HW2-805
ATU AL
I STALLATI
INST
DESIGNED
VESSEL
AND
CODE,
TESTED
SECTION
&
CTION
ACCORDING
TO
LE
G
GAS
E
A.S.M.E.
BOILER
IV FOR MAXIMUM ALLOWABLE
50 PSI, 345 kPa WATER
AND
WORKING
PRESSURE
NOTE TO INSTALLING
CONTRACTOR:
READ THESE INSTRUCTIONS
THEY WILL SAVE YOU TIME IN ASSEMBLING
BOILER PROPERLY.
Do not store or use gasoline or other flammable
in the vicinity of this or any other appliance.
What to do if you smell
PRESSURE
CAREFULLY.
vapors and liquids
gas:
, Do not try to light any appliance.
, Do not touch any electrical
building.
switch. Do not use any phone in your
, immediately call your gas supplier from a neighbor's
the gas supplier's instructions.
phone. Follow
, If you cannot reach your gas supplier, call the fire department.
installation and service must be performed
service agency or the gas supplier.
by a qualified
installer,
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
TEL. (413) 564=5515 FAX (413) 568-9613
In Canada: 5211 Creekbank
Road, Mississauga,
OF
Ont. L4W 1R3 (905) 625=2991 Fax (905) 625-6610
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
Page2
Ne pas entreposer ni utiliser d'essence
ou ni d'autres vapeurs ou liquides inflammables
proximite de cet appareil ou de tout autre appareil.
QUE FAIRE Sl VOUS SENTEZ
• Ne pas tenter
• Ne touchez
le b_timent.
d'allumer
a aucun
DE GAZ:
d'appareil.
interrupteur;
• Appelez
immediatement
intructions du foumisseur.
• Si vous ne purvez
UNE ODEUR
rejoindre
votre
ne pas vous servir
foumisseur
le foumisseur,
de gas depuis
appelez
L'installation
et I'entretien
doivent
_tre assures
d'entretien
qualifie ou par le foumisseur
de gaz.
CONTENTS
des telephones
le service
par
se trouvant
un voisin.
Suivez
darts
les
des incendies.
un installateur
ou un service
BEFORE YOU START
Getting Started
page 2
Boiler Ratings & Capacities
page 3
Locating the Boiler
page 3
Combustible Floor Option
page 5
Air for Combustion
page 5
Chimney & Vent Pipe Connections
page 6
Heating System Piping
page 8
Gas Supply Piping
page 11
Electrical Wiring
page 12
Starting the Boiler
page 18
Operating the Boiler
page 20
Checking & Adjusting
page 23
Boiler Maintenance
page 24
Instructions to the Owner
page 25
Replacement Parts
page 26
Canadian Supplement
page 28
Health Warnings
page 30
These instructionscover the HW gas fired, low pressure,
sectional, cast iron hot water boiler. HW boilers have
been design certified by CSA under the latest revision of
ANSI-Z21.13 for gas fired low pressure steam and hot
water boilers, for use with natural and propane gas.
Each unit has been constructed and hydrostatically
tested for a maximum working pressure of 50 psi, 345
kPa in accordance
with the A.S.M.E.
Boiler and
Pressure Vessel Code, Section IV for cast iron boilers.
Each boiler has been equipped with a 30 psi pressure
relief valve.
This manual covers the application,
installation,
operation and maintenance of a HW low pressure hot
water boiler,
To obtain the safe, dependable, efficient operation and
long life for which this boiler was designed, these
instructions must be read, understood and followed,
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
Directall questionsto yourHydrotherm
distributoror
writetothe CustomerServiceDepartment,260North
ElmStreet,Westfield,MA01085.Alwaysincludethe
modelandserialnumbersfromthe ratingplateofthe
boilerinquestion.
Page3
BOILER LOCATION
Theownershouldmaintaina recordofallservicework
performedwiththedateanda description
of thework
done.Includethenameofthe serviceorganization
for
futurereference.
.
Whererequiredbytheauthorityhavingjurisdiction,
the
installationmustconformto the Standardfor Controls
and SafetyDevicesfor AutomaticallyFired Boilers,
ANSI/ASMECSD-1.
The installationmustconformto the requirements
of
the authorityhavingjurisdictionor, in the absenceof
such requirements,
to the NationalFuel GasCode,
ANSI Z223.1/NFPA54-latestrevision.In Canada,
installation
mustbeinaccordance
withtherequirements
of CAN/CGAB149.1or 2 InstallationCodefor Gas
BurningAppliances
andEquipment.
BOILER
2. An optimum site will be level, central to the piping
system, close to a chimney and have adequate
fresh air for combustion.
.
RATINGS AND CAPACITIES
Before undertaking the installation of the HW check
the boiler rating plate to ensure that the boiler is the
proper size for the job. The "Net I=B=R Ratings" specify
the equivalent amount of direct cast iron radiation that
the boiler can handle under normal conditions. Also
ensure that the boiler has been set up for the type of
gas available at the installation site. Other important
considerations
are the availability of an adequate
electrical supply, fresh air for combustion and a suitable
chimney or vent system.
NOTES:
1. For altitudes above 2000 ft, 610 m, ratings should
be reduced at the rate of 4% for each 1000 ft, 305
m above sea level, 10% in Canada.
2. If ordering a boiler for use with LP gas add a P to
the model number, ie PHW.
Locate the boiler in an area that provides good
access to the unit. Keep in mind that servicing may
require the removal of jacket panels. Accessibility
clearances
must take precedence
over fire
protection clearances.
Ensure that the floor is structurally sound and will
support the weight of the boiler. This boiler is
designed for non combustible floors only! A special
base supplied by Hydrotherm must be used if the
boiler is to be installed on a combustible
floor.
NEVER USE A SUBSTITUTE
BASE ON A
COMBUSTIBLE FLOOR! Never install this boiler on
carpeting!
.
DO NOT install this boiler in a location that would
subject any of the gas ignition components to direct
contact with water or excessive moisture during
operation or servicing.
5. DO NOT place this boiler in a location that would
restrict the introduction of combustion air into the
boiler. NEVER store objects on or around the boiler.
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Page4
,
If the boiler is to be located in an alcove, closet or
other confined space the distances from the boiler
and it's vent system to all combustible construction
must be equal to or greater than the minimum
clearances in Figure 1. When installed in a closet or
confined space two permanent openings of equal
area adjoining another room or rooms having
sufficient volume to meet the requirements of an
unconfined space must be provided. Each opening
must have a minimum free area of one square inch
per 1000 Btu/hr, 2200 mm2/kWbased on the total
input rating of all gas utilization equipment in the
confined area. Each opening must be no less than
100 in 2, 64516 mm 2, in size. The upper opening
must be within 12 in, 305mm, of, but not less than
3 in, 76 mm, from the top of the enclosure. The
bottom opening must be within 12 in, 305 mm, of,
but not less than 3 in, 76 ram, from the bottom of the
enclosure.
Figure 1: Clearances
to Combustible
Construction
FRONT
For
AL
in
A
24
CL
mm
610
B
Servicing
mm
in
mm
51
1295
N/A
N/A
2
51
N/A
N/A
in
C
6
152
6
152
6
152
D
4
102
4
102
4
102
E
7
178
7
178
10
254
F
4
102
4
102
10
254
AL = Alcove
CL = Closet
*No Front Wall in Alcove
HW NATURAL OR PROPANE BOILER
INSTALLATION AND OPERATING INSTRUCTIONS
COMBUSTIBLE
FLOOR OPTION
The HW boiler has been designed
for use on
noncombustible floors only. If a HW boiler is to be
installed on combustible flooring of any type, it MUST
be installed using the Special Base designed by
Hydrotherm. Do NOT use any base other than the one
specifically designed for it if installing a HW boiler on
combustible flooring.
Page 5
Figure 2: Special Base installation
Combustible
Flooring
on
To order the Special Base contact the nearest
Hydrotherm distributor and ask for the "Noncombustible
Floor Pan" part number referenced in the Replacement
Parts List in back of the IOM.
Determine where the boiler will be located by following
the instructions in the Boiler Location section of this
manual. Place the Special Base in this location and
fasten it in place to prevent it from moving while the
boiler is being placed on it.
If the HW is being installed in an alcove or closet ensure
that the minimum distance to combustible construction
FRONT
GRILL
SUPPORT
CHANNEL
requirements, listed in Figure 1, are met.
Remove the sheet metal base pan attached to the
boiler. Position the boiler in front of the Special Base. It's
suggested that two lengths of 3" pipe the width of the
boiler, or longer, be placed under the boiler base side
panels.
COMBUSTION
AiR
CAUTION: Be careful not to damage the burners,
pilot assembly or any other gas train components
during this procedure,
if a component is damaged,
replace it!
Carefully roll the boiler up to the front of the Special
Base. Align the boiler base side panels with the Special
Base support channels. Using great care, slide the boiler
onto the Special Base.
