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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An ISO 9001-2000 Certified Company
UTICA BOILERS
P.O. Box 4729
Utica, NY 13504-4729
www.uticaboilers.com
MEMBER: The Hydronics Institute
R
Subject to change without notice.
National Excelsior Company
www.excelsiorhvac.com
3771201
P/N
, Rev. A [01/09]

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  • Page 1 National Excelsior Company www.excelsiorhvac.com UTICA BOILERS P.O. Box 4729 Utica, NY 13504-4729 www.uticaboilers.com MEMBER: The Hydronics Institute 3771201 An ISO 9001-2000 Certified Company , Rev. A [01/09] Subject to change without notice.
  • Page 2 National Excelsior Company www.excelsiorhvac.com NOTICE KEEP THIS MANUAL NEAR BOILER AND e following de ned symbols are used throughout this manual to notify the reader of potential hazards of varying risk RETAIN FOR FUTURE REFERENCE. levels. WARNING DANGER 1. Keep boiler area clear and free from combustible Indicates an imminently hazardous situation which, materials, gasoline and other ammable vapors and if not avoided, WILL result in death, serious injury or...
  • Page 3 National Excelsior Company www.excelsiorhvac.com FOR INSTALLATION ON NON-COMBUSTIBLE WARNING FLOORS ONLY. e boiler must not be installed on car- Improper installation, adjustment, alteration, service peting (For installation on combustible ooring 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: e installation must conform to the requirements of the authority having jurisdiction or, in absence of such...
  • Page 4 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com 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-o device at the time of refrigerated systems: boiler installation.
  • Page 6 National Excelsior Company www.excelsiorhvac.com Bypass piping is an option which gives the ability to adjust the supply SUPPLY boiler water temperature to t the SYSTEM system or condition of the installa- TEMPERATURE GAUGE tion. is method of piping is not typically required for baseboard FLOW VALVE...
  • Page 7 National Excelsior Company www.excelsiorhvac.com RETURN SYSTEM SYSTEM CIRCULATOR TEMPERATURE 12" GAUGE (31 cm) FLOW MAX. VALVE SUPPLY "A" VALVE PRIMARY CIRCULATOR "B" VALVE FEED EXPANSION WATER TANK GATE VALVE SYSTEM TANK CIR. CIRCULATOR REDUCED PRESSURE BACKFLOW PREVENTER FLOW CONTROL OR CHECK VALVE HOT WATER OUTLET COLD WATER...
  • Page 8 National Excelsior Company www.excelsiorhvac.com 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 By Federal Codes, gas appliances are categorized by the pres- Proper operation of the vent system and appliance is depen- sure and temperature of the ue gas vented from the appliance.
  • Page 9 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com Connect gas service meter to control assembly in accordance e boiler and its individual shuto 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 National Excelsior Company www.excelsiorhvac.com 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 gure #8)
  • Page 12 National Excelsior Company www.excelsiorhvac.com 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 TH-2 BLACK YELLOW YELLOW...
  • Page 13 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com 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 o all electric power to the appliance. is appliance is equipped with an ignition device which automatically lights the pilot.
  • Page 15 National Excelsior Company www.excelsiorhvac.com It is suggested that a quali ed 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 National Excelsior Company www.excelsiorhvac.com BAFFLES VENT PIPE ADAPTER PANEL COUPLING AIR BOX COVERS FRONT PANEL PRESSURE TAP Remove the burners from the combustion chamber by raising the burners up from the manifold ori ces and pull- Turn o gas to the boiler at the manual gas ing toward the front of the boiler.
  • Page 17 National Excelsior Company www.excelsiorhvac.com Visually inspect the ba es for any unusual wear or soot build up. Clean if necessary. Visually inspect the venter assembly for any unusual wear a. Check the burner throats and burner orifices for lint or dirt build up. Vacuum if necessary. and dust obstructions.
  • Page 18 National Excelsior Company www.excelsiorhvac.com e other part of the tee goes to the air box and venter pressure taps. Remove the pilot adjustment cover screw. Orange being the high negative. Turn inner screw (adjustment screw) clockwise White being the low negative. decrease and counterclockwise to increase the pilot ame, see gure #10.
