UTICA BOILERS USC SERIES Instruction manual

P/N 3771201, Rev. A [01/09]
USCSERIES
DirectVent
GasFiredHotWaterBoiler
INSTALLATION,OPERATION&
MAINTENANCEMANUAL
MEMBER: The Hydronics Institute
UTICA BOILERS
P.O. Box 4729
Utica, NY 13504-4729
www.uticaboilers.com
R
An ISO 9001-2000 Certified Company
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

2
TABLEOFCONTENTS
SAFETYSYMBOLS
SEALEDCOMBUSTION,GASFIRED,FORCEDHOTWATERBOILER
e following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying risk
levels.
IMPORTANT: Read the following instructions COMPLETELY
before installing!
Tested for 100 lbs. ASME
Working Pressure
H
C.S.A. Certified for
Natural gas or Propane
NOTICE
KEEP THIS MANUAL NEAR BOILER AND
RETAIN FOR FUTURE REFERENCE.
!
DANGER
Indicates an imminently hazardous situation which,
if not avoided, WILL result in death, serious injury or
substantial property damage.
!
WARNING
Indicates an imminently hazardous situation which,
if not avoided, may result in death, serious injury or
substantial property damage.
!
WARNING
1. Keep boiler area clear and free from combustible
materials, gasoline and other ammable vapors and
liquids.
2. DO NOT obstruct air openings to the boiler room.
3. Modication, substitution or elimination of factory
equipped, supplied or specied components 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 qualied installer.
5. To the installer: Leave all instructions with the
boiler for future reference.
6. When this product is installed in the Common-
wealth of Massachusetts the installation must be per-
formed by a Licensed Plumber or Licensed Gas Fitter.
!
CAUTION
Indicates an imminently hazardous situation which, if
not avoided, may result in injury or property damage.
NOTICE
Indicates information which should be followed to
ensure proper installation and operation.
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................................................................................................................................................... 11
LightingInstructions........................................................................................................................................... 13
SequenceOfOperation....................................................................................................................................... 14
GeneralInstructionForSeasonalStartUpAndMaintenance.......................................................................... 15
VentingInstructions............................................................................................................................................ 20
ReplacementParts............................................................................................................................................... 40
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

3
INTRODUCTION
e installation must conform to the requirements of 1.
the authority having jurisdiction or, in absence of such
requirements, to 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 eect in the area in which
the installation is to be made.
Where required by the authority having jurisdiction, the
2.
installation must conform to American Society of Me-
chanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME No.
CSD-1.
is boiler is classied as a Category I and II and vent
3.
installation shall be in accordance with Part 7 of the latest
revision of the National Fuel Gas Code, ANSI Z223.1 or
applicable provisions of the local building codes.
LOCATE BOILER on level, solid base as near the outside
4.
wall as possible and centrally located with respect to the
heat distribution system as practicable.
Allow 24 inches at the front and right side for servicing 5.
and cleaning.
When installed in utility room, the door should be wide 6.
enough to allow the largest boiler part to enter, or to
permit replacement of another appliance such as a water
heater.
e boiler shall be installed such that the gas ignition 7.
system components are protected from water, (drip-
ping, spraying, rain, etc.), during appliance operation and
service, (circulator replacement, condensate trap, control
replacement, etc.).
6" (15.2 cm) MIN.
9"
(22.9 cm)
MIN.
3"
(7.6 cm)
MIN.
4" (10.2 cm)
MIN.
FRONT OF
BOILER
!
WARNING
Improper installation, adjustment, alteration, service
or maintenance can cause injury or property damage.
Figure1-Min.ClearancesToCombustibleMaterials
!
WARNING
All installations of boilers and venting should be done only by a qualied expert and in accordance with the appropriate
boiler manual. Installing or venting a boiler or any other gas appliance with improper methods or materials may result
in serious injury or death due to re or to asphyxiation from poisonous gases such as carbon monoxide which is odor-
less and invisible.
FOR INSTALLATION ON NON-COMBUSTIBLE
8.
FLOORS ONLY. e boiler must not be installed on car-
peting (For installation on combustible ooring Special
Base Part NO.325-2-8.00 MUST BE USED). 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)
Refer to Figure 1. Greater clearances for access should super-
sede re protection clearances.
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