Table 1 : Vent and Chimney
Boiler Size
CAUTION: Never lift the boiler by the jacket panels
or flue collector/draft
diverter or severe damage to
the boiler may result!
Center the boiler from side to side on the Special Base.
Ensure that the back of the burner base side panels
are flush with the back of the Special Base support
channels. Install the front grill supplied with the Special
Base. Complete the installation in accordance with the
instructions set forth in this manual.
Vent Pipe
Dimensions
HW
HW
HW
HW
HW
HW
HW
50
75
1O0
125
150
175
200
5
5
6
6
7
7
8
Dia. (In.)
Chimney
Flue Size
Chimney
Height (Ft.)
8x8
18
18
18
8x12
17
17
17
16
HW NATURAL OR PROPANE BOILER
iNSTALLATiON AND OPERATING iNSTRUCTiONS
Page 6
To operate properly and safely this boiler requires a
continuous supply of air for combustion. Oxygen is used
by the burners in the boiler to burn the gas. In addition,
air is also used to assist in the safe disposal of the
products of combustion. This air is known as dilution
air and mixes with the products of combustion to assist
in it's exit through the flue pipe and chimney. An
adequate supply of outside air must be available to
replace that used by these processes.
Older houses often have enough "leakage" to provide
an adequate amount of combustion air provided that
the demand for combustion air is not too great. Homes
that are relatively new or "tight" will most likely require
the installation of a fresh air duct or other means of
providing air for combustion. Any home utilizing other
gas burning appliances, a fireplace, wood stove or any
type of exhaust fan must be checked for adequate
combustion air when all of these devices are in operation
at one time. Sizing of an outside air duct must be done
to meet the requirements of all such devices.
Table 2: Combustion
Air Duct Sizing
Fresh Air
Duct Size
Input Btuh
1/4" Wire
Mesh Screen
Input Btuh
Metal
Louvers
Input Btuh
Wooden
Louvers
3" x 12"
144,000
108,000
36,000
64,000
8"x 8"
256,000
192,000
8"x 12"
384,000
288,000
96,000
8-1/2" x 16"
512,000
384,000
128,000
VENT CONNECTIONS
Always use a type B or C vent pipe of the proper
diameter for the boiler. Use the shortest, straightest
vent system possible for the particular application. The
vent system should be sloped up toward the chimney
at a rate of 1/4 in/ft, 2 mm/m. Ensure that the flue pipe
is properly supported and each connection securely
fastened with at least 3 corrosion resistant sheet metal
screws. The termination of the vent pipe should be
flush with the inside of the chimney flue.
Always provide a minimum clearance of 6 in, 152 mm,
between type C vent pipe and any combustible
materials.
Type B1 vent may be used, clearance
between it and any combustible material must be as
listed.
If the boiler will be located in an alcove, closet or any
confined space refer to item 6 in the Boiler Location
section of this manual.
CHIMNEY & VENT PIPE CONNECTIONS
Chimney inspection & Sizing
if this boiler will be connected to a masonry chimney, a
thorough inspection of the chimney must be performed.
Ensure that the chimney is clean, properly constructed
and properly sized. Table 1 lists the flue size and
chimney height required for this boiler.
When more than one appliance is connected to the
same chimney flue, the flue must be large enough to
handle both appliances.
The vent installation must be in accordance with Part 7
of the latest revision of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54.
Common Vent Systems
If an existing appliance is removed from a common
venting system, the common venting system may then
be too large for the proper venting of the remaining
appliances connected to it. 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.
Au moment du retrait d'une chaudi_re existante, les
mesures suivantes doivent _tre prises pour chaque
appareil toujours raccorde au syst_me d'evacuation
commun et qui fonctionne alors que d'autres appareils
toujours raccordes au syst_me d'evacuation ne fonctionnent pas: syst_me d'evacuation.
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
a) Seal all unused openings
in the common
vent
system and repair any leaks.
Sceller toutes les ouvertures non utilisees du syst_me d'evacuation.
Page7
After it has been determined that each appliance
remaining connected to the 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 condition of use.
b). Visually inspect the vent system to ensure that it is
properly pitched and sized and that there are no
structural
deficiencies
such as blockages,
restrictions, leakage, or corrosion that could cause
an unsafe condition.
Inspecter de fagon visuelle le syst_me d'evacu-ation
pour determiner la grosser et I'inclinaison horizontale
qui conviennent et s'assurer que le syst_me est
exempt d"obstruction, d"etranglement de fruite, de
corrosion et autres defaillances qui pourraient
presenter des risques.
c) As far as is practical close all doors and windows
common to the space in which the vent system and
appliances connected to the common vent system
are contained. Turn on all exhaust fans, clothes
dryers, range hoods and appliances requiring air for
combustion that are not connected to the common
vent system. Ensure that all appliances operate at
maximum
speed. Do not operate a summer
exhaust fan. Close all fireplace dampers.
Dans la mesure du possible, fermer toutes les portes
et les fen_tres du b&timent et toutes les portes entre
I'espace oQ les appareils toujours raccordes du
syst_me d'evacuation sont installes et les autres
espaces du b&timent.
Mettre en marche les
secheuses, tousles
appareils non raccordes au
syst_me d'evacuation commun et tousles ventilateurs
d'extraction comme les hottes de cuisin_re et les
venfilateurs des salles de bain. S'assurer que ces
ventilateurs fonctionnent & la vitesse maximale. Ne
pas faire fonctionner les ventilateurs d'ete. Fermer
les registres des cheminees.
d) Place in operation the appliance being inspected.
Une fois qu"il a ete d etermine, selon la metode
indiquee ci-dessus, que chaque appareil raccorde
au syst_me d'evacuation est mis & I'air libre de fagor
adequate. Remettre les portes et les fen_tres, les
ventilateurs, les registres de cheminees et les
appareils au gaz & leur position originale.
g) Any improper operation of the common venting system should be corrected so the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/
NFPA 54. 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 F in
the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and or CSA B149 Installation Codes.
Tout mauvais fonctionnement du systeme d'evacution commun devrait etre corrig_ de fagor que
I'installation soit conforme au National Fue Gas
Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d'installation CSA-B149. Si la grosseur d'une section du
syst_me d"evacuation doit etre modifiee, le syst_me
devrait etre modifie pour respecter les valeurs
minimales des tableaux pertinents de I'appendice F
du National Fuel Gas Code, ANSI Z223.1/NFPA 54
et (ou) des codes d'installation CSA-B149.
Vent Dampers
This boiler comes from the factory equipped with a
vent damper specifically engineered for it. The vent
damper must be properly installed to obtain the high
performance for which this boiler was designed. If the
damper is damaged or missing do not install the boiler
without it! Contact the nearest Hydrotherm distributor
to obtain the proper vent damper.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
Mettre I"appareil inspecte en marche. Suivre les
instructions d'allumage.
Regler le thermostat de
fagon que I'appareil foncfionne de fa£on continue.
e) Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
Fake fonctionner le brOleur principal pendant 5 min
ensuite, determiner si le coupe-tirage deborde &
I'ouverture de decharge. Utiliser la flamme d'une
allunette ou d'une chandelle ou la fumee d'une cigarette, d'un cigare ou d'une pipe.
Vent dampers are designed for use with only one
appliance. NEVER connect more than one appliance
to a single vent damper.
Locate the vent damper so that it is accessible and the
damper position indicator is visible. Maintain a minimum
of 6 inches between the damper and any combustible
materials!
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Page8
Fastentheventdamperto thefluecollarandventpipe
usingat least3 corrosionresistantsheetmetalscrews
perjoint.Connectthedamperharnessto thetoppanel
with the BX connector supplied. Plugthe Molex
connectoronthedamperharnessintothe matingplug
onthe harnesslocatedinsidethecontrolcompartment.
Figure 4: Heating System Piping
DISCHARGE
SIZE
PIPE
TO EQUAL
VALVE
OUTLET.
DO NOT
SUPPORT
DISCHARGE
SO AS TO
AVOID
THE
RESTRICT
FLOW.
VALVE
PIPING
STRAIN
ON
BODY.
/
....
FOR
DISCHARGE
THROUGH
ROOF
CONSULT
Theventdamperis operatingproperlywhenit opens
completelyupona callfor heatandclosescompletely
whenthecallfor heatends.Theventdampermustbe
inthe openpositionwhentheboilersmainburnersare
inoperation.
Figure3:
HYDROTHERM.
1" CLEARANCE
MUST
MAINTAINED
BETWEEN
HOT WATER
AND
__
BE
PIPING
COMBUSTIBLE
CON STRUCTION.
Vent Damper Location
_
....
'4_'
DAMPER BLADE POSiTiONED
FRONT TO BACK OF BOILER
0o o
_j
/
J
MOTOR TO FACE
FRONT OF BOILER
/
FRONTOF
BOILER
HEATING
SYSTEM
PIPING
CAUTION: All piping must be installed by a qualified
technician
in accordance
with the provisions set
forth in the applicable ANSI/ASME standards and
local building
codes and regulations,
improper
piping of this boiler can cause flooding, extensive
property
damage,
heating
system damage or
damage to the boiler.
