

  • Page 13: Lighting Instructions

    LIGHTING INSTRUCTIONS FOR BOILER WITH A HOT SURFACE PILOT SySTEm WARNING CAUTION IF YOU DO NOT FOLLOW THESE INSTRUC- Before operating, make certain the boiler and system TIONS EXACTLY, A FIRE OR EXPLOSION MAY are full of water to minimum pressure (this is usu- RESULT CAUSING PROPERTY DAMAGE, PER- ally 12 lbs.

  • Page 14: Sequence Of Operation

    LIGHTING INSTRUCTIONS OPERATING INSTRUCTIONS Figure 10 STOP! Read the safety information in the user’s informa- PILOT FLOW ADJ. tion manual. SCREW BENEATH COVER SCREW Set thermostat to lowest setting. IGNITION SYSTEM CONTROL SWITCH Turn off all electric power to the appliance. This appliance is equipped with an ignition device which automatically lights the pilot.

  • Page 15: General Instruction For Seasonal Start Up And Maintenance

    GENERAL INSTRUCTION FOR SEASONAL START UP AND mAINTENANCE It is suggested that a qualified service agency be employed to Periodic cleaning of the condensate collection system is re- make an annual inspection of the boiler and the heating sys- quired. When a condensate collection system is installed in a tem.
  • Page 16 GENERAL INSTRUCTION FOR SEASONAL START UP AND mAINTENANCE Figure 12 Figure 13 BAFFLES VENT PIPE ADAPTER PANEL COUPLING AIR BOX COVERS FRONT PANEL PRESSURE TAP The following procedure should be followed to clean and check the flue gas passageways: Remove the burners from the combustion chamber by raising the burners up from the manifold orifices and pull- Turn off gas to the boiler at the manual gas ing toward the front of the boiler.
  • Page 17 GENERAL INSTRUCTION FOR SEASONAL START UP AND mAINTENANCE Visually check the main burners and pilot flame at Visually inspect the baffles for any unusual wear or soot the start of each heating season and again midway build up. Clean if necessary. through the season.
  • Page 18 GENERAL INSTRUCTION FOR SEASONAL START UP AND mAINTENANCE The other part of the tee goes to the air box and venter Adjusting the pilot flame: pressure taps. Remove the pilot adjustment cover screw. Orange being the high negative. Turn inner screw (adjustment screw) clockwise White being the low negative.
  • Page 19 GENERAL INSTRUCTION FOR SEASONAL START UP AND mAINTENANCE CHECK GAS INPUT RATE TO BOILER If minor adjustment is necessary, install a manometer 1. Maximum permissible gas supply pressure must not be on the outlet side of the gas valve. Adjust the pressure higher and minimum supply pressure must not be lower regulator on the combination gas control.

