UTICA BOILERS USC SERIES Technical Document

INSTINST INSTINST
INSTALLAALLA
ALLAALLA
ALLATION MANUTION MANU
TION MANUTION MANU
TION MANUALAL
ALAL
AL AND OPERAAND OPERA
AND OPERAAND OPERA
AND OPERATING INSTRTING INSTR
TING INSTRTING INSTR
TING INSTRUCTIONSUCTIONS
UCTIONSUCTIONS
UCTIONS
USCUSC
USCUSC
USC
DIRECT VENT GAS FIRED BOILERS
FOR FORCED HOT WATER
Utica Boilers, Inc. • P.O. Box 4729 • Utica, NY 13504
SS
SS
SEALED
CC
CC
C OMBUSTION

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TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE 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

PAGE 1
Safety SymbolsSafety Symbols
Safety SymbolsSafety Symbols
Safety Symbols
The following defined symbols are used throughout this manual to notify the
reader of potential hazards of varying risk levels.
DANGERDANGER
DANGERDANGER
DANGER
DANGER - Indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.
WW
WW
WARNINGARNING
ARNINGARNING
ARNING
WARNING - Indicates a potentially hazardous situation which, if not avoided, COULD
result in death or serious injury
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
CAUTION - Indicates a potentially hazardous situation which, if not avoided, MAY
result in minor or moderate injury. It may also be used to alert against unsafe practices.
IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANT!ANT!
ANT!ANT!
ANT! READ ALL INSTRUCTIONS BEFORE INSTALLING.
WARNING:WARNING:
WARNING:WARNING:
WARNING:
1.Keepboilerareaclearandfreefromcombustiblematerials,gasolineandotherflammable
vaporsandliquids.
2.DO NOT obstruct air openings to the boiler room.
3.Modification,substitutionoreliminationoffactoryequipped,suppliedorspecifiedcompo
nents 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 qualified
installer.
5.To the installer: Leave all instructions with the boiler for future reference.
6.WhenthisproductisinstalledintheCommonwealthofMassachusetts,theinstallationmust
be performed by a licensed Plumber or Licensed Gas Fitter.
WARNING:WARNING:
WARNING:WARNING:
WARNING: ALL INSTALLATIONS OF BOILERS ANDALL INSTALLATIONS OF BOILERS AND
ALL INSTALLATIONS OF BOILERS ANDALL INSTALLATIONS OF BOILERS AND
ALL INSTALLATIONS OF BOILERS AND
VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT ANDVENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT AND
VENTING SHOULD BE DONE ONLY BY A QUALIFIED EXPERT ANDVENTING 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.IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS, INC.
IN ACCORDANCE WITH THE APPROPRIATE UTICA BOILERS, INC.
MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHERMANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER
MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHERMANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER
MANUAL. INSTALLING OR VENTING A BOILER OR ANY OTHER
GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAYGAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY
GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAYGAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY
GAS APPLIANCE WITH IMPROPER METHODS OR MATERIALS MAY
RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TORESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO
RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TORESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO
RESULT IN SERIOUS INJURY OR DEATH DUE TO FIRE OR TO
ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBONASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON
ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBONASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON
ASPHYXIATION FROM POISONOUS GASES SUCH AS CARBON
MONOXIDE WHICH IS ODORLESS AND INVISIBLE.MONOXIDE WHICH IS ODORLESS AND INVISIBLE.
MONOXIDE WHICH IS ODORLESS AND INVISIBLE.MONOXIDE WHICH IS ODORLESS AND INVISIBLE.
MONOXIDE WHICH IS ODORLESS AND INVISIBLE.

INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION PRTION PR
TION PRTION PR
TION PROCEDUREOCEDURE
OCEDUREOCEDURE
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. (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 effect in the area in which the installation is to be made.
When installed in Canada: The latest revision of the CAN1-B149.1 and/or B149.2
Installation Codes for Gas-Burning Equipment and/or local codes.
2. Where required by the authority having jurisdiction, the installation must conform to
American Society of Mechanical Engineers Safety Code for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME No. CSD-1.
3. This boiler is classified as a Direct Vent and vent installation shall be in accordance with
Part 7 of the latest revision of the National 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 clearance is recommended at the front and right side for servicing
and cleaning.
6. When installed in utility room, the door should be wide enough to allow the largest boiler
part to enter, or to permit replacement of another appliance such as a water heater.
7. The boiler shall be installed such that the gas ignition system components are protected
fromwater(dripping,spraying,rain,etc.)
during appliance operation and service,
(circulatorreplacement,condensatetrap,
control replacement, etc.).
8. THIS BOILER IS DESIGN CERTIFIED
FOR INSTALLATION ON NON-
COMBUSTIBLE FLOORS ONLY. FOR
INSTALLATION ON COMBUSTIBLE
FLOORING SPECIAL BASE PART
NUMBER 325-2-8.00 MUST BE USED.
The boiler must NEVER be installed on
carpeting. 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)
(SEE FIGURE 1 AT RIGHT)
NOTE : GREATER CLEARANCES FOR
ACCESS SHOULD SUPERSEDE FIRE
PROTECTION CLEARANCE. PAGE 2
FIGURE 1
CLEARANCE TO COMBUSTIBLE MATERIAL

PAGE 3
FIGURE 2 FIGURE 3
BYPASS PIPING
CONNECTING SUPPLCONNECTING SUPPL
CONNECTING SUPPLCONNECTING SUPPL
CONNECTING SUPPLYY
YY
Y AND RETURN PIPINGAND RETURN PIPING
AND RETURN PIPINGAND RETURN PIPING
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.
B.Useappropriatevalvestopreventthechilledmediumfromenteringtheheatingboiler.
1.DuringheatingcycleopenvalvesAand B. Close valves C and D.
2.Duringcoolingcycle open valves C andD,closevalves A and B.
C.Maintainaminimumclearanceof1inch(2.54cm)tohotwaterpipes.Inairhandlingunits
where they may be exposed to refrigerated air circulation, the boiler piping system
MUSTbesuppliedwithflowcontrolvalvesorotherautomaticmeanstopreventgravity
circulationoftheboilerwaterduringthecoolingcycle.
2.Hotwaterboilersinstalledaboveradiationlevelmustbeprovidedwithalowwatercut-off
deviceatthetimeofboilerinstallation.
3.Whenaboilerisconnectedtoaheatingsystemthatutilizesmultiplezonedcirculators,each
circulatormustbesuppliedwithaflowcontrolvalvetopreventgravitycirculation.
*Reducedpressureback flowpreventermustbeusedunder provisionsrequiredbythe
EnvironmentalProtectionAgency,(EPA).
4. Bypass piping is an option which gives the ability to adjust the supply boiler water
temperaturetofitthesystemorconditionoftheinstallation.Thismethodofpipingisnot
typicallyrequiredforbaseboardheatingsystems.
A.Thismethodisusedtoprotectboilersfromcondensateformingduetolowtemperature
returnwater.Generallynoticedinlargeconvertedgravitysystemsorotherlargewater
volumesystems.Seefigure3above.
B.Thesemethodsareusedtoprotectsystemsusingradiantpanelsandthematerial
theyareencasedinfromhightemperaturesupplywaterfromtheboilerandprotect
the boiler from condensation. See figures 4 & 5 below.
5.Note:Whenusingbypasspiping,adjustvalvesAandB,infigures3and5,untildesired
systemtemperatureisobtained.
1.Connectsupplyandreturnpipingassuggestedinfigure2belowwhentheboilerisusedin
connectionwithrefrigeratedsystems:
A.ThechilledmediumMUSTBE INPARALLELwiththeboiler.

PAGE 4
FIGURE 4 FIGURE 5
FIGURE 6
MIXING-VALVE PIPING PRIMARY SECONDARY PIPING
WITH BYPASS
6.Note:Whenusinga4-waymixingvalve,setcontrolknobuntildesiredtemperaturesare
met.Seeinstructionsuppliedwithvalve.
7.Bypasslooppipingmustbethesamesizepipingasthesupplyandthereturn.
8.Typicalinstallationusingcirculatorsisshowninfigure6onpage 4.
9.Typicalinstallationusingzonevalvesisshowninfigure7,below.
10.ForfurtherpipinginformationrefertotheI=B=Rinstallationandpipingguide.