The HW hot water boiler comes from the factory ready
to be piped to the heating system. Each boiler is
equipped with a safety relief valve. This valve must be
piped in accordance with the ANSl/ASME Boiler and
Pressure Vessel Code, Section IV. Figure 4 provides a
pictorial description of the boiler and piping components.
DISCHARGE
SO AS
HOT
OR
LIQUID
PERIODIC
TO
VAPOR.
INSPECTION
AVOID
LEAVE
FOR
EXPOSURE
OPEN
SLOW
OF
END
LEAKAGE
PERSONS
VISIBLE
OR
TO
FOR
DRIPS.
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Theboilershouldbeplacedin thelocationselectedfor
it. Referto the BOILERLOCATIONsectionin this
manual.Ensurethatthe boileris levelfromfrontto
backandfromsideto side.Usemetalshimsto level
the boiler. NEVER use wood, plastic or other
combustible
materialsas shims.
All heating system piping must be installed in
accordance
withtheANSI/ASME
BoilerandPressure
VesselCode,SectionIV, andANSI/ASMECSD-1,
Standard for Controls and Safety Devices for
Automatically
FiredBoilers.Allapplicablelocalcodes
andordinances
mustalsobefollowed.
Page 9
Figure 5: TACO 007 Performance Curve
10
rr
LU
_6
FuJ
g4
<
If the boileris installedaboveanyradiationelementsit
mustbefittedwitha lowwatercutoffdevice,L.W.C.O.,
installedabovethenormalboilerwaterlevel.
Circulators
A TACO007circulatorhasbeensuppliedas standard
equipment
withtheboiler.The007is sizedforuseina
closedheatingsystemwitha 30 psi, 207kPa, maximum
operating pressure. If the 007 circulator furnished with
this boiler does not have the required capacity for the
system in which it is to be installed, an extra zone
circulator must be provided. A circulator with a higher
capacity may also be used. Figure 5 depicts the
performance curve for the TACO 007 circulator.
LU
7-
10
FLOW
15
20
25
- GPM
Figure 6: Chiller Schematic
NOTE
FOR HEATING:VALVES"H"OPEN,
FOR COOLING:VALVES"H"CLOSED,
VALVES"C"CLOSED.
VALVES"C"OPEN.
Piping For Use With Cooling Units
The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be
used to prevent the chilled water from entering the
boiler. See Figure 6 for the proper piping layout.
When a boiler is connected to a heating coil that may
be exposed to refrigerated air from an air handling
device, the piping system must be equipped with flowcontrol valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.
CAUTION: To prevent damage due to excessive
condensation,
one of the following piping options
should be used.
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
Page10
SystemBypass
Forsystemsusinga circulatoronthereturnas eithera
singlezone,or multiplezoneswithzonevalves,install
a systembypassline betweenthe supplyandreturn
on the suctionside of the circulator,see Figure7.
Installa meteringvalvein this bypasslineto regulate
theamountof flowthatwillbedivertedto thereturn.A
plugvalveoffersthe bestcontrolfor this application.
Althoughothervalvesmaybe lessexpensive,
a plug
valvewillbeeasierto setaccurately.
In the absenceof a flow indicator,set the metering
valveusingtemperature
asa guide.Theaccompanying
diagramsuggestsonescenario.Thisadditionrequires
onlytwotees,a plugvalve,anda smallamountofpipe
and offersthe simplestapproachto reliablycontrol
condensation.
Forthis systemandthosethatfollow,
beawarethatyouareusinga percentage
of thepump
capacityto blend,but the frictionlossfor the entire
pumpflow has been reduced.In mostcases,the
standardpumppackagedwiththe boilerhasenough
capacitytofeedthebaseboard
distribution
systemand
thebypassline.
Figure7: SystemBypass
SUPPLY
Figure 8: Pump Away Bypass
SUPPLY
RETURN
50%
120 ° F
50%
160 ° F
100%
140 ° F
100%
160 ° F
PUMP AWAY
BYPASS
Pumped Blend
An additional circulator can also be used to provide a
return water temperature blend. This method works
well with systems with multiple zones with circulators,
see Figure 9. The dedicated bypass circulator provides
a strong blending flow without diminishing the flow
available to any heating zone. Any residentially sized
circulator is adequate for this purpose.
RETURN
50%
120 ° F
50%
160°F
100%
160°F
100%
140°F
Each of these bypass solutions also has the added
benefit of increasing circulation in the boiler which will
maximize tankless coil output and increase the accuracy
of temperature sensing controls.
Figure 9: Pumped Bypass
RETURN
_
SYSTEM
BYPASS
_
SUPPLY
100%
160 ° F
120 ° F
160 ° F
Pump Away Bypass
For systems that use a single circulator to pump away
from the boiler, the bypass should be installed on the
discharge side of the circulator, see Figure 8. Full
temperature water supplies the baseboard distribution
system as before. Half of the circulator's volume moves
through the bypass, blending and heating the cooler
return water. Again, the cost of installing the bypass is
small and setting it by temperature can be accomplished
with a contact thermometer.
200%
160 ° F
200%
140 ° F
PUMPED
BYPASS
HW NATURAL OR PROPANE BOILER
INSTALLATION AND OPERATING INSTRUCTIONS
Reverse Acting Aquastats
An alternative
for existing systems experiencing
condensation that does not require re-piping the boiler
utilizes a reverse acting aquastat, one that makes on
temperature rise. This approach works best in single
zone systems. Wired in series with the circulator, this
control holds the circulator off until the boiler reaches
an acceptable temperature
circulation, see Figure 10.
GAS SUPPLY PIPING
and then starts system
The most commonly available reverse acting aquastat
is a Honeywell L4006B. The aquastat should be
mounted in an immersion well directly installed in the
boiler. The use of heat conductive grease, Honeywell
part # 972545, in the immersion well is strongly
recommended
for fast and accurate temperature
response. Set this adjustable aquastat to make at no
less than 130 ° F, 54°C. While this method can cause
the circulator to cycle more frequently, setting the
aquastat's differential to the maximum 25-30°F will
minimize short cycling.
Figure 10: Reverse Aquastat
reverse
115 volts
_,,.]
N.O.
_-,i[
24 volts
1
REVERSE
AQUASTAT
The HW hot water boiler comes from the factory ready
to be piped to the gas supply.
If for any reason the boiler is not for the type of gas
available at the installation
site, call the nearest
Hydrotherm distributor to resolve the problem.
aquastat
SET AT 120 ° F
Page 11
_
I
Table 3 should be used to ensure that the gas supply
piping is sized properly. If more than one appliance is
supplied by the same supply pipe, the piping must be
sized based on the maximum possible demand. Do not
neglect the pressure drop due to pipe fittings. Table 4
should be used in conjunction with Table 3 to ensure
that the supply piping has the capacity to meet the
demand.
Table 3: Gas Pipe Capacity
N.C.
Maximum pipe capacity in fP/hr based on 0.60 specific gravity gas
at pressure of 0.5 psig or less and a 0.3" W.C. pressure drop.
Nominal
Iron Pipe
Pipe length in feet
10
20
Size (in.)
30
40
50
60
80
100
150
Maximum gas volume in cubic feet!hr, (fP/hr)
3/4"
278
190
152
130
115
105
90
79
64
1"
520
350
285
245
215
195
170
150
120
1-1/4"
1050
730
590
500
440
400
350
305
250
1-1/2"
1600
1100
890
760
670
610
530
460
380
Table 4: Equivalent
Length Chart
Eqivalent length of pipe fittings in feet
Nominal
Iron Pipe
Type of pipe fitting
90 ° Elbow
Size
Tee
Gate Valve
Gas Cocks
(flow thru branch) (full port)
(inches.)
Equivalent length in feet
3/4"
2.06
4.12
0.48
1.25
1"
2.62
5.24
0.61
1.60
1-1/4"
3.45
6.90
0.81
2.15
1-1/2"
4.02
8.04
0.94
2.50
HW NATURAL OR PROPANE BOILER
INSTALLATION AND OPERATING INSTRUCTIONS
Page 12
Figure 11 depicts the proper way to connect the boiler
to the gas supply piping. The manual shut-off valve
MUST be installed in the supply piping. It should be
approximately 5 ft, 1.5 m above the floor. Provide a
drip leg/sediment trap at the bottom of the vertical
section of the gas supply pipe. A ground joint union
should be installed between the boiler gas controls
and the supply piping. Each of these items are needed
to ensure long life and ease of servicing. Always use a
pipe sealant that is suitable for use with LP gas.
Figure 11: Gas Supply
Piping
ELECTRICAL
Electrical
Power Connections
CAUTION: Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation!