4
BOILERRATINGS,CAPACITIES&DIMENSIONS
Boiler
No.
A.G.A
Input
Btu/Hr.
Heating
Capacity
Btu/Hr.
I=B=R
Net Out-
put
Btu/Hr.
Natural
Gas
Inlet
Dimensions Supply &
Return
Tappings
No. Of
Burn-
ers
Water
Content
AFUE
Rat-
ings
A B C D
3 Sec-
tion
50,000
(14.7
KW)
44,000
(12.9 KW)
38,000
(11.1
KW)
1/2"
(1.27
cm)
15.1/8"
(38
cm)
3.1/2"
(9 cm)
3.1/2"
(9 cm)
5"
(12.7
cm)
1.1/4"
(3.2 cm) 2
4.0 gals
(15.14
liters)
87%
4 Sec-
tion
100,000
(29.3
KW)
87,000
(25.5 KW)
76,000
(22.3
KW)
1/2"
(1.27
cm)
19"
(48
cm)
3.1/2"
(9 cm)
3.1/2"
(9 cm)
6.1/2"
(16.5
cm)
1.1/4"
(3.2 cm) 3
5.6 gals
(21.20
liters)
87%
5 Sec-
tion
140,000
(41.0
KW)
122,000
(35.7 KW)
107,000
(31.3
KW)
1/2"
(1.27
cm)
22.7/8"
(58
cm)
4.1/4"
(11
cm)
4.1/8"
(11
cm)
8.3/8"
(21.3
cm)
1.1/4"
(3.2 cm) 4
7.2 gals
(27.25
liters)
87%
NOTE: For altitudes above 2,000 . ratings should be reduced at the rate of 4% for each 1,000 . above sea level.
STANDARDEQUIPMENT:
Boiler Jacket, Cast Iron Boiler Battery, Limit Control, Remov-
able Transformers, Plug in Relay, eraltimeter Gauge, Cir-
culator (eld mounted), Main Gas Burners, Hot Surface Pilot;
A.S.M.E Relief Valve, Drain Cock, Induced DraFan, Safety
Pressure Switch, and Combination Intake/Exhaust Termina-
tion Kit.
All boilers are design certied for installation on non-combus-
tible oors. For installation on combustible oors, use combus-
tible oor kit.
is boiler is a Direct Vent Designed Certied appliance which
requires a special horizontal through the wall venting system.
Use ONLY the venting material products listed below:
HEAT-FAB® SAF-T-VENT™t
FLEX-L® STAR-34™t
ProTech™ FasNSeal®t
Z-FLEX® Z-VENT™t
Consult venting addendum for maximum vent lengths and
proper congurations.
Electrical service to be 120 Volts, 15 Amps, 60 Hz.
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

5
Connect supply and return piping as suggested in 1. Fig-
ure #2 below when the boiler is used in connection with
refrigerated systems:
e chilled medium MUST BE IN PARALLEL withA.
the boiler.
Use appropriate valves to prevent the chilled mediumB.
from entering the heating boiler.
During heating cycle open valves A and B. Closet
valves C and D.
During cooling cycle open valves C and D, close valvest
A and B.
Maintain a minimum clearance of 1 inch (2.54 cm) toC.
hot water pipes. In air handling units where they may
be exposed to refrigerated air circulation, the boiler
piping system MUST be supplied with ow control
valves or other automatic means to prevent grav-
ity circulation of the boiler water during the cooling
cycle.
CONNECTINGSUPPLYANDRETURNPIPING
EXPANSION
TANK
B
A
D
CHECK
VALVE
CIRCULATOR
FROM HEATING
AND COOLING
ELEMENT
SUPPLY PIPING
TO HEATING
AND COOLING
ELEMENT
WATER
CHILLER
C
RETURN PIPING
FEED
WATER
NOTICE
* Reduced pressure back ow preventer must be used
under provisions required by the Environmental Pro-
tection Agency, (EPA).
Hot water boilers installed above radiation level must be
2.
provided with a low water cut-odevice at the time of
boiler installation.
When a boiler is connected to a heating system that 3.
utilizes multiple zoned circulators, each circulator must
be supplied with a ow control valve to prevent gravity
circulation.
Figure1-NearBoilerSupply&ReturnPiping
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

