UTICA BOILERS USC Installation Manual And Operating Instructions
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UTICA BOILERS USC Installation Manual And Operating Instructions

Direct vent gas fired boilers for forced hot water
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DIRECT VENT GAS FIRED BOILERS
FOR FORCED HOT WATER
S S S S S
EALED
C C C C C
OMBUSTION
Utica Boilers, Inc. • P.O. Box 4729 • Utica, NY 13504
USC
USC
USC
USC
USC

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Summary of Contents for UTICA BOILERS USC

  • Page 1 DIRECT VENT GAS FIRED BOILERS FOR FORCED HOT WATER S S S S S EALED C C C C C OMBUSTION Utica Boilers, Inc. • P.O. Box 4729 • Utica, NY 13504...

  • Page 2: Table Of Contents

    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...

  • Page 3: Safety Symbols & Warnings

    VENTING 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.

  • Page 4: Installation Procedure

    INST INST INSTALLA ALLA ALLA ALLATION PR TION PR TION PROCEDURE TION PR OCEDURE OCEDURE OCEDURE INST INST ALLA TION PR 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.

  • Page 5: Connecting Supply And Return Piping

    CONNECTING SUPPL CONNECTING SUPPL CONNECTING SUPPLY Y Y Y Y AND RETURN PIPING AND RETURN PIPING AND RETURN PIPING AND RETURN PIPING CONNECTING SUPPL CONNECTING SUPPL 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.
  • Page 6 6. Note: When using a 4-way mixing valve, set control knob until desired temperatures are met. See instruction supplied with valve. 7. Bypass loop piping must be the same size piping as the supply and the return. 8. Typical installation using circulators is shown in figure 6 on page 4. 9.

  • Page 7: General Information: Gas Vents And Appliances

    FIGURE 7 GENERAL INFORMA GENERAL INFORMA GENERAL INFORMATION TION TION TION GENERAL INFORMA GENERAL INFORMA TION GAS VENTS AND APPLIANCES GAS VENTS AND APPLIANCES GAS VENTS AND APPLIANCES GAS VENTS AND APPLIANCES GAS VENTS AND APPLIANCES By Federal Codes, gas appliances are categorized by the pressure and temperature of the flue gas vented from the appliance.

  • Page 8: Vent Pipe Modification

    VENT PIPE MODIFICA VENT PIPE MODIFICA VENT PIPE MODIFICATION TION TION TION VENT PIPE MODIFICA VENT PIPE MODIFICA 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.

  • Page 9: Connect Gas Service

    CONNECT GAS SER CONNECT GAS SERVICE CONNECT GAS SER VICE VICE VICE CONNECT GAS SER CONNECT GAS SER VICE Connect gas service meter to control assembly in accordance with the latest revision of ANSI Z223.1 and local codes or utility. A ground joint union should be installed for easy removal of gas control for servicing.

  • Page 10: Electrical Wiring

    Relay Coil Roll-Out Switch Relay Contacts 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.
  • Page 11 FIGURE 9 PAGE 9...

  • Page 12: Lighting Instructions

    THERMOST THERMOST THERMOSTA A A A A T INST INST INSTALLA ALLA ALLA ALLATION TION TION TION THERMOST THERMOST INST INST ALLA TION 1. Thermostat should be installed on an inside wall about 4 ft (122 cm) above the floor. 2.
  • Page 13 3. Use only your hand to move the ignition system control switch. Never use tools. If the switch will not move by hand, don’t try to repair it, call a qualified service technician. W W W W W ARNING: ARNING: ARNING: ARNING: ARNING:...

  • Page 14: Sequence Of Operation

    SEQUENCE OF OPERA UENCE OF OPERA UENCE OF OPERA UENCE OF OPERATION TION TION TION UENCE OF OPERA TION On a call for heat: 1.) The thermostat will actuate, completing the circuit between terminals T and T. 2.) The R8222C relay coil will energize thus pulling in the relay contacts. 3.) The circulator starts and power is switched to the limit.