GAS INLET
ATTENTION:
SHUT-OFF VALVE -MANUAL
5INSTALL
FT. ABOVE
FLOOR
WHERE REQUIRED
BY
GAS SUPPLY
PIPING
.......................
i
LOCAL CODES
i
_:_.
GROUND JOINT
UNION
SEDIMENT TRAP
OR
DRIP LEG
Au
moment
de
I'entretien
des
commandes,
_tiquetez tous les ills avant de les
d_brancher. Des erreurs de c_blage peuvent ent rafner
un fonctionnement
in=ad_quat
et dangereux.
S'assurer que I'appareil fonc-tionne ad_quatement
une fois I'entretirn termin_.
//
The electrical connections to this boiler must be made
BOILER
(TO EXTEND TO FLOOR)
\\\\
FLOOR LEVEL
WIRING
i
i
\_
in accordance with all applicable local codes and the
latest revision of the National Electrical Code, ANSI/
NFPA-70. Installation should also conform with CSA
C22.1 Canadian Electrical Code Part l if installed in
Canada. Install a separate 120 volt 15 amp circuit for
the boiler. A shut-off switch should be located at the
CAUTION: Always use a wrench on the gas
body when making gas connections
to it.
over-tighten the piping entering the gas valve
Failure to comply with this caution may result
valve failure!
valve
Never
body.
in gas
Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided
on the boiler. All gas connections MUST be leak tested
before putting the boiler into operation.
boiler. The boiler must be grounded in accordance with
the authority having jurisdiction, or if none, the latest
revision of the National Electrical Code, ANSI/NFPA70.
Line voltage field wiring of controls and other devices
must conform to the temperature limitation of type T
wire at 95°F, 35°C, above room temperature. Use
copper conductors with a minimum size of #14 awg.
Low voltage wiring must not be less than #18 awg with
a neoprene, thermoplastic or other equivalent insulation
having a minimum insulation thickness of 0.012 in,
0.3 mm.
Thermostat Installation
ALWAYS follow the instructions
included
with the
thermostat to be used to control the boiler. Proper
location of the thermostat will ensure efficient troubleWhenever the gas supply piping is pressure tested the
boiler gas controls must be protected. If the test
pressure is equal to, or less than 1/2 psig, 3.5 kPa,
isolate the boiler by closing it's manual shut off valve,
see Figure 11. If the test pressure is greater than, or
equal to 1/2 psig, 3.5 kPa, disconnect the boiler and
it's individual shut-off valve.
free operation of the boiler. Mount the thermostat to an
inside wall at a height approximately five feet above
the floor. Avoid placing the thermostat in areas that will
not provide an accurate measurement of the room
temperature. Locating the thermostat behind a door, in
an alcove, close to a source of thermal radiation or in a
drafty area will cause poor or sporadic heating.
Vent Damper
The vent damper supplied with the boiler has been
wired with a 6 pin molex connector that will plug directly
into the boiler's wiring harness.
m.
o
o
FIELD WIRING
FACTORY WIRING
--
o
115V/1/60
L1
L2
NOT BY HYDROTHERM
_
SERVICE
SWITCH
TI
SERVICE
STACK DAMPER
SWITCH
II
\
o
M35
q_
I
r ......
R-_
'I',
CO_NEOTSx_O[Ig*_E_wN
w
BK
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o
LI
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LOW-V_OLTAG E_
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I
_l
24VTHERMOSTAT
iii, i,,
Y
BK
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6
4
t
I
MOLEX RECEPTACLE
I
I
I
40VA
I_
RELAY
g_
COIL
'-'4Z
_ j,,w _L MOLEXPLUG
I
I I
I
IIi
BLZ
----J--SK--JI
_
THERMAL
CUTOFF
÷
LOW-_OLTAGE
--SL
--
J
N.O.
CONTACT
HIGH
LIMIT
SWITCHES
€'_
I_;1
W
W
THERMAL
z_
CUTOFF
--_SWITCHES
CO
HONEYWELL
4OVA
R
$8600
ELECTRONIC
B4V GND
W
CONNECT
STACK DAMPER
WITH MOLEX PLUG AS SHOWN
BL WW
I
BL - BLU E
BK - BLACK
HI-LIMIT
R - RED
W- WHITE
Y - YELLOW
G - GREEN
:: d
t
W
GAS VALVE
3 - 12 SECTION
[ ....
I
_---.BK
........
J
I
MV/P
_R8304
MV
R@
I
PILOT
Q345A
......
I
BL - BLUE
BK - BLACK
R - RED
W - WHITE
Y - YELLOW
G - GREEN
PV
GND
0
W@
I
/
- S8600
BK
MV
W
MV/PV
MV/PV /
S8600
3-12
GAS VALVE
SECT.VR8304
o=
O
24V. (GND)
Z
_- R_
_ SPARK
_v. I
HONEYWELL
I
I
HONEYWELL
BK@
I
I
E i i
/
PROVIDE DISCONNECT
MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
,,,4
T1
TRANSFORMER
_b
1
Z
I
I
B4V THERMOSTAT
T1
oRR82272U1
RELAY
|
,
I BK
I
A_
_,_K
m,
o
1
i
1
m
PILOT
Q345A
TERMINALS
/L._
_
'_
NOT
BY
IN
JUNCTION
TERMINALS
ON
CONTROLS
TERMINALS
ON
HSI
HYDROTHERM
BOX
CONTROL
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,
IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR IT'S EQUIVALENT.
_3
_Q
0
co
_3
P3
_Q
(b
m.
4_
o
L1
@
o
NOT BY HYDROTHERM
o
M35
_
SERVICE
SWITCH
T
I
_
[_l
I
I
I
i,
r ......
l
I
I
I
I
I
1
q-
STACK DAMPER
WR
G--
i it .... oK
/_J
I
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I
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115V/1/60
L1
L2
O
L2
/\
115V/1/60
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I
i SERV,CESW,TCH
+
+
W
BK
\/I
!
/
....
\
F
_-I
_7,,
o
24VTHERMOSTAT
I
I
,/_
_I
l r I
,
Y BK
BK
W
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{{{
i_\\MOLEXRECEPTACLE
IIII
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BL
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T1
TRANSFORMER
{{
_'k
"_
CUTOFF
SWTCHES
N,O,
a4_
I T1
t
BK------J
24vL_ h_ _
R8222U RELAY
57-01 V1W
L OR R8285A
BL
------J
I
_CUTOFF
SVVITCHES
-BL:_
i ;CONTACT
_'_,__
L_FR%4
\J/
I-,/y_BL_o
I \J
. _BL-J
_
LOW--VOLTAGE
24V THERMOSTAT
z:_
_,
L-BL_
W
I
BL
40VA
I_W_
BL WW
I
BL- BLUE
BK - BLACK
R - RED
W - WHITE
Y - YELLOW
G - GREEN
HI-LIMIT
CONNECT
WITH
STACK
MOLEX
DAMPER
PLUG
BK
AS SHOWN
IBLI
LLLL
\
\\\
Li_
[
--
]
w
}
GAS VALVE
3 - 7 SECTION - VR8200
3 - 12 SECTION -VR8300
-_
,,
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,
_---BK
' ', ', ',
........
J
I I
W_/TH_
BL- BLUE
BK - BLACK
R - RED
W - WHITE
Y - YELLOW
G - GREEN
'\_"_ TERMINALS ON CONTROLS
FIELD
8=
Z
0_
AS REQUIRED•
/_}_ TERMINALS IN JUNCTION BOX
OO
O
DISCONNECT
AND
OVERLOAD
PROTECTION
!
W
R _
GAS VALVE
3-7 SECT.
- VR8200
3-12 SECT,
- VR8300
I I II
R
PROVIDE
MEANS
COIL 1
THERMAL
'
_414_s
-4Z
RELAY
r
CONTROLC_f_,_
g_
4OVA
MOLEXPLUG
o
I
m
Z
¢0
-4
N,O, CONTACT
CONNECT STACK DAMPER
WITH MOLEX PLUG AS SHOWN
WIRING
FACTORY
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,
IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR IT'S EQUIVALENT,
WIRING
NOT
BY HYDROTHERM
HW NATURAL OR PROPANE BOILER
iNSTALLATiON AND OPERATING iNSTRUCTiONS
Figure 14: Multi Zone Diagram
Page 15
Figure 15: Multi Zone Diagram
,,TF,O.E2_
"F'O"E'O
6
V8043F
L_ ,
VS043F
I..............
LOWVOL
I
A
--
VS043F
LINE VOLTAGE
TO ADDITIONAL
_--_
,IF
J_
_ _, R_ARELA_
;1[i _ ,......................
....................................
®_1
_
.......................................
_, i4 ) i
........
..................