6
CONNECTINGSUPPLYANDRETURNPIPING
Bypass piping is an option which 4.
gives the ability to adjust the supply
boiler water temperature to t the
system or condition of the installa-
tion. is method of piping is not
typically required for baseboard
heating systems.
is method is used to protectA.
boilers from condensate forming
due to low temperature return
water. Generally noticed in large
converted gravity systems or
other large water volume sys-
tems. See Figure #3.
ese methods are used to pro-B.
tect systems using radiant panels
and the material they are encased
in from high temperature supply
water from the boiler and protect
the boiler from condensation.
See Figures #4 & #5.
NOTE:
5. When using bypass piping,
adjust valves A and B, in Figures #3
& #5, until desired system tempera-
ture is obtained.
NOTE: 6. When using a 4-way mixing
valve, set control knob until desired
temperatures are met. See instruction
supplied with valve.
Bypass loop piping must be the same 7.
size piping as the supply and the
return.
Typical installation using circulators 8.
is shown in Figure #6 on following
page.
Typical installation using zone 9.
valves is shown in Figure #7 on fol-
lowing page.
For further piping information refer
10.
to the I=B=R installation and piping
guide.
ZONE
CIR.
VALVE
FLOW
VALVE
EXPANSION
TANK
VALVE
SYSTEM
TEMPERATURE
GAUGE
RETURN
SUPPLY
"A"
"B"
WATER
FEED
ZONE
CIR.
EXPANSION
TANK
SYSTEM
TEMPERATURE
GAUGE
RETURN
SUPPLY
4 WAY MIXING
VALVE
WATER
FEED
Figure3-BypassPiping
Figure3-MixingValvePiping
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

7
CONNECTINGSUPPLYANDRETURNPIPING
CIRCULATOR
VALVE
EXPANSION
TANK
VALVE
RETURN
SUPPLY
(31 cm)
MAX.
CIRCULATOR
FLOW
VALVE
SYSTEM
TEMPERATURE
GAUGE
"B"
"A"
SYSTEM
PRIMARY
12"
FEED
WATER
TANK
CIRCULATOR
SYSTEM
CIR.
REDUCED PRESSURE
BACKFLOW PREVENTER
FEED
WATER
SYSTEM
RETURN
COLD WATER
PUMP CONTROL
THERMOSTAT/
WIRING FOR
TRAP
THERMAL
OUTLET
HOT WATER
DRAIN
COCK
RELIEF VALVE
FLOW CONTROL
INLET
OR CHECK VALVE
GATE VALVE
PRESSURE
REDUCING
VALVE
Figure5-PrimarySecondaryPipingwithBypass
Figure6
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

8
By Federal Codes, gas appliances are categorized by the pres-
sure and temperature of the ue gas vented from the appliance.
Category I and II appliances are natural dra(drahood)
vented, with high ue gas temperatures (Category I), or low
ue gas temperatures (Category II).
Category III and IV appliances are fan forced vents with high
temperature (Category III) or low temperature (Category IV)
ue gasses. Appliance eciency is directly related to ue gas
temperature. Higher eciency appliances remove more heat
from the gas, so they will have lower temperature ue prod-
ucts.
When ue 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 corro-
sive resistant venting systems are required for higher eciency
appliances.
CONNECTINGSUPPLYANDRETURNPIPING
GENERALINFORMATIONGASVENTSANDAPPLIANCES
TANK ZONE
VALVE
SYSTEM ZONE
VALVE
CIR.
WATER
FEED
INLET
COLD WATER
HOT WATER
OUTLET
PUMP CONTROL
WIRING FOR
THERMOSTAT/
TRAP
TERMAL
RELIEF VALVE
DRAIN COCK
RETURN
SYSTEM
PRESSURE
REDUCING
VALVE
BACKFLOW PREVENTER
REDUCED PRESSURE
GATE VALVE
!
WARNING
Vents for Category I appliances may not be suitable
for use with Category II, III, or IV appliances because
condensate may corrode the vent.
Vents for Category III appliances may not be suitable
for use with Category I appliances because ue gas
temperatures may be too high.
Proper operation of the vent system and appliance is depen-
dent upon the use of all parts specied by the manufacturer for
use in the particular installation. Appliance and vent system
performance may be aected by improper assembly.
Figure7
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