  • Page 19 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com NFPA 54/ANSI Z223.1 …National Fuel Gas Code (Part 7) NFPA/ANSI211 …Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances CAN1-B149.1 …Installation Codes for Gas-Burning Equipment B149.2 …Installation Codes for Gas-Burning Equipment ese 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 National Excelsior Company www.excelsiorhvac.com In the event that the requirements of this subdivision can not be met at the time of completion of installa- tion, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, In the State of Massachusetts, boiler installation must conform however, that during said thirty (30) day period, a to state code 248 CMR which includes but is not limited to:...
  • Page 22 National Excelsior Company www.excelsiorhvac.com is boiler is design certi ed 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 ttings are used for venting gas burning category iii, iv, and direct vent appliances. Do not use this vent pipe or ttings for venting appliances burning fuels such as wood, oil, kerosene or coal.
  • Page 23 National Excelsior Company www.excelsiorhvac.com 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. Subject to change without notice.
  • Page 24 National Excelsior Company www.excelsiorhvac.com Boiler Size Vent Pipe Dia Max Vent Length* Min Vent Length* Inlet Pipe 30 (914 cm) with 2 (61 cm) with 1 30 (914 cm) with 2 3 Section 3" (8 cm) condensate tee & 2 elbow elbows elbows.
  • Page 25 National Excelsior Company www.excelsiorhvac.com Using the template provided as a guide, cut a hole through the wall. en secure the template to the inside of the wall over the hole. (See gures 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 National Excelsior Company www.excelsiorhvac.com Subject to change without notice.
  • Page 27 National Excelsior Company www.excelsiorhvac.com TERMINATION TEE THIMBLE VENT PIPE VENT CONDENSATE TRAP ASSY NOTE: REFER TO “VENT CONDENSATE PIPE LENGTHS” FOR DRAIN USAGE. 12" (30.5 cm) MINIMUM NOTICE WARNING Condensate Drains are only needed when horizontal Do not place condensate drain where freezing may vent lengths exceed 10 feet occur.
  • Page 28 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com 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. Subject to change without notice.
  • Page 30 National Excelsior Company www.excelsiorhvac.com 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. Subject to change without notice.
  • Page 31 National Excelsior Company www.excelsiorhvac.com 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. Subject to change without notice.
  • Page 32 National Excelsior Company www.excelsiorhvac.com 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. Subject to change without notice.
  • Page 33 National Excelsior Company www.excelsiorhvac.com Notes: * Insert vent pipe in boiler venter outlet (vent adapter), apply silicone completely around edge of outlet and tighten clamp. Subject to change without notice.
  • Page 34 National Excelsior Company www.excelsiorhvac.com WARNING do not insulate or other wise wrap vent pipe or t- tings. Follow the vent pipe manufacturers installation instructions for vertical venting. e Vent Termination Must Be Located: With a 2" (5.1 cm) clearance to combustible materials. g.
  • Page 35 National Excelsior Company www.excelsiorhvac.com Subject to change without notice.
  • Page 36 National Excelsior Company www.excelsiorhvac.com Subject to change without notice.
  • Page 37 National Excelsior Company www.excelsiorhvac.com Subject to change without notice.
  • Page 38 National Excelsior Company www.excelsiorhvac.com Subject to change without notice.
  • Page 39 National Excelsior Company www.excelsiorhvac.com Subject to change without notice.
  • Page 40 National Excelsior Company www.excelsiorhvac.com 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 Subject to change without notice.
  • Page 41 National Excelsior Company www.excelsiorhvac.com 10 9 ITEM # DESCRIPTION QTY. 100-2-2.01 B-Le 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 National Excelsior Company www.excelsiorhvac.com 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...
  • Page 43 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com 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 HW09501...
  • Page 47 National Excelsior Company www.excelsiorhvac.com 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 National Excelsior Company www.excelsiorhvac.com ITEM # PART # DESCRIPTION QTY. 31710202 Panel - Le 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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