00
........
t
/.OT/
R
_
_
ZONE1
L_ONNECT
2 POWER 1
SUPPLY
SUPPLY
K
/_
MEANS
• 1_
E
THERMOSTAT
AND OVERLOAD
AS REQUIRED,
CIRCULATOR
SUPPLY
L2
1_
PROVIDE
//_,
SI,E
DISCONNECT
ADDmONAL
MEANS
AND OVERLOAD
TRANSFORMER
8VA
PER EACH
PROTECTION
VSO43F ,ONE
AS
REQUIRED
VALVE
THAT
B REQUIRED
Figure 16: Multi Zone Diagram
LINE VOLTAGE
LOW VOLTAGE
THERMOSTAT
ZONE 1
(_
ZONE 3
THERMOSTAT
THERMOSTAT
ZONE 2
(_
|
R8285D
I
I
I_---
,IF-,
R882C
491 NO
ol N.C.
_'_l COM.
R882C
q::)l N.O.
io| N.C.
_|
COM.
R882C
4.)! NO
oi N.C.
ml COM.
24
VAC
i
'_J| N (b
iuI
NC
,_0| COM.
-uII KIN
u E h.! f:
-oll COM.
w________B
u I
)(
K! C
-4)1 COM.
W
B
I
I
W
W
BK
BK
CIRCULATOR
ZONE 1
CIRCULATOR
ZONE 2
CIRCULATOR
ZONE 3
L2_
_ L1
POWER
SUPPLY
PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
POWER
SUPPLY
SIZE ADDITIONAL TRANSFORMER 15VA PER EACH R882C ZONE RELAY THAT IS REQUIRED.
PROTECTION
Page 16
HW NATURAL OR PROPANE BOILER
iNSTALLATiON AND OPERATING iNSTRUCTiONS
BOILER SET UP
NOTE: Before starting the boiler, turn off the
electrical supply going to it. Make sure that gas is
available at the combination control inlet. Open the
valves in the return and supply piping.
Failure to
take these precautions will prevent the boiler from
operating properly.
Fill the boiler and all of the radiation with water. Make
sure that the system is completely purged of air.
Review these instructions and make sure that the boiler
installation complies with ALL of the stated instruction up
to this point.
Flame Roll=out Safety Shutoff System
The HW gas boiler is fitted with a flame roll-out switch
that detects the presence of hot flue gases in the control
compartment. If something prevents the combustion
products from property passing through the boiler, the
roll-out switch will shut the boiler off. If the flame roll-out
safety system is activated, contact qualified service
agency to correct the problem and reset the flame rollout safety switch. Do not attempt to start the boiler until
problem has been corrected and the switch has been
reset.
Never attempt to bypass the flame roll=out safety
shutoff switch for the purpose of operating
the
boiler!
The boiler should be inspected and serviced before
each heating season by a qualified service agency. The
boiler flue passages,
venting
system,
ignition
components and the burners should be cleaned and
examined for deterioration
due to corrosion.
All
operational
characteristics
of the boiler such as
combustion products, the ignition safety shutoff devices
and proper control function must be thoroughly checked
out.
During the heating season, the owner should check the
boiler and the area around it at least once a month.
Clear away all objects on or near the boiler. Ensure that
there is no discoloration
of adjacent combustible
materials due to heat. If there is, IMMEDIATELY call the
installer or a qualified service agency.
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
FOR YOUR SAFETY
Page17
READ BEFORE OPERATING
WARNING
if you do not follow these instructions exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
1. If this appliance is equipped with a pilot that must
be lit by hand, follow lighting instructions exactly
when lighting the pilot.
2. if this appliance is equipped with an ignition
device that automatically
lights the pilot or
burner, follow operating instruction, do not try to
light the pilot or burner by hand.
A.
B.
BEFORE
LIGHTING
smell
all
around
the
appliance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and will
settle on the floor.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electric switch;
phone in your building.
do not use any
LiGHTiNG
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.
C. Use only your hand to push in or turn the gas control
knob. Never use tools. If the knob will not push in or
turn by hand, don't try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire
or explosion.
D. 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 the
control system and any gas control which has been
under water.
iNSTRUCTiONS
1.
2.
3.
4.
5.
6.
STOP! Read the safety information above.
Set the thermostat to lowest setting.
Turn off all electric power to the appliance.
Remove control access panel.
Turn the gas control knob clockwise
to "OFF".
Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above. If you don't smell gas, go to the next step.
7. Remove the pilot access panel located just above
the burner tubes.
8. The pilot's located behind this panel.
9. Turn the knob on the gas control counterclock-wise
to "PILOT".
10. Push and hold down the red button next to the
control knob.
approximately
PRESSURE
Light the pilot with a match and wait
one (1) minute before releasing the
REGULATOR
OUTLET
11.
12.
13.
14.
15.
16.
button. The button should pop back and the pilot
remain lit. If it goes out repeat steps 5 - 10.
*If the button does not pop up when released, stop
and immediately call your service technician or gas
supplier.
*If the pilot will not stay lit after several tries, turn
the gas control knob to "OFF" and call your
service technician or gas supplier.
Replace the pilot access panel.
Turn the gas control knob counterclock-wise
to "ON".
Replace control access panel.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
If the appliance
will not operate,
follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your service technician or gas supplier.
PRESS. TAP
ADJUSTMENT(UNDER
CAP SCREW)
GAS INLET
GAS OUTLET
_
PILIT
_""_
BRACKET
J
RED RESET BUTTON
\\
GAS CONTROL
KNOB
CONTINUOUS
PILOT
TBUBRN
ER
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Page18
POUR VOTRE Si CURITi
LISEZ AVANT D'ALLUMER
AVERTISSEIVIENT. Quiconque ne respecte pas a la lettre les instructions dans la pr_sente notice risque
de d_clencher un incendie ou une explosion entrainant des dommages, des blessures ou la mort.
A. Cet appareil est muni d'une veilleuse qui doit _tre
allumee manuellement.
Respectez les instructions
cidessois _. la lettre.
B. Avant d'allumer la veilleuse, reniflez tout autour de
I'appareil pour deceler une odeur de gaz. Reniflez pros
du plancher, car certains gaz sont plus Iourds que I'air et
peuvent s'accumuler au niveau du sol.
QUE PAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
Ne pas tenter d'allumer d'appareil.
Ne touchez _.aucun interrupteur; nepas vous servir des
telephones se trouvant dans le b&timent.
Appelez immediatenemt votre fournisseur de gas depuis
un voisin. Suivez les instructions du fournisseur.
INSTRUCTIONS
1. ARRI_TEZ! Lisez les instructions de s6curite sur la
2.
3.
4.
5.
portion superieure de cette etiquette.
Reglez le thermostat _.la temperature la plus basse.
Coupez I'alimentation electrique de I'appareil.
Enlever le panneau de porte du rechauffer.
Poussez legerement la manette de commande de
gaz et tournez-la vers la droite jusqu'/-_.
_. la
position "OFF".
ajustement
du
regulateur de pressior_
sortie de pression.
TAP
(sous le capuchon)
entree
I
bouton rouge de
redemarrage
L
....
sortie
de gaz
manette de
commande de gaz
6. Attendre cinq (5) minutes pour laisser echapper tout
le gaz. Reniflez tout autour de I'appareil, y compris
pres du plancher, pour deceler une 'odeur de gaz.
Si vous sentez une odeur de gas, ARRI_TEZ! Passez _. I'etape "B" des instructions de securite sur la
portion sep_rieure (b.gauche) de cette etiquette. S'il
n'y a pas d'odeur de gaz, passer A I'etape suivante.
7. Ouvrez la trappe d'observation
de la chambre
de combustion
situee au-dessus des brGleurs
principaux.
COMMENT
COUPER
Si vous ne pouvez rejoindre le fournisseur, appelez le
service des incendies.
C. Ne poussez ou tournez la manette d'admission du
gaz qu'& la main; ne jamzis utiliser d'outil. Si la manette
reste coincee, ne tentez pas de la reparer; appelez un
technicien qualifie. Le fait de forcer la manette ou de la
reparer peut delencher une explosion ou un incendie.
D. N'utilisez pas cet appareil s'il ete plonge dans I'eau,
m_me partiellement. Faites inspecter I'appareil par un
technicien qualifie et remplacez toute partie du systeme
de contr61e et toute commende qui ont ete plonges dans
I'eau.
D'ALLUMAGE
8. Identifiez la veilleuse,
suivez le tube metallique de la manette de
commade de gaz. La
I
veilleuse
se trouve
entre les deuxtubes de
brOleurs derriere
la
trappe d'observation.
9. Tournez la manette de commande de gaz dans le
sens contraire des aiguilles d' une montre jusqu' _. la
position (Veilleuse).
10. Enfoncez la manette de commande et maintenez-la.
Allumez immediatement
la veilleuse avec des
allumettes. Continuez _. appuyer sur la manette
pendant environ 1 minute apr_s I' allumage de la
veilleuse. Rel&cher la veilleuse et elle reprendra sa
position initiale. La veilleuse doit rester allumee. Si
elle s' eteint, repettez les etapes de 4 _. 9.
