UTICA BOILERS USC SERIES Page 2 Installation Manual And Operating Instructions Download

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TABLE 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

Summary of Contents for USC SERIES

Page 1: ... AL AL AL AND OPERA AND OPERA AND OPERA AND OPERA AND OPERATING INSTR TING INSTR TING INSTR TING INSTR TING INSTRUCTIONS UCTIONS UCTIONS UCTIONS UCTIONS USC USC USC USC USC DIRECT VENT GAS FIRED BOILERS FOR FORCED HOT WATER Utica Boilers Inc P O Box 4729 Utica NY 13504 S S S S SEALED C C C C COMBUSTION ...

Page 2: ...e 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 FIRE...

Page 3: ... INSTALLATIONS OF BOILERS AND ALL INSTALLATIONS OF BOILERS AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND 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 ...

Page 4: ... 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 cle...

Page 5: ...tion 3 Whenaboilerisconnectedtoaheatingsystemthatutilizesmultiplezonedcirculators each circulator must be supplied with a flow control valve to prevent gravity circulation Reduced pressure back flow preventer must be used under provisions required by the EnvironmentalProtectionAgency EPA 4 Bypass piping is an option which gives the ability to adjust the supply boiler water temperature to fit the s...

Page 6: ...red temperatures are met Seeinstructionsuppliedwithvalve 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 Typical installation using zone valves is shown in figure 7 below 10 For further piping information refer to the I B R installation and piping guide ...

Page 7: ...move more heat from the gas so they will have lower temperature flue products When flue 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 corrosive resistant venting systems are required for higher efficiency appliances W W W W WARNING ARNING ARNING ARNING ARNING Vents for Category I...

Page 8: ...paces 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 operate at maximum speed Do not operate 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 c...

Page 9: ...ngth 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 ...

Page 10: ...tch 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 WIRING ELECTRICAL WIRING ELECTRICAL WIRING ELECTRICAL WIRING ELECTRICAL WIRING Electrical wiring mus...

Page 11: ...TES 1 SWITCHES ARE SHOWN IN POSITION TAKEN DURING THE HEATING CYCLE 2 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 NOT ALL COMPONENTS LISTED ARE USED IN ALL CONTROL SYSTEMS WIRING LINE VOLTAGE BY FACTORY LOW VOLTAGE BY FACTORY LINE VOLTAGE BY INSTALLER LOW VOLTAGE BY INSTALLER COMPONENT CODE HO HO HO...

Page 12: ...kPa on most systems and system is vented of air See the operating and lighting instructions LIGHTING PROCEDURE FOR BOILER WITH LIGHTING PROCEDURE FOR BOILER WITH LIGHTING PROCEDURE FOR BOILER WITH LIGHTING PROCEDURE FOR BOILER WITH LIGHTING PROCEDURE FOR BOILER WITH A HO A HO A HO A HO A HOT SURF T SURF T SURF T SURF T SURFA A A A ACE PIL CE PIL CE PIL CE PIL CE PILO O O O OT SY T SY T SY T SY T S...

Page 13: ...e which automatically lights the pilot DO NOT try to light the pilot by hand 5 Move the ignition system control switch to the OFF position See figure 10 above 6 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow step 2 in the lighting procedure on page 10 What To Do If You Smell Gas If you don t smell gas go to the next step 7 Move the ignition system control switch to the ...

Page 14: ... be interrupted to the venter motor and TR 2 thus interrupting power to the ignition system Power will remain off until the water temperature drops below the high limit setting The circulator will continue to operate under this condition until the thermostat is satisfied 8 Should the air flow static pressure be interrupted ie blocked flue the pressure switch will sense a drop in pressure opening t...

Page 15: ... is filled with water to minimum pressure and open air vents if used to expel any air that may have accumulated in the system C Check automatic air vents for leakage D Inspect the venting system at the start of each heating season Check the pipe from the boiler for signs of deterioration and sagging joints Repair if necessary Remove the vent pipe from the boiler and check for obstructions E Clean ...