9
VENTPIPEMODIFICATION
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SYSTEM
At the time of removal of an existing boiler, the following steps
shall be followed with each 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.
Seal any unused openings in the common venting system.
1.
Visually inspect the venting system for proper size and 2.
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deciencies which
could cause an unsafe condition.
Insofar as is practical, close all building doors and win- 3.
dows and all doors between the space in which the ap-
pliances remaining connected to the common venting
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 hoods and bathroom exhausts, so they will oper-
ate at maximum speed. Do not operate a summer exhaust
fan. Close replace dampers.
Place in operation the appliance being inspected. Follow
4.
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
Test for spillage at the drahood relief opening aer 5 5.
minutes of main burner operation. Use the ame of a
match or candle, or smoke from a cigarette, cigar or pipe.
Aer it has been determined that each appliance remain- 6.
ing connected to a common venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans, replace dampers and any other gas burning
appliance to their previous conditions of use.
Any improper operation of the common venting system 7.
should be corrected so the installation conforms with
either the latest revision of the National Fuel Gas Code,
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
resizing any portion of the common venting system, the
common venting system should 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.
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

10
CONNECTGASSERVICE
ZONE I
TANK CIR.
SYSTEM
CIR.
TANK
CONTROL
BRASS TEE
P-T RELIEF
VALVE, LONG
ELEMENT
DRAIN
BRASS
TEE
PREFERRED METHOD
FOR THERMAL TRAP
COLD WATER
INLET
HOT WATER
OUTLET
RETURN
PIPING
SYSTEM
COCK
CONTROL
VALVES
FLOW
Connect gas service meter to control assembly in accordance
with the latest revision of ANSI Z223.1 and local codes or util-
ity. A ground joint union should be installed for easy removal
of gas control for servicing. A drip or trap must be installed
at the bottom of a vertical section of piping at the inlet to the
boiler. A pipe compound resistant to the action of liqueed pe-
troleum gases must be used on all threaded pipe connections.
Check with the local utility for location of manual shutovalve
if required. (See Figure #8)
e gas line should be of adequate size to prevent undue
1.
pressure drop and never smaller than the pipe size of the
main gas control valve. See chart below.
To check for leaks in gas piping, use a soap and water 2.
solution or other approved method.
!
WARNING
DO NOT USE AN OPEN FLAME.
NOTICE
For additional information refer to Part 10, table 10-2
of the National Fuel Gas Code Handbook, latest revi-
sion, or in Canada, the CAN1-B149.1 and/or B149.2
Installation Codes for Gas-Burning Equipment.
Figure8
e boiler and its individual shutovalve must be discon- 3.
nected from the gas supply piping system during any pres-
sure testing of that system at test pressures in excess of ½
psig (3.5 kPa).
e boiler must be isolated from the gas supply piping sys- 4.
tem by closing its individual manual shutovalve during
any pressure testing of the gas supply piping system at test
pressures equal to or less than ½psig (3.5 kPa).
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