*Si la manette ne se soul_ve pas d' elle- m_me
Iorsqu' on la reDche, arr_tez et appelez immediatement le technicien ou le fournisseur de gaz.
*Si la veilleuse ne reste pas allumee apr_s plusieurs
tenatives, tournez la manette de commande de gaz
sur
la position "OFF" et appelez le technicien
ou le fournisseur.
11. Refermez la trappe de la chambre d' observation.
12. Deplacez la manette de commande de gaz vers la
gauche jusqu' fm
_. la position "ON"
13. Rebranchez I' alimentation electrique de I'appareil.
14. R_glez le thermostat & la temperature desiree.
L'ADMISSION
1. Mette le thermostat A la temperature la plus basse.
2. Si un entretien doit _tre effectue, coupez I'alimentation
electrique de I'appareil.
3. Lever le panneau de parte du rechauffer.
veilleuse
DE GAZ DE L'APPAREIL
4. Tourner le bouton de commande de gaz vers
droite, s_,
en position d'arr_t "OFF". Ne pas forcer!
5. Replacer le panneau de parte du rechauffer.
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
OPERATING
INSTRUCTIONS
1.
2.
3.
4.
STOP! Read the safety information above.
Set the thermostat to lowest setting.
Turn off all electric power to the appliance.
This appliance is equipped with an ignition device
which automatically lights the pilot or burner. Do not
try to light the pilot or burner by hand!
5. Remove control access panel.
6. Turn the gas control knob clockwise _
to the
full "OFF" position, on W-R 36C/E push the knob
before turning.
7. Wait five (5) minutes to clear out any gas. Then
PRESSURE REGULATOR
ADJUSTMENT (UNDER
CAP SCREW)
OUTLET PRESS. TAP
.....
_,
GROUND
TERMINALS
Page19
smell for gas, including near the floor. If you smell
gas, STOP! Follow "B" in the safety information
above. If you don't smell gas, go to the next step.
8. Turn the gas control knob counterclock-wise
to "ON".
9.
10.
11.
12.
Replace control access panel.
Turn on all electric power to the appliance.
Set thermostat to desired setting.
If the appliance
will not operate,
follow the
instructions "TO TURN OFF GAS TO APPLIANCE"
and call your service technician or gas supplier.
PRESSURE REGULATOR
ADJUSTMENT(UNDER
CAP SCREW)
OUTLET PRESS. TAP
/
\\
....
GAS INLET
GAS INLET
GROUND
/TERMINALS(2)
(2)
, GAS OUTLET
GAS OUTLET
\,
GAS CONTROL KNOB
GAS CONTROL KNOB
HONEYWELL
VR8304A/P
HONEYWELL
PRESS.
PRESS. REGULATOR
VR8305M/P
REGULATOR
\
GAS OUTLET
GAS
GAS
GAS CONTROL KNOB
SHOWN IN "OFF" POSITION
PILOT FLOW ADJ. SCR.
CONTROL
_ _ _,- '_,F _
KNOB
/
SHOWN IN "ON" POSITION
WHITE RODGERS 36E
TOTURN
INLET
GAS OUTLET
_,
I_
PILOT
FLOW
ADJ.
SCR.
WHITE RODGERS 36C
OFF GASTO
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service
is to be performed.
3. Remove control access panel.
APPLIANCE
4. Turn the gas control knob clockwise
_.
to
"OFF". On W-R controls push the knob in before
turning, don't force it.
5. Replace control access panel.
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Page20
POUR VOTRE S¢:CURITE
LISEZ AVANT DE iVlETTRE EN iVlARCHE
AVERTISSEMENT. Quinconque ne respecte pas a la lettre les instructions dans la pr6sente
notice risque de d6clencher un incendie ou une explosion entraTnant des dommages, des
blessures ou la mort.
A.
2. Cet appareil ne comporte pas de veilleuse. II
est muni d'un dispositif d'allumage qui allume
automatique la brQleur. Ne tentez pas d'allumer
la brGleur manuellement.
AVANT DE FAIRE FONCTIONNER, reniflez tout
autour de I'appareil pour deceler une odeur de
gaz. Reniflez pr6s du plancher, car certains gaz
sont plus Iourds que Fair et peuvent s'accumuler
au niveau du sol.
B,
Appelez immediatement votre fournisseur de gaz
depuis un voisin. Suives les instructions
du
fournisseur.
Si vous ne pouvez rejoindre le fournisseur, appelez
le service de incendies.
1. Cet appareil est muni d'ue veilleuse qui doit 6tre
allumee manuellement. Respectez lis instructions
cidessous _. la lettre.
Ne poussez ou tournez la maneette d'admission
du gaz qu'& la main; ne jamais utiliser d'outil. Si
la manette reste coincee; ne pas tenter de la
r@arer; appelez un technicien qualifie. Le fait de
forcer la manette ou de la reparer peut declencher
une explosion ou un incendie.
C,
N'utilisez pas cet appareil s'il a ete plonge dans
I'eau, m6me partiellement.
Faites inspecter
I'appareil par un tecnicien qualifie et remplacez
toute partie du syst6me de contr61e et toute
commande qui ont ete plonges dans I'eau.
D,
QUE FAIRE Sl VOUS SENTEZ UNE ODEUR DE GAZ
Ne pas tenter d'allumer d'appareil.
Ne touchez _.aucun interrupteur; ne pas vous servir
des tel6phones se trouvant dans le b&timent.
iNSTRUCTiONS
1.
ARRETEZ! Lisez les instructions de securite sur
la portion sup@ieure de cette etiquette.
2.
Mette le thermostat
basse.
3.
Coupez I'alimentation electrique de I'appareil.
4.
Cet appareil est equip_ d'un dispositif d'allumage
automatique la brGleur.
BOUTON
DE GAZ
POSITION
_. la temp@ature
X
7.
la plus
DE COMMANDE
MONTRE EN
D'ARRET---
DE iVlISE EN iVIARCHE
,
Hel IGII IK'moh
_
"OFF"
0
[]
,
Attendre cinq (5) minutes pour laisser echapper
tout le gaz. Reniflez tout autour de I'appareil, y
compris pr6s du plancher, pour deceler une odeur
de gaz. Si vous sentez une odeur de gaz,
ARRETEZ! Passez _. I'etape B des instructions de
s6curite sur la portion sup@ieure de cette
etiquette. S'il n'y a pas d'odeur de gaz, passez _.
I'etape suivante.
Tourner le bouton de commande de gaz vers la
gauche _f--\,
en position de marche "ON".
Replacer le panneau de parte du rechauffer.
10. Retablir toute
chaudiere.
RE_ULATEUR
,
6.
DE
PRESSION
J
Enlever le panneau de parte du rechauffer.
Tourner le bouton de commande de gaz vers la
droite P"_,,
en position d'arr6t "OFF". Ne pas
forcer!
COOPURE
DE L'ARRIVE
1.
Mette lethermostat & latemp@ature la plus basse.
2.
Si un entretien
doit 6tre effectue,
I'alimentation electrique de I'appareil.
3.
Lever le panneau de parte du rechauffer.
I'alimentation
11. Mette le thermostat
desire.
thermostat
electrique
de la
sur le regleage
12. Si I'appareil ne fonctionne pas, voir les instructions
de "COOPURE DE L'ARRIVE DE GAZ A LA
CHAUDIERE" et appeler un technicien reparateur
ou le fournisseur de gaz.
DE GAZ A LA CHAUDIERE
4.
Tourner le bouton de commande de gaz vers la
droite, _,F-_ en position d'arr6t "OFF". Ne pas
forcer!
5.
Replacer le panneau de parte du rechauffer.
coupez
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
BOILER OPERATION
Page21
C. Raise the thermostat at least 5 degrees above the
room temperature. The burners should light.
D. A boiler designed for use with natural gas should
have a manifold gas pressure of 3.5" WC. On an LP
boiler, the manifold pressure should be 10" WC. To
adjust the manifold
gas pressure, remove the gas
valve pressure regulator cap and turn the regulator
screw to obtain the correct pressure.
E. Test the ignition safety shutoff device, turn the gas
control knob on the gas valve to "PILOT". The burners
should go out. Extinguish the pilot and wait 3 minutes.
Turn the gas valve control knob to "ON". There should
be NO gas flow to the main burners with the pilot out! If
gas flow is detected, immediately turn the gas valve
control knob to "OFF" and have the problem corrected.
Should overheating occur orthe gas supply fail to shut off,
do not turn off or disconnect the electrical supply to the
pump. Instead, shut off the gas supply at a location
external to the appliance.
En cas de surchauffe ou si I'alimentation de gaz ne peut
_tre coupee, ne pas couper ni debrancher I'alimentation
electrique de la ponpe.
Fermer plut6t le robinet
d'admission de gaz & I'exterieur de I'appareil..