FIGURE 7
GENERAL INFORMAGENERAL INFORMA
GENERAL INFORMAGENERAL INFORMA
GENERAL INFORMATIONTION
TIONTION
TION
GAS VENTS AND APPLIANCESGAS VENTS AND APPLIANCES
GAS VENTS AND APPLIANCESGAS VENTS AND APPLIANCES
GAS VENTS AND APPLIANCES
By Federal Codes, gas appliances are categorized by the pressure and temperature of
thefluegas vented from theappliance. Category I and II appliancesare natural draft (draft
hood) vented, with high flue gas temperatures (Category I), or low flue gas temperatures
(Category II). Category III and IV appliances are fan forced vents with high temperature
(CategoryIII)orlowtemperature(CategoryIV)fluegasses. Applianceefficiencyisdirectly
related to flue gas temperature. Higher efficiency appliances remove more heat from the
gas, so they will have lower temperature flue products. When flue gas temperatures are
lowered,corrosivecondensatesmayforminthegasventorintheappliance. Condensates
may form in Category II, III, IV appliance vents, so special corrosive resistant venting
systems are required for higher efficiency appliances.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: VentsforCategoryIappliancesmaynotbesuitableforusewith
Category II, III, or IV appliances because condensate may corrode the vent.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: Vents for Category III appliances may not be suitable for use
with Category I appliances because flue gas temperatures may be too high.
Properoperationoftheventsystemandapplianceisdependentupontheuseofallparts
specified by the manufacturer for use in the particular installation. Appliance and vent
system performance may be affected by improper assembly.
PAGE 5

PAGE 6
VENT PIPE MODIFICAVENT PIPE MODIFICA
VENT PIPE MODIFICAVENT PIPE MODIFICA
VENT PIPE MODIFICATIONTION
TIONTION
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. If this situation occurs, the following test procedure must be followed:
REMOVAL OF BOILER FROM VENTING SYSTEMREMOVAL OF BOILER FROM VENTING SYSTEM
REMOVAL OF BOILER FROM VENTING SYSTEMREMOVAL OF BOILER FROM VENTING SYSTEM
REMOVAL OF BOILER FROM VENTING SYSTEM
Atthetimeofremovalofanexistingboiler,thefollowingstepsshallbefollowedwitheach
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.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine
thereisnoblockageorrestriction,leakage,corrosionandotherdeficiencieswhichcould
cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the
spaceinwhich the appliances remainingconnected to the commonventing 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
hoodsand bathroom exhausts, sothey will operate atmaximum speed. Do notoperate
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 continuously.
5.Testforspillageat thedrafthoodreliefopeningafter5 minutesofmainburneroperation.
Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to a common
venting system properly vents when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas burning appliance to their previous
conditions of use.
7. Any improper operation of the common venting system should be corrected so the
installationconformswitheitherthelatestrevisionofthe NationalFuelGasCode,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
resizinganyportionofthecommonventingsystem,thecommonventingsystemshould
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.

CONNECT GAS SERCONNECT GAS SER
CONNECT GAS SERCONNECT GAS SER
CONNECT GAS SERVICEVICE
VICEVICE
VICE
Connect gas service meter to control
assembly in accordance with the latest
revision of ANSI Z223.1 and local codes or
utility.Agroundjointunionshouldbeinstalled
foreasyremovalofgascontrolfor servicing.
Adriportrap must be installed at thebottom
ofaverticalsectionofpipingattheinlettothe
boiler. A pipe compound resistant to the
action of liquefied petroleum gases must be
usedonallthreadedpipeconnections.Check
with the local utility for location of manual
shutoff valve if required. (See figure 8 at
right.)
PAGE 7
FIGURE 8
1. The gas line should be of adequate size to prevent undue pressure drop and never
smaller than the pipe size of the main gas control valve. See chart below.
Maximum Capacity of Pipe in Cubic Feet of Gas Per Hour (Cubic Meters per Hour)
(Gas pressure = 0.5 psig (3.45 kPa) or less pressure drop = .5 in.w/c(1.27 cm w/c))
Nominal Length 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) (11.33)
For additional information refer to Part 10, table 10-2 of the National Fuel Gas Code
Handbook, or in Canada, the CAN1-B149.1 and/or B149.2 Installation Codes for Gas-
Burning Equipment.
2.Tocheckforleaksingaspiping,useasoapandwatersolutionorotherapprovedmethod.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: DO NOT USE AN OPEN FLAME.
3. The boiler and its individual shutoff valve must be disconnected from the gas supply
piping system during any pressure testing of that system at test pressures in excess of
1/2 psig (3.5 kPa).
4. The boiler must be isolated from the gas supply piping system by closing its individual
manualshutoffvalveduringanypressuretestingofthegassupplypipingsystemattest
pressures equal to or less than 1/2 psig (3.5 kPa).