  • Page 15: General Instructions

    GENERAL INSTRUCTION FOR SEASONAL GENERAL INSTRUCTION FOR SEASONAL GENERAL INSTRUCTION FOR SEASONAL GENERAL INSTRUCTION FOR SEASONAL GENERAL INSTRUCTION FOR SEASONAL STAR ART UP T UP T UP T UP AND MAINTEN T UP AND MAINTEN AND MAINTEN AND MAINTENANCE AND MAINTEN ANCE ANCE ANCE...
  • Page 16 FIGURE 13 FIGURE 12 2. THE FOLLOWING PROCEDURE SHOULD BE FOLLOWED TO CLEAN AND CHECK THE FLUE GAS PASSAGEWAYS: A. Turn off gas to the boiler at the manual gas valve. B. Remove the jacket front panel. (See figure 12 above.) C.
  • Page 17 FIGURE 16 FIGURE 17 J. Visually inspect the baffles for any unusual wear or soot build up. Clean if necessary. K. Visually inspect the venter assembly for any unusual wear or dirt build up. Vacuum if necessary. L. Place a sheet of heavy paper or similar material in the bottom of the combustion chamber and brush down the flue passageways.

  • Page 18: Check Venter Static Pressure

    4. Turn the boiler back on and read the static pressure. The reading should be - .55±.05 inches water column or higher for the USC series boilers. 5. If the static pressures are not at the minimum allowable level, check the intake and exhaust pipes for obstructions or damage.

  • Page 19: Checking Gas Input Rate To Boiler

    TS - PIL ITEM NO DESCRIPTION QTY. PBO1401 PILOT Q3450B 1039 HW NAT (FOR NATURAL GAS ONLY) PB01402 PILOT Q3450B 1112 LP USC (FOR PROPANE GAS ONLY) 32711102 BASE - PILOT BRACKET HW-024.01 SCREW #10 32X3/16 MS-003.05 PILOT TUBE 1/4"X24-1/4" ALUMINUM...
  • Page 20 USC SERIES REPLA USC SERIES REPLACEMENT P USC SERIES REPLA CEMENT P CEMENT PAR CEMENT P ARTS - J TS - J TS - J TS - JA A A A A CKETS CKETS CKETS CKETS USC SERIES REPLA USC SERIES REPLA...
  • Page 21 USC SERIES REPLA USC SERIES REPLA USC SERIES REPLACEMENT P CEMENT P CEMENT P CEMENT PAR ARTS USC SERIES REPLA USC SERIES REPLA CEMENT P HEAT EX T EX T EX T EX T EXCHANGER CHANGER CHANGER CHANGER CHANGER ITEM NO.
  • Page 22 5611604 KIT - BASE WITH INSUL USC5 3271801 AIR BOX WRAPPER GASKET 355-1-5.09 ORIFICE #36 USC5 10 VG01701 GAS VALVE USC (SV9501H2417)1 355-1-5.10 ORIFICE #37 USC4 (FOR NATURAL GAS ONLY) 355-1-5.11 ORIFICE #43 USC3 VG01702 GAS VALVE USC (SV9501H2425) 355-1-5.12...
  • Page 23 USC SERIES REPLA USC SERIES REPLA USC SERIES REPLACEMENT P CEMENT P CEMENT PAR CEMENT P ARTS USC SERIES REPLA USC SERIES REPLA CEMENT P AIR BO AIR BO AIR BO AIR BO AIR BOX CO X CO X CO...
  • Page 24 PIPING & CONTROLS PIPING & CONTROLS PIPING & CONTROLS PIPING & CONTROLS ITEM NO DESCRIPTION QTY. 3772301 WIRE HARNESS - GAS VALVE USC 28" 37519501 HARNESS CIRCULATOR 72" PF-006.07 PIPE - NIPPLE 1.1/4 X 4.1/2 NPT HW-016.03 DRAIN SHORT PF-008.03 PIPE FIT TEE - 1.1/4X3/4X1.1/4...
  • Page 25 USC REPLA USC REPLA USC REPLACEMENT P CEMENT P CEMENT PAR CEMENT P ARTS - ELECTRICAL TS - ELECTRICAL TS - ELECTRICAL TS - ELECTRICAL USC REPLA USC REPLA CEMENT P TS - ELECTRICAL ITEM NO DESCRIPTION QTY. SS00801 PRESSURE SWITCH (FS6205A)
  • Page 26 USC SERIES REPLA USC SERIES REPLA USC SERIES REPLACEMENT P CEMENT P CEMENT PAR CEMENT P ARTS USC SERIES REPLA USC SERIES REPLA CEMENT P FLUE COLLECT UE COLLECT UE COLLECT UE COLLECT UE COLLECTOR & OR & OR &...
  • Page 27 USC SERIES REPLA USC SERIES REPLA USC SERIES REPLACEMENT P CEMENT P CEMENT P CEMENT PAR ARTS USC SERIES REPLA USC SERIES REPLA CEMENT P TERMIN TERMIN TERMIN TERMIN TERMINA A A A A TION KIT TION KIT TION KIT...
  • Page 28 3771201 REV: 6.3, September 2004...

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