Do not
water.
inspect
control
water.
use this appliance if any part has been under
Immediately call a qualified service technician to
the appliance and to replace any part of the
system and any gas control that has been under
N'utilisez pas cet appareil s'il a ete plonge dans I'eau,
m_me partiellement. Faites inspecter I'appareil par un
tecnicien qualifie et remplacez toute partie du syst_me de
contr61e et toute commande qui ont ete plonges dans
I'eau.
Continuous Pilot System
A. Connect
a manometer
having
a minimum
capacity of 10" WC to the outlet pressure port of the gas
valve. Make sure that the gas supply piping has been
purged of air and that all gas joints up to the gas valve
have been thoroughly checked for leaks. Wait at least
five minutes for the gas to dissipate before turning on the
electrical power.
B. Read,
understand
and follow
the lighting
instructions contained in this manual that are applicable
to the type of ignition system installed on the boiler.
CAUTION: To prevent being burned, take care not to
touch any hot metal parts. Stand clear of the boiler
during ignition to prevent being burned in the case
of flashback.
Intermittent Ignition Systems
A. Connect a manometer having a minimum capacity
of 10 in, 254 mm, WC to the outlet pressure port of the
gas valve. Make sure that the gas supply piping has
been purged of air and that all gas joints up to the gas
valve have been thoroughly checked for leaks. Wait at
least five minutes for the gas to dissipate before turning
on the electrical power.
B. Read, understand
and follow
the lighting
instructions contained in this manual that are applicable
to the type of ignition system installed on the boiler.
C. Raise the thermostat at least 5 degrees above the
room temperature.
For models equipped with an
intermittent pilot the pilot should light and then the
burners. If a direct ignition system is employed, a delay
of approximately 20 seconds will take place as the
silicon carbide ignitor heats up. Once the ignitor is hot,
the main gas valve will open and the burners should
light. If the burners fail to light the system will make
two more ignition attempts. If the burners light, but go
out within 4 seconds, the system will make three more
ignition attempts. If the burners have not lit after the
last ignition try, the gas valve will close and the system
will go into lock out. DO NOT attempt to reset the
system until the ignition system has been inspected
and the problem resolved. After 5 minutes has passed
since the last ignition attempt, reset the system by
turning the thermostat to it's lowest setting and then
back to where it was. Momentarily interrupting the
electrical power to the boiler will also reset the system.
D. With the burners in operation, close the manual
shutoff valve in the gas supply line. As soon as the
burner flames go out, open the manual shutoff valve. A
normal ignition sequence should take place.
HWNATURAL
ORPROPANE
BOILER
INSTALLATION
ANDOPERATING
INSTRUCTIONS
Page22
E. Withthe burnersin operation,interruptthe power
to the controlcircuit by loweringand raisingthe
thermostat.
Anormalignitionsequence
shouldfollow.
F. Totesttheignitionsafetyshutoffdevice,closethe
manualshutoffvalvein the gassupplyline.Within6
secondsof mainburnerflameextinction,
themaingas
valvesolenoidshouldclosewithanaudiblenoise.
Onintermittent
pilotsystemsa tickingnoiseshouldbe
heardwhilethe ignitionmoduletriesto relightthe pilot.
After1 minutethe moduleshouldlockoutandthe try
forignitionend.
If a directignitionsystemisemployed,
theignitorshould
glow and an attemptat ignition take place. After
unsuccessfully
attempting
to lightthe mainburnersthe
ignitionmoduleshouldlockout.
Openthe manualshutoffvalveinthe gassupplyline.
Resetthe ignitioncontrolsystemby interrupting,
then
restoring electrical power to the boiler. A normal
ignitionsequence
shouldtakeplace.
BOILER CHECKING
& ADJUSTMENT
Pilot Adjustment
The pilot burner flame should envelope 3/8 in, 9.5 mm
to 1/2 in, 13 mm, of the thermocouple
tip or flame
sensing probe, depending on the pilot type. If the pilot
flame is out of adjustment, remove the cap next to the
pilot tube fitting on the gas valve. Turn the pilot
adjustment screw clockwise to decrease the flame,
counterclockwise
to increase it. Figure 18 depicts a
constant pilot, but the adjustment dimensions for an
intermittent pilot would be the same.
Figure 18: Pilot Location
Gas Pressure Adjustment
NATURAL GAS: Optimum results are obtained when
the boiler is operated at its full input rating, with 3.5 in,
89 mm, WC of manifold pressure.
The manifold
pressure should not be more that 5% off this value. The
gas valve pressure regulator has been preset at the
factory. If adjustment is necessary the following steps
must be followed:
1. Attach a manometer to the pressure tap on the gas
valve body.
2. Remove the regulator adjustment screw cap from
the gas valve body.
3. Rotate the regulator adjustment screw clockwise to
increase the manifold pressure, counterclockwise to
decrease it.
4. Replace the regulator adjustment
pressure tap plug.
screw cap and
CAUTION: Never force the regulator adjustment
screw beyond the stop limits or damage to the gas
valve will occur!
PROPANE GAS: A manifold pressure of 10.0 in,
254 mm, WC must be maintained for proper operation of
the boiler. If the manifold pressure is off by more than
5% adjust it according to steps 1 through 4 above.
input Rate
Gas appliances are rated based on sea level operation
with no adjustment required at elevations up to 2000
feet. At elevations above 2000 ft, 610 m, input ratings
should be reduced by 4% for each 1000 ft, 305 m above
sea level. Check the input rate as follows:
1. Turn off all other gas appliances that use the same
gas meter as the boiler.
2. Call your gas supplier and ask for the heating
value of the gas.
3. Start the boiler and let it run for 15 minutes.
4. Using the gas meter and a stop watch, clock the
time that it takes to burn 1 cubic foot of gas. To
increase the accuracy of the time, clock the time
that it takes to burn 10 cubic feet of gas and divide
the time by 10.
5. Insert the heating value and the time, in seconds,
into the formula below.
RATE in = HEATING VALUE (BTU/FT 3) (3600S/HR)
Time (s/ft 3)
- PILOT
BRACKET
EXAMPLE: If: heating value = 1000 BTU/ft 3
time/ft 3 = 18 s/ft3
RATE in = (1000 BTU/ft 3) (3600 s/hr)
18 s/ft 3
RATE in = 200,000 BTU/hr
HW NATURAL OR PROPANE BOILER
INSTALLATION AND OPERATING INSTRUCTIONS
If the computed rate deviates by more than 5% from the
rated input value of the unit adjust the gas valve
pressure accordingly.
DO NOT adjust the manifold
pressure by more than 5%. If a proper rate cannot be
maintained without adjusting the manifold pressure
beyond the 5% limit, the main burner orifices must be
replaced. If the input rate is too low, go to the next lager
size orifices. If the input rate is too high, go to the next
smaller size.
CAUTION: Never increase the input to the boiler
above that for which it is rated. Doing so can cause
premature failure of the boiler!
Low Water Cutoff
If the boiler is equipped with a low water cutoff device
make sure that the main burners will NOT light when the
boiler has no water in it. To check, turn the boiler off,
close the valves in the water supply and return lines and
drain the boiler. If the boiler's main burners light shut the
boiler off immediately and correct the problem.
Thermostat Adjustment
For a thermostat that employs an adjustable
heat
anticipator, adjust the anticipator to match the current
measured in the thermostat
circuit. An increased
anticipator setting may be necessary if the unit cycles
frequently. If the room temperature over-shoots the
thermostat setting, reduce the anticipator setting.
BOILER MAINTENANCE
CAUTION: Servicing,
inspection and adjustment
must be done by a trained technician in accordance
with all applicable local and national codes. Verify
proper operation after servicing. Improper servicing
or adjustment can damage the boiler!
The boiler should be cleaned and inspected once a
year, before each heating season. Make sure that the
burners and ignition components are free from dust,
soot, dirt, corrosion or other deposits that would impair
the boiler's performance. Refer to Replacement Parts
page for component identification.
Page 23
Burner Removal
1. Close the manual shutoff valve in the gas supply
line and turn off electrical power to the boiler.
2. Disconnect the boiler ground joint union, see
Figure 12.
3. Remove the front access panel.
4. Where applicable, disconnect the wires, pilot tube
and thermocouple from the gas valve.
5. Remove the two nuts that retain the manifold
assembly and remove the assembly.
6. The burner support panel has two jacket screws in
it. Remove the screws to free the support panel and
burners.
Burner Installation
1. DO NOT install damaged or badly corroded
burners - replace them.
2. Insert the crimped end of each burner into the
burner base rear panel slots. Carefully slide the
burner support panel over the burner tubes and
studs.
3. Work the manifold assembly into position and
reattach it using the two nuts.
4. Replace the two jacket screws and reconnect all
wires,
tubing and anything
else that was
disconnected during the burner removal operation.
5. Complete
the reassembly
and follow
the
instructions in the BOILER OPERATION section
of this manual.