11
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. (See
gure #8)
1. When an external electrical source is utilized, the boiler,
1.
when installed, MUST BE electrically grounded in accor-
dance with these requirements.
2. Install a fused disconnect switch between boiler and
2.
meter at a convenient location.
ComponentAndWireCodingKeys
e keys that follow pertain to the HOT WATER CONTROL
AND HOT SURFACE PILOT WIRING FOR SEALED COM-
BUSTION SERIES (diagrams on following page).
3. Honeywell hot water control and intermittent ignition wir-
ing for ODVB series boiler with fail safe relay.
COMPONENT KEY CODING
Thermostat (24 Volt) TH-2
Transformer (120V/24V 40VA) TR-1
Transformer (120V/24V 40VA) TR-2
24 Volt Gas Valve SV9501H
Pressure Switch PS
Control Terminal
Relay Coil 1K
Relay Contacts 1K1
Relay Contacts 1K2
Limit Switch LS
Circulator CIR
Wire Connection
Not all components listed are used in all control
systems.
WIRING CODE KEY
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
NOTICE
t4XJUDIFTBSFTIPXOJOQPTJUJPOEVSJOHUIFIFBUJOH
cycle.
t*GBOZPGUIFPSJHJOBMXJSJOHTVQQMJFEXJUIUIFCPJMFS
is replaced it must be replaced with like wire size and
type of insulation or equivalent.
THERMOSTATINSTALLATION
ermostat should be installed on an inside wall about
1.
four feet above the oor.
Never 2. install a thermostat on an outside wall.
Check thermostat operation by raising and lowering ther- 3.
mostat setting as required to start and stop the burners.
Instructions for the nal adjustment of the thermostat are 4.
packaged with the thermostat (adjusting heating anticipa-
tor, calibration, etc.)
THINGS TO AVOID WHEN LOCATING THERMO-
STATS
DEAD SPOTS:
Corners and alcoves Behind doors
COLD SPOTS: HOT SPOTS:
Concealed pipes or ducts Concealed pipes
Fireplace or chimney
Stairwells - drasTV sets
Radios
Unheated rooms on
other side of wall
Lamps
Direct sunlight
outside wall Kitchens
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

12
HOTWATERCONTROLANDHOTSURFACEPILOTWIRING
120V
60HZ
SUPPLY
C
NO
INDUCED
DRAFT
BLOWER
TH-2
R8222C
14
36
CIR
L1 L2 C2 LM FT TV T
VM/LM
VM C1
1K
BLUE
TR-2TR-1
BLUE
L4080B
LS
PS
B
RED
GREEN
AND
WHITE
SV9501H
Q3450B
ORANGE
IGNITION
CONTROL
Honeywell
ORANGE
GREEN
120V
60HZ
SUPPLY
C
INDUCED
DRAFT
BLOWER
TH-2
14
36
CIR
1K1
1K2
1K
L1 L2 C2 LM
FT
TV
T
VM
VM
C1
L4080B
LS
PS
B
NO
LM
GREEN
AND
WHITE
SV9501H
Q3450B
Honeywell
CONTROL IGNITION
WHITE
WHITE
BLUE
BLUE
GREEN
YELLOW
YELLOW
RED
BLACK
RED
BLACK
RED
ORG
BLUE
BLUE
ORG
ORG
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

13
LIGHTINGINSTRUCTIONS
FORBOILERWITHAHOTSURFACEPILOTSYSTEM
!
WARNING
IF YOU DO NOT FOLLOW THESE INSTRUC-
TIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT CAUSING PROPERTY DAMAGE, PER-
SONAL INJURY OR LOSS OF LIFE.
!
CAUTION
Before operating, make certain the boiler and system
are full of water to minimum pressure (this is usu-
ally 12 lbs. per square inch on most systems) and
system is vented of air. See the operating and lighting
instructions.
is appliance is equipped with an ignition device which
1.
automatically lights the pilot. Do not try to light the pilot
by hand.
BEFORE OPERATING smell all around the appliance 2.
area for gas. Be sure to smell next to the oor because
some gas is heavier than air and will settle on the oor.
WHATTODOIFYOUSMELLGAS
Do not try to light any appliance.t
Do not touch any electrical switcht
Dt o not use any phone in your building.
Immediately call your gas supplier from a neighbor’st
phone.
Follow the gas supplier’s instructions.t
If you cannot reach your gas supplier, call the ret
department.
Use only your hand to move the system control switch. 3.
Never use tools. If the switch will not move by hand, don’t
try to repair it, call a qualied service technician. Force or
attempted repair may result in a re or explosion.
!
WARNING
Force or attempted repair may result in a re or ex-
plosion.
Do not use this appliance if any part has been under water.
4.
Immediately call a qualied service technician to inspect the
appliance and to replace any part of the control system and
any gas control which has been under water.
FORYOURSAFETY,READBEFOREOPERATING!
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