Page 16: ...ng location E Remove the air box covers See figure 13 above F Remove the burners from the combustion chamber by raising the burners up from the manifold orifices and pulling toward the front of the boiler See figure 14 below G Remove the top panel See figure 12 above H Remove the flue collector and venter assembly from the boiler castings by removing thehold downscrewslocatedoneachsideofthefluecol...

Page 17: ...ndonefortheshaftbearing Putabout one teaspoon of SAE 20 or 30 non detergent motor oil in each opening twice per year DO NOT OVER OIL Follow the manufacturer s instructions attached to the circulator Whenoilcupsorholesarenotprovided bearingsareeitherpermanently lubricated or water lubricated 3 VISUALLY CHECK THE MAIN BURNERS AND PILOT FLAME AT THE START OF EACH HEATING SEASON AND AGAIN MIDWAY THROU...

Page 18: ...ubing is required If the tubing is cut replace it only with O E M high temperature silicone tubing CAUTION CAUTION CAUTION CAUTION CAUTION Do not replace with vinyl or plastic tubing because it will melt 3 The other part of the tee goes to the air box and venter pressure taps A Orange being the high negative B White being the low negative 4 Turn the boiler back on and read the static pressure The ...

Page 19: ...s necessary install a manometer on the outlet side of the gas valve Adjust the pressure regulator on the combination gas control Increase or decrease manifold pressure to obtain gas input required as described on the rating plate To increase turn the regulator adjusting screw clockwise or counterclockwise to decrease pressure see figure 10 on page 11 After adjustment has been completed turn the bo...

Page 20: ...PART DESCRIPTION QTY 1 31721102 PANEL LEFT HAND SIDE 1 2 3172801 PANEL FRONT USC3 1 3172802 PANEL FRONT USC4 3172803 PANEL FRONT USC5 3 3172401 PANEL SEPARATOR PLATE USC3 1 3172402 PANEL SEPARATOR PLATE USC4 3172403 PANEL SEPARATOR PLATE USC5 4 31721101 PANEL RIGHT HAND SIDE 1 5 31721401 PANEL REAR USC3 1 31721402 PANEL REAR USC4 31721403 PANEL REAR USC5 6 3172201 PANEL TOP USC3 1 3172202 PANEL TO...

Page 21: ...SC3 1 USC4 2 USC5 3 3 100 2 3 01 B RIGHT SECTION 1 4 HW 011 01 TIE ROD 1 4X11 1 2 USC3 2 HW 011 03 TIE ROD 1 4X15 1 2 USC4 HW 011 05 TIE ROD 1 4X19 1 2 USC5 5 HW06901 NUT 5 16 18 WISLOCK 4 6 PF 004 13 PIP FIT BUSHING 3 4 X 1 4 1 7 43300976 NIPPLE 2 MACH USC3 4 USC4 6 USC5 8 8 3472301 FLUECOLLECTORBAFFLE USC3 4 USC4 6 USC5 8 9 HW 008 01 WASH 5 16 FLAT STL ZP 4 10 HW 003 02 NUT 1 4 20 HEX STL ZP 2 F...

Page 22: ...FICE 52USC5LP 4 355 1 5 13 ORIFICE 54USC3LP 2 4 3572201 MANIFOLDUSC3 1 3572202 MANIFOLDUSC4 3572203 MANIFOLD USC5 5 3272101 AIR BOX WRAPPER USC3 1 3272102 AIR BOX WRAPPER USC4 3272103 AIR BOX WRAPPER USC5 6 HW10101 PILOT GROMMET 1 7 HW10201 MANIFOLD GROMMET 1 8 3271901 AIR BOX WRAPPER GSKT BOT USC3 2 3271902 AIR BOX WRAPPER GSKT BOT USC4 3271903 AIR BOX WRAPPER GSKT BOT USC5 9 3271801 AIR BOX WRAP...