  • Page 20: Venting Instructions

    VENTING INSTRUCTIONS VENTING INSTRUCTIONS APPLICABLE FEDERAL CODES UNITED STATES NFPA 54/ANSI Z223.1 …National Fuel Gas Code (Part 7) NFPA/ANSI211 …Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances CANADA CAN1-B149.1 …Installation Codes for Gas-Burning Equipment B149.2 …Installation Codes for Gas-Burning Equipment These codes contain information on special gas vents for Category II, III and IV appliances, vent sizing, lo- cation, air space clearances to combustibles and safe installation practices.
  • Page 21 VENTING INSTRUCTIONS In the event that the requirements of this subdivision Installation Requirements Specific To The State Of can not be met at the time of completion of installa- massachusetts For Direct Vent, mechanical Vent, And tion, the owner shall have a period of thirty (30) days Domestic Hot Water Appliances to comply with the above requirements;...
  • Page 22 VENTING INSTRUCTIONS VENT PIPE INSTALLATION INSTRUCTIONS This boiler is design certified for use with the following venting systems. Company HEAT-FAB® FLEX-L® Z-FLEX® ProTech® Product SAF-T-VENT™ STAR-34™ Z-VENT™ FasNSeal™ CAUTION the above vent pipe and fittings are used for venting gas burning category iii, iv, and direct vent appliances. Do not use this vent pipe or fittings for venting appliances burning fuels such as wood, oil, kerosene or coal.
  • Page 23 VENTING INSTRUCTIONS Figure 2 - HORIZONTAL VENT PIPING (TyPICAL INSTALLATION) Notes: *1 : A condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. *2 : Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 24 VENTING INSTRUCTIONS Horizontal Vent Pipe Lengths Boiler Size Vent Pipe Dia Max Vent Length* Min Vent Length* Inlet Pipe 30 ft (914 cm) with 2 ft (61 cm) with 1 30 ft (914 cm) with 2 3 Section 3" (8 cm) condensate tee &...
  • Page 25 VENTING INSTRUCTIONS Using the template provided as a guide, cut a hole through the wall. Then secure the template to the inside of the wall over the hole. (See figures 5a and 5b. NOTE: If installing through a non combustible wall make (2) 3-1/2" (8.9 cm) holes on center through the wall. (Approxi- mately 5-1/4"...
  • Page 26 VENTING INSTRUCTIONS Figure 5a - Top View Of Termination Kit And Wall (For Combustible Wall Installation) Figure 5b - Top View Of Termination Kit And Wall (For Non-Combustible Wall Installation Remove Thimble wall Plate Assembly)
  • Page 27 VENTING INSTRUCTIONS For vent pipe installation refer to the vent pipe manufacturers instructions. Figure 6 - Vent System For All models Figure 7 - RECOmmENDED TERMINATION TEE THIMBLE VENT PIPE VENT CONDENSATE TRAP ASSY NOTE: REFER TO “VENT CONDENSATE PIPE LENGTHS” FOR DRAIN USAGE.
  • Page 28 VENTING INSTRUCTIONS Figure 9 - Vent Clearances NOTE: IF THERE IS A POTENTIAL FOR EXCESSIVE WINDS, SPECIAL CONSIDERATION SHOULD BE GIVEN TO LOCATE THE VENT TERMINATION AWAY FROM THE WINDWARD SIDE OF THE BUILDING. MOUNT VENT CAP AT LEAST 12” (31CM) FROM INSIDE CORNERS AND VENT CAP MUST BE AT LEAST 12”...
  • Page 29 VENTING INSTRUCTIONS Figure 10 - Flex-L® Star-34™ Vent Pipe Components Notes: *1 : A condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. *2 : Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 30 VENTING INSTRUCTIONS Figure 11 - Heat Fab® Saf-T Vent™ Vent Pipe Components Notes: *1 : A condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. *2 : Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 31 VENTING INSTRUCTIONS Figure 12 - Z-Flex® Z-vent™ Vent Pipe Components Notes: *1 : A condensate tee/drain is only needed when horizontal vent lengths exceed 10 feet. *2 : Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 32 VENTING INSTRUCTIONS Figure 13 - ProTech® FasNSeal™ Vent Pipe Components Notes: *1 : A condensate tee/drain is only needed when hoizontal vent lenghts exceed 10 feet. *2 : Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 33 VENTING INSTRUCTIONS Figure 14 - Vertical Vent Piping Typical Installation Notes: * Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp.
  • Page 34 VENTING INSTRUCTIONS INSTALLATION PROCEDURE FOR VERTICAL VENTING WARNING do not insulate or other wise wrap vent pipe or fit- tings. Follow the vent pipe manufacturers installation instructions for vertical venting. The Vent Termination Must Be Located: With a 2" (5.1 cm) clearance to combustible materials. fig.
  • Page 35 VENTING INSTRUCTIONS Figure 17 - Termination 10 Ft (305 cm) Or Less From Ridge Figure 18 - Termination more than 10 Ft (305 cm) from Ridge...
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  • Page 40: Replacement Parts