14
Onacallforheat:
e thermostat will actuate, completing the circuit be- 1.
tween terminals T and T.
e R8222C relay coil will energize thus pulling in the 2.
relay contacts.
e circulator starts and power is switched to the limit. If 3.
limit circuit is closed the venter motor and TR-2 trans-
former are energized.
e venter motor starts and develops static pressure. 4.
When the static pressure is reached the pressure switch 5.
pulls in completing the circuit between TR-2 and the
SV9501H gas valve system.
e SV9501H opens the pilot valve and ignites pilot. Aer 6.
pilot is proven the main burner will ignite.
In the event the boiler water temperature exceeds the high 7.
limit setting the power will be interrupted to the venter
motor, and TR-2, thus interrupting power to the ignition
OPERATINGINSTRUCTIONS
STOP! Read the safety information in the user’s informa-
1.
tion manual.
Set thermostat to lowest setting. 2.
Turn oall electric power to the appliance. 3.
is appliance is equipped with an ignition device which 4.
automatically lights the pilot. DO NOT try to light the
pilot by hand.
Move the ignition system control switch to the "OFF" 5.
position. See gure #10.
Wait ve (5) minutes to clear out any gas. If you then
6.
smell gas, STOP. Follow step 2 in the lighting procedure
previous page, "What To Do If You Smell Gas." If you
don't smell gas, go to the next step.
Move the ignition system control switch to the "ON" posi- 7.
tion. See gure #10 above.
Turn on all electric power to the appliance. 8.
Set thermostat to desired setting. 9.
If the appliance will not operate, follow the instructions 10.
"To Turn OGas To Appliance" (Below) and call a quali-
ed service technician or your gas supplier.
SEQUENCEOFOPERATION
system. Power will remain ountil the water temperature
drops below the high limit setting. e circulator will con-
tinue to operate under this condition until the thermostat
is satised.
Should the air ow (static pressure) be interrupted (ie. 8.
blocked ue), the pressure switch will sense a drop in
pressure, opening the circuit between the ignition system
and TR-2. e venter motor will continue to operate until
static pressure is reached or thermostat is satised.
In the event the ow of combustion products through the 9.
boiler ueways becomes reduced or blocked, the Q34505
pilot will lose ame rectication and shut othe main
burners. e boiler will try for ignition but will not light.
If this condition occurs, turn othe main power and do
not put the unit into operation.
When the thermostat is satised power is interrupted to 10.
the relay coil and the relay drops out cutting power to the
circulator, venter motor, and TR-2.
ON OFF
GAS
GAS
PRESSURE REGULATOR
ADJUSTMENT BENEATH
COVER SCREW
PILOT FLOW ADJ.
SCREW BENEATH
CONTROL
IGNITER
IGNITION SYSTEM
COVER SCREW
CONTROL SWITCH
PRESSURE
TAP
OUTLET INLET
TOTURNOFFGASTOAPPLIANCE
Set thermostat to lowest setting. 1.
Turn oall electric power to the appliance if service is to 2.
be performed.
Move the ignition system control switch to the "OFF" 3.
position. DO NOT FORCE
LIGHTINGINSTRUCTIONS
Figure10
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

15
CONDENSATE
VENT
FLEXIBLE
TUBING
FROM
BOILER
CONNECTOR
DRAIN
3/8" (1cm.)
TRAP
BEGINNINGOFEACHHEATINGSEASON
Before seasonal start up it is advisable to have a competent 1.
service agency check the boiler for soot and scale in the
ues, clean the burners and check the gas input rate to
maintain high operating eciency and safe operation.
e service agency should make certain the system is lled 2.
with water to minimum pressure and open air vents - if
used - to expel any air that may have accumulated in the
system.
Check automatic air vents for leakage. 3.
Inspect the venting system at the start of each heating sea- 4.
son. Check the pipe from the boiler for signs of deteriora-
tion and sagging joints. Repair if necessary. Remove the
vent pipe from the boiler and check for obstructions.
Clean condensate tee & trap. 5.
Periodically check the condensate trap for water/conden- 6.
sate. e trap should always have water in it. Rell the
trap if it runs dry. If the trap runs dry then ue gasses can
escape.
GENERALINSTRUCTIONFORSEASONALSTARTUPANDMAINTENANCE
It is suggested that a qualied service agency be employed to
make an annual inspection of the boiler and the heating sys-
tem. ey are experienced in making the inspection outlined
below.
In the event repairs or corrections are necessary they can make
the proper changes for safe operation of the boiler.
Periodic cleaning of the condensate collection system is re-
quired. When a condensate collection system is installed in a
venting system, it is recommended that the cleaning become
a part of the annual servicing. e procedure for cleaning this
system is as follows:
Remove tubing from condensate tee.
1.
Empty all liquid from tubing. 2.
Rinse tubing inside & out in a sink with water. 3.
If the inside of the tubing cannot be cleaned, the tubing 4.
should be replaced with the same type and size of tubing.
Add water to trap before replacing. 5.
Replace tubing as described in 6. gure #11 .
Visually inspect entire piping system and if any leaks ap- 7.
pear, have them repaired as soon as possible. DO NOT
use petroleum based stop leak compounds.
!
CAUTION
Label all wires prior to disconnection when servic-
ing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation aer
service.
Figure11-CondensateCollectionSystem
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