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.
•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.
5. WIRING CODE
LINE VOLTAGE BY FACTORY
LOW VOLTAGE BY FACTORY
LINE VOLTAGE BY INSTALLER
LOW VOLTAGE BY INSTALLER
1K2 Relay Contacts
LS Limit Switch
MS Manual Switch
CIR Circulator
ECO Energy Cut-Off
PSC Pilot Safety Coil
Wire Connection
LWCO Low Water Cut Off
EWF Electric Water Feeder
PG Power Generator
RSW Roll-OutSwitch
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 WIRINGELECTRICAL WIRING
ELECTRICAL WIRINGELECTRICAL WIRING
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.
1. When an external electrical source is utilized, the boiler, when installed, MUST BE
electrically grounded in accordance with these requirements.
2. Install a fused disconnect switch between boiler and meter at a convenient location.
PAGE 8
3. COMPONENT CODING (SEE WIRING DIAGRAM ON PAGE 9)

FIGURE 9
PAGE 9
TH-1 THERMOSTAT (MILLIVOLT) TH-2 THERMOSTAT (24 VOLT) TH-3 THERMOSTAT (LINE VOLTAGE) TR-1 TRANSFORMER (120V/24V 40VA) TR-2 TRANSFORMER (120V/24V 50VA) MGV MILLIVOLT GAS VALVE LGV 24 VOLT GAS VALVE LGV-1 24 VOLT GAS VALVE
MS MANUAL SWITCH CIR CIRCULATOR ECO ENERGY CUT-OFF LWCO LOW WATER CUT-OFF EWF ELECTRIC WATER FEEDER PG POWER GENERATOR PSC PILOT SAFETY COIL
WIRE CONNECTION
PS PRESSURESWITCH MR-PS MANUAL RESET PRESSURE SW. SD STACK DAMPER
CONTROL TERMINAL
1 K RELAY COIL 1 K1 RELAY CONTACTS 1 K2 RELAY CONTACTS LS LIMIT SWITCH
NOTES: 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
HOHO HOHO
HOTT
TT
T WW
WW
WAA
AA
ATER CONTRTER CONTR
TER CONTRTER CONTR
TER CONTROLOL
OLOL
OL AND HOAND HO
AND HOAND HO
AND HOT SURFT SURF
T SURFT SURF
T SURFAA
AA
ACE PILCE PIL
CE PILCE PIL
CE PILOO
OO
OTT
TT
T WIRING FOR USC SERIESWIRING FOR USC SERIES
WIRING FOR USC SERIESWIRING FOR USC SERIES
WIRING FOR USC SERIES