Page 23: ...AKE BOX ASSY USC5 6 3571201 BASE OBS WINDOW 1 7 3272701 AIR BOX FRT PNL ASSY USC31 3272702 AIR BOX FRT PNL ASSY USC4 3272703 AIR BOX FRT PNL ASSY USC5 INCLUDES OBS WINDOW 9 INSUL 11 ITEM PART DESCRIPTIONS QTY ITEM PART DESCRIPTION QTY 8 3572401 INSUL FRT COV USC3 1 3572402 INSUL FRT COV USC4 3572403 INSUL FRT COV USC5 9 HW10001 AIR BOX TAP 2230 RL 1 10 3572304 INSUL AIR BOX COVER 2 11 3272401 AIR ...

Page 24: ...1 3772301 WIRE HARNESS GAS VALVE USC 28 1 2 37519501 HARNESSCIRCULATOR72 1 3 PF 006 07 PIPE NIPPLE 1 1 4 X 4 1 2 NPT 1 4 HW 016 03 DRAINSHORT 1 5 PF 008 03 PIPE FIT TEE 1 1 4X3 4X1 1 4 1 6 PF 006 01 PIPE FIT NIPPLE 1 1 4 CLOSE 1 7 37518901 HARNESS CONTROL TO LIMIT 1 8 GA 001 00 GAUGE THERALTIMETER 1 9 AQ02201 CONTROL LIMIT L4080B 1212 HW 1 10 AQ 020 01 WELL 3 4 X 3 HW 1 11 VR 001 01 RELIEFVALVE30 ...

Page 25: ...SCRIPTION QTY 1 SS00801 PRESSURE SWITCH FS6205A 1 2 3171101 TERMINAL STRIP COVER 1 3 EF03801 TRANSFORMERS 40VA 2 4 RY 002 01 CONTROL R8222C 1008 1 5 HW09601 TUBING SILICON CLEAR 12 6 EF04001 9 TERM STRIP 1 7 HW09701 TUBING SILICON ORANGE 17 8 HW09001 SCREW 10 32X5 16 GREEN GROUND 1 9 3172701 PANEL CONTROL SUPPORT BRACKET 1 3772201 COMPLETE CONTROL BRACKET ASSEMBLY 1 THIS INCLUDES PART 1 2 3 5 7 8 ...

Page 26: ...ECTOR OR OR OR OR VENTER COMPONENTS VENTER COMPONENTS VENTER COMPONENTS VENTER COMPONENTS VENTER COMPONENTS PAGE 24 FIGURE 26 ITEM PART DESCRIPTIONS QTY 1 3472501 FLUE COLLECTOR ASSY USC3 1 3472502 FLUE COLLECTOR ASSY USC4 3472503 FLUE COLLECTOR ASSY USC5 2 345 2 7 01 VENT ADAPTER 1 3 HW 005 01 SCREW 1 4 20X1 2 SELF TAP 5 4 DC00402 VENTER USC MAGNETEK 1 5 3571501 GASKET VENTER USC 1 6 HW09501 BOLT...

Page 27: ... KIT TION KIT TION KIT TION KIT ITEM PART DESCRIPTION QTY 1 34721501 VENT TERMINATION THIMBLE PLATE ASSY 1 2 34721002 TERMINATION ASSEMBLY 1 3 34721401 VENT TERMINATION DEFLECTOR 1 4 HW 003 06 NUT 10 24 HEX 1 5 30A004312 SCREW 10 24 X 1 1 2 ROUND HEAD 1 6 3471701 DRAW COLLAR USC 1 7 HW 009 01 SCR 8 18X1 2 SLT HX WASH 8 8 3471901 VENT TEMPLATE 1 5612601 TERMINATION KIT INCLUDES ALL OF THE ABOVE FIG...

Page 28: ... Certified for Natural gas or Propane USC SERIES Cast Ir Cast Ir Cast Ir Cast Ir Cast Iron on on on on Dir Dir Dir Dir Direct ect ect ect ect V V V V V ent Sealed Comb ent Sealed Comb ent Sealed Comb ent Sealed Comb ent Sealed Combustion ustion ustion ustion ustion Gas Fir Gas Fir Gas Fir Gas Fir Gas Fired ed ed ed ed Hot Hot Hot Hot Hot W W W W W a a a a a ter Boiler ter Boiler ter Boiler ter Boi...

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