16
HONEYWELL
ON
OFF
FRONT
PANEL
TOP
PANEL
VENT PIPE
ADAPTER
HONEYWELL
ON
OFF
BAFFLES
PRESSURE TAP
COUPLING
AIR BOX
COVERS
ORIFICES
BURNERS
VENTER ASSEMBLY
FLUE COLLECTOR
GAS VALVE
HONEYWELL
OFF
ON
HOLD DOWN
SCREW
HONEYWELL
ON
OFF
BURNER TUBES
ORIFICES
GAS VALVE
PILOT TUBE
PILOT WIRE
AIR BOX
WRAPPER
MAIN GAS
MAIN BURNER
GENERALINSTRUCTIONFORSEASONALSTARTUPANDMAINTENANCE
Thefollowingprocedureshouldbefollowedtoclean
andcheckthefluegaspassageways:
Turn ogas to the boiler at the manual gas 1.
Remove the jacket front panel. (See 2. gure #12 )
Disconnect the vent pipe from the vent pipe adapter. 3.
Disconnect the air inlet pipe from the coupling. (See 4. g-
ure 13 for coupling location.)
Remove the air box covers. (See 5. gure #13 )
Remove the burners from the combustion chamber by
6.
raising the burners up from the manifold orices and pull-
ing toward the front of the boiler. (See gure #14 )
Remove the top panel. (See 7. gure #12 )
Remove the ue collector and venter assembly from the 8.
boiler castings by removing the hold-down screws located
on each side of the ue collector. (See gure #15 )
Remove the baes from the heat exchanger. 9. (See gure
#13)
Figure12
Figure14
Figure13
Figure15
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

17
Visuallycheckthemainburnersandpilotflameat
thestartofeachheatingseasonandagainmidway
throughtheseason.
a. Check the burner throats and burner orifices for lint
and dust obstructions. (See figure #15)
b. The main burner flame should have a well defined
inner blue mantel with a lighter blue outer mantel. (See
figure #16)
c. The pilot flame should envelop 3/8" (.95 cm) to 1/2"
(1.27 cm) of the tip of the pilot sensing device. (See
figure #17)
GENERALINSTRUCTIONFORSEASONALSTARTUPANDMAINTENANCE
Visually inspect the baes for any unusual wear or soot 10.
build up. Clean if necessary.
Visually inspect the venter assembly for any unusual wear 11.
or dirt build up. Vacuum if necessary.
Place a sheet of heavy paper or similar material in the bot- 12.
tom of the combustion chamber and brush down the ue
passageways. e soot and scale will collect on the paper
and is easily removed with the paper.
Replace the Flue Collector using the hold down screws 13.
and silicone in place with GE IS 808 silicone or similar.
(See gure #15 )
Repeat steps A-E in reverse order to reassemble the boiler. 14.
Start boiler to insure proper operating condition. 15.
KEEP the area around the boiler clean and free of combus- 16.
tible materials such as gasoline, paints, paint thinner and
other such ammable vapors and liquids.
e free ow of combustion and ventilating air to the 17.
boiler and boiler room must not be restricted or blocked.
Some circulators require periodic servicing. ese cir- 18.
culators usually have oil cups or openings at each end of
the motor and one for the shabearing. Put about 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.
When oil cups or holes are not provided, bearings are
either permanently lubricated or water lubricated.
e main burner ame should form a sharp blue inner mantel
with no yellow.
Figure16-BurnerFlame Figure1-Pilot
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