PAGE 10
THERMOSTTHERMOST
THERMOSTTHERMOST
THERMOSTAA
AA
AT INSTT INST
T INSTT INST
T INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
1. Thermostat should be installed on an inside wall about 4 ft (122 cm) above the floor.
2. NEVER install a thermostat on an outside wall.
3. Do not install a thermostat where it will be affected by:
A. Drafts
B. Hot or cold pipes
C. Sun light
D. Lighting fixtures
E. Television
F. Near a fireplace or chimney
4. Check thermostat operation by raising and lowering thermostat as required to start
and stop the burners.
5. Instructions for the final adjustment of the thermostat are packaged with the thermo-
stat (adjusting heating anticipator, calibration, etc.).
LIGHTING INSTRUCTIONSLIGHTING INSTRUCTIONS
LIGHTING INSTRUCTIONSLIGHTING INSTRUCTIONS
LIGHTING INSTRUCTIONS
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS
EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY
DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: Beforeoperating,makecertainthe boilerandsystemarefullof
water to minimum pressure (this is usually 12 lbs. per square inch (82.7 kPa) on most
systems) and system is vented of air. See the operating and lighting instructions.
LIGHTING PROCEDURE FOR BOILER WITHLIGHTING PROCEDURE FOR BOILER WITH
LIGHTING PROCEDURE FOR BOILER WITHLIGHTING PROCEDURE FOR BOILER WITH
LIGHTING PROCEDURE FOR BOILER WITH
A HOA HO
A HOA HO
A HOT SURFT SURF
T SURFT SURF
T SURFAA
AA
ACE PILCE PIL
CE PILCE PIL
CE PILOO
OO
OT SYT SY
T SYT SY
T SYSTEMSTEM
STEMSTEM
STEM
FOR YOUR SAFETY READ BEFORE OPERATINGFOR YOUR SAFETY READ BEFORE OPERATING
FOR YOUR SAFETY READ BEFORE OPERATINGFOR YOUR SAFETY READ BEFORE OPERATING
FOR YOUR SAFETY READ BEFORE OPERATING
1. Thisapplianceisequippedwithanignitiondevicewhichautomaticallylightsthepilot. Do
not try to light the pilot by hand.
2. Before operating, smell all around the appliance for gas. Be sure to smell next to the
floor because some gas is heavier than air and will settle on the floor.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: WHAT TO DO IF YOU SMELL GASWHAT TO DO IF YOU SMELL GAS
WHAT TO DO IF YOU SMELL GASWHAT TO DO IF YOU SMELL GAS
WHAT TO DO IF YOU SMELL GAS
•Do not try to light any appliance.
•Do not touch any electric switch.
•Do not use any phone in your building.
•Immediately call your gas supplier from a neighbor’s phone.
•Follow the gas supplier’s instructions.
•If you cannot reach your gas supplier, call the fire department.

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.
WW
WW
WARNING:ARNING:
ARNING:ARNING:
ARNING: FORCE OR
ATTEMPTED REPAIR MAY RESULT
IN A FIRE OR EXPLOSION.
4. Do not use this appliance if any part has
been under water. Immediately call a
qualified service technician to inspect
the appliance and to replace any part of
thecontrolsystemandgascontrolwhich
has been under water.
“OPERATING INSTRUCTIONS”“OPERATING INSTRUCTIONS”
“OPERATING INSTRUCTIONS”“OPERATING INSTRUCTIONS”
“OPERATING INSTRUCTIONS”
1. STOP! Read the safety information in the user’s information manual.
2. Set thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Thisapplianceisequippedwithanignitiondevicewhichautomaticallylightsthepilot. 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 "ON" position. See figure 10 above.
8. Turn on all electric power to the appliance.
9. Set thermostat to desired setting.
10.If the appliance will not operate, follow the instructions "TO TURN OFF GAS TO
APPLIANCE" (Below) and call a qualified service technician or your gas supplier.
TO TURN OFF GAS TO APPLIANCETO TURN OFF GAS TO APPLIANCE
TO TURN OFF GAS TO APPLIANCETO TURN OFF GAS TO APPLIANCE
TO TURN OFF GAS TO APPLIANCE
1. Set thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to be performed.
3. Move the ignition system control switch to the "OFF" position. DO NOT FORCE
PAGE 11
FIGURE 10

PAGE 12
SEQSEQ
SEQSEQ
SEQUENCE OF OPERAUENCE OF OPERA
UENCE OF OPERAUENCE OF OPERA
UENCE OF OPERATIONTION
TIONTION
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. If limit circuit is closed the venter
motor and TR-2 transformer are energized.
4.) The venter motor starts and develops static pressure.
5.) When the static pressure is reached the pressure switch pulls in completing the circuit
between TR-2 and the SV9501H gas valve system.
6.) The SV9501H opens the pilot valve and ignites pilot. After pilot is proven the main
burner will ignite.
7.) In the event the boiler water temperature exceeds the high limit setting the power will
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 the circuit between the ignition system
and TR-2. The venter motor will continue to operate until static pressure is reached or
thermostat is satisfied.
9.) In the event the flow of combustion products through the boiler flueways becomes
reduced or blocked, the Q34505 pilot will lose flame rectification and shut off the main
burners. The boiler will try for ignition but will not light. If this condition occurs, turn off
the main power and do not put the unit into operation.
10.) When the thermostat is satisfied power is interrupted to the relay coil and the relay
drops out cutting power to the circulator, venter motor, and TR-2.