    REPLACEmENT PARTS PILOT ITEM # PART # DESCRIPTION QTY. PBO1401 Pilot Q3450b 1039 HW NAT (For Natural Gas Only) PB01402 Pilot Q3450b 1112 LP (For Propane Gas Only) 3771101 Pilot Assembly HW-024.01 Screw #10 32x3/16 43300201 Pilot Tube 1/4"X24-1/4" Aluminum...
  • Page 41 REPLACEmENT PARTS HEAT EXCHANGER 10 9 ITEM # DESCRIPTION QTY. 100-2-2.01 B-Left Hand Section B-Center Section 3 Section 100-2-1.01 B-Center Section 4 Section B-Center Section 5 Section 100-2-3.01 B-Right Section HW-011.01 Tie Rod 1/4x11.1/2 3 Section HW-011.03 Tie Rod 1/4x15.1/2 4 Section HW-011.05 Tie Rod 1/4x19.1/2 5...
  • Page 42 REPLACEmENT PARTS BASE ITEM ITEM PART # DESCRIPTIONS QTY. PART # DESCRIPTIONS QTY. Burner Tube 3 Section 3272101 Air Box Wrapper 3 Section 240005543 Burner Tube 4 Section 3272102 Air Box Wrapper 4 Section Burner Tube 5 Section 3272103 Air Box Wrapper 5 Section 5611602 Kit - Base With Insul 3 Section 240007769 Pilot Grommet...
  • Page 43 REPLACEmENT PARTS AIR BOX COVERS ITEM # PART # DESCRIPTIONS QTY. ITEM PART # DESCRIPTIONS QTY. HW10301 Hose Clamp Sst 3572401 Insul Frt Cov. 3 Section 3271601 Air Intake Adapter 3572402 Insul Frt Cov. 4 Section 3271203 Air Intake Sleeve 3572403 Insul Frt Cov.
  • Page 44 REPLACEmENT PARTS PIPING & CONTROLS TO GAS VALVE ITEM # PART # DESCRIPTIONS QTY. 3772301 WIRE HARNESS - GAS VALVE 28" 37519501 HARNESS CIRCULATOR 72" 1310002 PIPE - NIPPLE 1.1/4 X 4.1/2 NPT HW-016.03 DRAIN SHORT 1510001 PIPE FIT TEE - 1.1/4X3/4X1.1/4 PF-006.01 PIPE FIT NIPPLE 1.1/4 CLOSE 37518901...
  • Page 45 REPLACEmENT PARTS ELECTRICAL ITEM # PART # DESCRIPTIONS QTY. SS00801 PRESSURE SWITCH (FS6205A) 3171101 TERMINAL STRIP COVER 550001339 TRANSFORMERS - 40VA 1410001 CONTROL R8222C-1008 HW09601 TUBING - SILICON - CLEAR 12" EF04001 9 TERM STRIP HW09701 TUBING - SILICON - ORANGE 17"...
  • Page 46 REPLACEmENT PARTS FLUE COLLECTOR & VENTER COmPONENTS ITEM # PART # DESCRIPTIONS QTY. 3472501 FLUE COLLECTOR ASSY 3 Section 3472502 FLUE COLLECTOR ASSY 4 Section 3472503 FLUE COLLECTOR ASSY 5 Section 345-2-7.01 VENT ADAPTER HW-005.01 SCREW 1/4-20X1/2 SELF TAP DC00402 VENTER - JAKEL 3571501 GASKET - VENTER...
  • Page 47 REPLACEmENT PARTS TERmINATION KIT ITEM # PART # DESCRIPTIONS QTY. 34721501 VENT TERMINATION THIMBLE PLATE ASSY 34721002 TERMINATION ASSEMBLY 34721401 VENT TERMINATION DEFLECTOR 1330006 NUT #10-24 HEX 30A004312 SCREW #10-24 X 1.1/2" ROUND HEAD 3471701 DRAW COLLAR - HW-009.01 SCR #8-18X1/2" SLT HX WASH 3471901 VENT TEMPLATE 5612601...
  • Page 48 REPLACEmENT PARTS JACKET ITEM # PART # DESCRIPTION QTY. 31710202 Panel - Left Hand Side 3172801 Panel - Front 3 Section 3172802 Panel - Front 4 Section 3172803 Panel - Front 5 Section 3172401 Panel - Separator Plate 3 Section 3172402 Panel - Separator Plate 4 Section 3172403...

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