18
GENERALINSTRUCTIONFORSEASONALSTARTUPANDMAINTENANCE
Adjustingthepilotflame:
Remove the pilot adjustment cover screw. 1.
Turn inner screw (adjustment screw) clockwise 2. to
decrease and counterclockwise to increase the pilot
ame, see gure #10.
Aer adjustment, be sure to replace cover screw to prevent 3.
possible gas leakage.
e main burners and the pilot burner should be checked 4.
for signs of corrosion or scale build up.
Clean main burners and pilot burner with a steel bristle 5.
brush.
CheckVenterStaticPressure
(Refer to gure #18 for the following instructions)
With the boiler o, disconnect the orange and white tub- 1.
ings from the pressure switch on the air box and venter
motor.
Install a 3/16" (.48 cm) plastic barbed tee between a slope 2.
manometer and the pressure switch.
TO AIR
BOX TAP
TAP
TO VENTER
SWITCH, WHITE
TO PRESSURE
HONEYWELL
ON
OFF
TO PRESSURE
SWITCH, ORANGE
e other part of the tee goes to the air box and venter 3.
pressure taps.
Orange being the high negative.A.
White being the low negative.B.
Turn the boiler back on and read the static pressure. e
4.
reading should be -.55 ±.05 inches water column or higher
for the Sealed Combustion series boilers.
If the static pressures are not at the minimum allowable 5.
level, check the intake and exhaust pipes for obstructions
or damage.
To reassemble, remove the tees and additional tub- 6.
ing and replace the orange tube to the venter tap, and
the white tube to the air box tap.
!
CAUTION
Do not cut original tubing. Additional tubing is
required. If the tubing is cut, replace it only with
O.E.M. high temperature silicone tubing.
Do not replace with vinyl or plastic tubing because it
will melt.
Figure18-CheckingStaticPressure
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

19
GENERALINSTRUCTIONFORSEASONALSTARTUPANDMAINTENANCE
CHECKGASINPUTRATETOBOILER
1. Maximum permissible gas supply pressure must not be 1.
higher and minimum supply pressure must not be lower
than what is specied on the rating plate.
2. To check for proper ow of natural gas to boiler using 2.
the gas meter, proceed as follows:
Turn othe gas supply to all other appliances, exceptA.
the boiler.
With the boiler operating, determine the ow of gasB.
through the meter for two minutes and multiply by 30
to get the hourly rate.
Divide the input rate shown on the rating plate by theC.
heating value of the gas as obtained from the lo-
cal gas company. is will determine the number of
cubic feet of gas required per hour.
If minor adjustment is necessary, install a manometerD.
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
gure #10.
Aer adjustment has been completed, turn the boilerE.
oand remove the manometer and the shut-ocock.
Relight all the other appliances turned oin step AF.
above. Be sure all pilot burners are operating.
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.

20
VENTINGINSTRUCTIONS
VENTINGINSTRUCTIONS
VENTINGINSTRUCTIONS
VENTILATION&COMBUSTIONAIR
!
WARNING
air openings to combustion area must not be obstructed. By following the chart below, adequate com-
bustion air can be maintained.
For Closet Installation a vent opening must
be placed in wall or door directly across from the
front of the boiler with a minimum opening as
listed above. e vent opening must be located
28" (71.12 cm) up from the oor. (See gure 1)
Note: If covering the hole with screen or us-
ing louvers, the opening must have the same free
owing area as the opening in the wall with no
screen or louvers.
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
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. e gas vent installer should be familiar
with these National or Canadian Codes as well as Local Codes and Regulations.
Figure1-ClosetInstallation
Venting Requirements Combustion Air Requirements
Boiler Size Vent Opening Dimensions 3" (8cm) Inlet Pipe length
3 Section 5" X 5" (13 cm x 13 cm) 30 Ft (914cm) with 2 Elbows
4 Section 8" x 8" (20 cm x 20 cm) 30 Ft (914cm) with 2 Elbows
5 Section 9" x 9" (23 cm x 23 cm) 20 Ft (610 cm) with 2 Elbows
National Excelsior Company
www.excelsiorhvac.com
Subject to change without notice.