PAGE 13
GENERAL INSTRUCTION FOR SEASONALGENERAL INSTRUCTION FOR SEASONAL
GENERAL INSTRUCTION FOR SEASONALGENERAL INSTRUCTION FOR SEASONAL
GENERAL INSTRUCTION FOR SEASONAL
STST
STST
STARAR
ARAR
ART UPT UP
T UPT UP
T UP AND MAINTENAND MAINTEN
AND MAINTENAND MAINTEN
AND MAINTENANCEANCE
ANCEANCE
ANCE
It is suggested that a qualified service agency be employed to make an annual
inspection of the boiler and the heating system. They 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.
CAUTION:CAUTION:
CAUTION:CAUTION:
CAUTION: Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous operation. Verify proper
operation after service.
1. 1. BEGINNING OF EACH HEATING SEASON
A. Before seasonal start up it is advisable to have a competent service agency
check the boiler for soot and scale in the flues, clean the burners and check the
gas input rate to maintain high operating efficiency and safe operation.
B. The service agency should make certain the system 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. Inspecttheventingsystematthestartof eachheatingseason. Checkthepipefrom
theboilerforsignsofdeteriorationandsaggingjoints. Repairifnecessary. Remove
the vent pipe from the boiler and check for obstructions.
E. Clean condensate tee & trap.
Periodically check the condensate trap for water/condensate. The trap should
always have water in it. Refill the trap if it runs dry. If the trap runs dry then flue
gasses can escape.
Periodic cleaning of the condensate
collectionsystemisrequired.Whena
condensate collection system is
installed in a venting system, it is
recommended that the cleaning
becomeapartoftheannualservicing.
The procedure for cleaning this
system is as follows:
1. Remove tubing from condensate
tee.
2. Empty all liquid from tubing.
3. Rinse tubing inside & out in a sink
with water.
4.Iftheinsideofthetubingcannotbe
cleaned, the tubing should be replaced with the same type and size of tubing.
5. Add water to trap before replacing.
6. Replace tubing as described in figure 11 above.
7. Visuallyinspectentirepipingsystemandifanyleaksappear,havethemrepaired
as soon as possible. DO NOT use petroleum based stop leak compounds.
FIGURE 11

PAGE 14
2. THEFOLLOWINGPROCEDURESHOULDBEFOLLOWEDTOCLEANANDCHECK
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. Disconnect the vent pipe from the vent pipe adapter.
D. Disconnect the air inlet pipe from the coupling. (See figure 13 above for coupling
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
themanifoldorificesand pulling toward the front oftheboiler. (See figure 14 below.)
G. Remove the top panel. (See figure 12 above.)
H. Removethefluecollectorandventerassemblyfromtheboilercastingsbyremoving
thehold-downscrewslocatedoneachsideofthefluecollector.(Seefigure15below.)
I. Remove the baffles from the heat exchanger. (See figure 13 above.)
FIGURE 14 FIGURE 15
FIGURE 13
FIGURE 12

J. Visuallyinspectthebafflesforanyunusualwearorsootbuildup.Cleanifnecessary.
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. The soot and scale will collect on
the paper and is easily removed with the paper.
M.ReplacetheFlue Collectorusingtheholddownscrews andsiliconeinplacewithGE
IS 808 silicone or similar. (See figure 15 on page 14.)
N. Repeat steps A-E in reverse order to reassemble the boiler.
O. Start boiler to insure proper operating condition.
1. KEEP the area around the boiler clean and free of combustible materials such as
gasoline, paints, paint thinner and other such flammable vapors and liquids.
2. The free flow of combustion and ventilating air to the boiler and boiler room must
not be restricted or blocked.
3. Some circulators require periodic servicing. These circulators usually have oil
cupsoropeningsateachendofthemotorandonefortheshaftbearing.Putabout
oneteaspoonofSAE20or30non-detergentmotoroilineachopeningtwiceper
year.DONOTOVEROIL.Followthemanufacturer'sinstructionsattachedtothe
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 THROUGH THE SEASON.
A. Check the burner throats and burner orifices for lint and dust obstructions. See
figure 15 on page 14.
B. The main burner flame should have a well defined inner blue mantel with a lighter
blue outer mantel. (See figure 16 above.)
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 above.)
4. ADJUSTING THE PILOT FLAME:
A. Remove the pilot adjustment cover screw.
B. Turn inner screw (adjustment screw) clockwise to decrease and
counterclockwise to increase the pilot flame, see figure 10 on page 11.
C. After adjustment, be sure to replace cover screw to prevent possible gas leakage.
D. The main burners and the pilot burner should be checked for signs of corrosion or
scale build up.
E. Clean main burners and pilot burner with a steel bristle brush.
PAGE 15
FIGURE 16 FIGURE 17

CHECKCHECK
CHECKCHECK
CHECK VENTER STVENTER ST
VENTER STVENTER ST
VENTER STAA
AA
ATIC PRESSURETIC PRESSURE
TIC PRESSURETIC PRESSURE
TIC PRESSURE AS FOLLAS FOLL
AS FOLLAS FOLL
AS FOLLOO
OO
OWS:WS:
WS:WS:
WS:
(Refer to figure 18 below for the following instructions.)
1. With the boiler off, disconnect the orange and white tubings from the pressure switch
on the air box and venter motor.
2. Install a 3/16" (.48 cm) plastic barbed tee between a slope manometer and the
pressure switch. ( CAUTIONCAUTION
CAUTIONCAUTION
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. CAUTIONCAUTION
CAUTIONCAUTION
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 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.
6. To reassemble, remove the tees and additional tubing and replace the orange tube
to the venter tap, and the white tube to the air box tap.
PAGE 16
FIGURE 18

CHECK GAS INPUT RACHECK GAS INPUT RA
CHECK GAS INPUT RACHECK GAS INPUT RA
CHECK GAS INPUT RATETE
TETE
TE TT
TT
TO BOILERO BOILER
O BOILERO BOILER
O BOILER
1. Maximum permissible gas supply pressure must not be higher and minimum supply
pressure must not be lower than what is specified on the rating plate.
2. Tocheckforproperflowofnaturalgas to boilerusingthegasmeter,proceedasfollows:
A. Turn off the gas supply to all other appliances, except the boiler.
B. Withtheboileroperating,determinetheflowofgasthroughthemeterfortwominutes
and multiply by 30 to get the hourly rate.
C. Divide the input rate shown on the rating plate by the heating value of the gas as
obtained from the local gas company. This will determine the number of cubic feet
of gas required per hour.
D. If minor adjustment is 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.
Afteradjustmenthasbeencompleted,turntheboileroffandremovethemanometer
and the shut-off cock.
E. Relight all the other appliances turned off in step A above. Be sure all pilot burners
are operating.
PAGE 17
ITEMNO P/N DESCRIPTION QTY.
1 PBO1401 PILOT Q3450B 1039 HW NAT 1
(FORNATURALGASONLY)
PB01402 PILOT Q3450B 1112 LP USC
(FORPROPANEGASONLY)
2 32711102 BASE-PILOTBRACKET 1
3 HW-024.01 SCREW#1032X3/16 1
4 MS-003.05 PILOTTUBE1/4"X24-1/4"ALUMINUM 1
FIGURE 19
USC SERIES REPLAUSC SERIES REPLA
USC SERIES REPLAUSC SERIES REPLA
USC SERIES REPLACEMENT PCEMENT P
CEMENT PCEMENT P
CEMENT PARAR
ARAR
ARTS - PILTS - PIL
TS - PILTS - PIL
TS - PILOO
OO
OTT
TT
T

USC SERIES REPLAUSC SERIES REPLA
USC SERIES REPLAUSC SERIES REPLA
USC SERIES REPLACEMENT PCEMENT P
CEMENT PCEMENT P
CEMENT PARAR
ARAR
ARTS - JTS - J
TS - JTS - J
TS - JAA
AA
ACKETSCKETS
CKETSCKETS
CKETS
PAGE 18
FIGURE 20
ITEM # 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 - TOP USC4
3172203 PANEL - TOP USC5