Heat Exchanger Cleaning
The burners should be removed to protect them from
falling rust and scale. Follow the Burner Removal
instructions in this manual.
1. Disconnect the vent pipe and the stack damper.
2. Remove the front access and top panels.
3. Disconnect the spill switch wires.
4. Remove the two screws from the flue collector
retaining clips. Separate the flue collector from the
heat exchanger.
5. Remove the flue collector.
6. Remove as much of the old flue collector sealant as
possible. Thoroughly clean the flue passages with a
wire brush.
7. Vacuum out the burner base and clean and
inspect all of the components.
Replace any
damaged or badly corroded parts.
8. Reseal the flue collector using Dow Coming #732 or
an equivalent sealant. And install the flue collector
retaining clips and screws.
9. Replace the top panel and reconnect the spill switch
wires and vent system.
10. Follow
the Burner
Installation
procedure
outline in this section.
Page24
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
VentSystem
Thoroughlyinspect
the vent system for any signs of
blockage, corrosion or leakage, immediately replace any
unsound vent system piping.
Controls
Use the BOILER
OPERATION
and BOILER
CHECKING
AND ADJUSTMENT
sections of this
manual as a reference.
1. Check the thermostat for proper operation.
2. if the boiler has been equipped with a low water
cutoff device, L.W.C.O, ensure that it operates
properly. A float type L.W.C.O. should be flushed
out.
3. The relief valve should vent water when the test
lever is lifted. It should not weep or discharge
water at normal system pressure. NEVER try to
clean or repair the relief valve! if the valve fails to
operate properly, replace it!
4. The aquastat high limit controls the maximum
water temperature in the boiler. It is adjustable
from 140°F, 60°Cto 240°F, 116°C. If the water
temperature reaches the set temperature before
the demand for heat has been met, the aquastat
high limit should shut the boiler off. The water
temperature should never exceed the maximum set
point of240°F,
60°C. Theaquastat
high limit
cannot be repaired, if it fails to function properly
replace it.
INSTRUCTIONS
TO THE INSTALLER
This copy of the INSTALLATION AND OPERATING
INSTRUCTIONS should be given to the owner of this
boiler and kept on file.
The INSTALLER must make sure that the owner or
operator has a basic understanding of the following:
1. The lighting instructions,
the type of ignition
system installed and how it operates.
2. What the labels on the boiler say.
3. How to start up and shut off the boiler.
4. How to turn the gas and electrical power on or off.
5. What to do if the boiler shuts down on ignition
system lock out.
6. Where to check the system temperature
and
pressure and what they should be.
7. The importance of reading, understanding
and
following these instructions.
The INSTALLER MUST make sure that the owner
knows to shut the boiler off and call for service if the
following conditions occur:
1. Yellow lazy flames or flames outside the boiler
jacket.
2. Gas smell or other strange odors.
3. Discoloration of boiler or surrounding materials due
to overheating.
4. Water leaking from the heating system piping or
relief valve.
5. Flue products leaking from the vent system into the
living space. Dampness or condensation
in the
building is a good indicator of this condition.
6. The boiler's blocked vent shutoff system is actuated.
7. The boiler's flame roll-out safety system is actuated.
8. Control malfunction or sporadic operation.
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
REPLACEMENT
PARTS
HW SERIES
REPAIR
PARTS
Number
Ref#
1
Name of Part
Part No.
HW-50
Top, Rear, Inner Front and Front Panels
BM-8751
BM-8752
BM-8753
BM-8754
BM-8755
BM-8756
BM-8757
BM-8749
BM-8750
BM-8826
BM-8827
BM-8828
BM-8829
BM-8830
BM-8831
BM-8832
BM-8758
BM-8759
BM-8760
BM-8761
BM-8762
BM-8763
BM-8764
1
2
Left Side Panel
3
4
Right Side Panel
Floor Pan
Page25
Flue Collector/Drafthood
HW-75
of Sections
HW-IO0 HW-125 HW-150 HW-175 HW-200
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
HW NATURAL OR PROPANE BOILER
iNSTALLATiON AND OPERATING iNSTRUCTiONS
Page 26
Number
Ref#
6
7
8
Name of Part
Heat Exchanger/Assembled
Block
Burner
Burner Orifice (#42, NG)
Burner Orifice (#54, LP)
Manifold
10
11
12
13
14
High Limit (L4080B-1253)
Control Center (R8285D-1026)
Spill Switch (262 deg. F) 404257A
Rollout Switch (350 deg. F) 30T15
Vent Damper (5")
Vent Damper (6")
Vent Damper (7")
Vent Damper (8")
Part No.
HW-50
BM-8765
BM-8766
BM-8767
BM-8768
BM-8769
BM-8770
BM-8771
BM-8772
BM-8773
BM-8774
BM-8775
BM-8776
BM-8777
BM-8778
BM-8779
BM-8780
BM-8781
BM-8782
BM-8783
BM-8784
BM-8785
02-5875
1
HW-75
of Sections
HW-100 HW-125 HW-150 HW-175 HW-200
1
1
1
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
7
7
7
8
8
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
02-5876
02-5877
02-5878
1
Vent Damper (9")
Pressure Relief Valve (30 psi)
Temp & Pressure Gauge
02-5879
22-1203
20-1019
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Spark ignition - Honeywell
Ignition Module (S8600M-1013)
Pilot-Ignitor Sensor PSE-NA29 NG & LP*
***For LP also order LP orifice
BM-8786
BM-8787
BM-8788
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Gas Valve (VR8304M-3103) NG & LP**
***For LP also order LP orifice
BM-8789
BM-8790
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-20
Standing Pilot - Honeywell
Thermocouple (K16RA)
Gas Valve (VR8200) NG (HW-50 thru 150) & LP**
***For LP also order LP orifice
BM-8791
BM-8792
BM-8790
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
....
1
1
21
Gas Valve (VR8300) NG Only
Pilot Burner (Q314A-6961)***
***For LP also order LP orifice
BM-8793
BM-8794
BM-8795
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15
16
17
18
19
1
HW NATURAL OR PROPANE BOILER
iNSTALLATiON AND OPERATING iNSTRUCTiONS
CANADIAN
Page 27
SUPPLEMENT
METHOD OF INSTALLATION FOR MOTORIZED VENT DAMPER
METHOSE D'INSTALLATION
POUR LE VOLET MOTORISE DE VENTILATION
The damper must be mounted as close as possible to
the draft hood without modifying the draft hood or
damper device.
Le registre doit _tre installe aussi pros que possible du
coupe-tirage sans qu'une modification de ce coupetirage ou le registre ne soit necessaire.
Attach the lower portion of the vent damper to the draft
hood with 1/2 in, 13 mm or shorter screws or pop rivets.
Attacher la partie inferieure du volet de ventilation au
coupe-tirage & I'aide de vis de 13 mm ou plus courtes
ou des rivets aveugles.
Do not install within 6 in, 152 mm, of combustible
materials. Make sure the motor actuator and position
indicator are readily visible and accessible.
Plug the Molex connector on the damper harness into
the mating plug on the harness located inside the control
compartment.
Determine the amperage draw of the gas control circuit
and damper device. Check heat anticipator in comfort
thermostat to determine that it's properly adjusted.
To manually open the damper, follow instructions inside
the damper cover.
Ne pas installer le registre & moins de 152mm des
materiaux de combustion. S'assurer que dispositif de
commande du moteur est visible et facilement accessible.
Enficher la prise Molex sur le faisceau de ills du volet de
ventilation dans la prise a I'interieur d'armoire
de
commande.
D_terminer I'appel de courant en amperes du circuit du
regulateur de gaz et du registre. Verifier la resistance
anticipatrice de chaleur du thermostat d'ambiance afin
de determiner si elle est correctement reglee.
Pour ouvrir manuellement
le registre suivre les
instructions apparaissant & I'interieur du couverele.
DAMPER MUST BE IN OPEN POSITION WHEN APPLIANCE MAIN
BURNERS ARE OPERATING.
WIRE HARNESS
VENT DAMPER
FOR
LE REGISTRE DOlT €:TRE EN
POSITION OUVERTE LORSQUE
LE BRULEOR PRINCIPAL EST EN
MARCHE.
FAISCEAU
DE FILLS DU
VOLET DE VENTILATION
POSITION INDICATOR
DISPOSITIF DE COMMANDE
/
/
CLOSED
CLOS
PEN
_
CONNECT
BRANCHER
WIRE HARNESS
LE FAISCEAU
DU FILLS
OUVERTE
FLOW DIRECTION
SENS DE DEBIT
i
LiMiTED LiFETiME WARRANTY
FOR RESiDENTiAL WATER BOILERS
Page28
This warranty statement is effective for all units manufactured after December 15, 1992 and supersedes all other warranties,
including those contained in other documents which might be included with this merchandise. This warranty applies only to the
original homeowner at the original place of installation.
First Through Tenth Year
Hydrotherm warrants that the cast iron sections of its residential water boiler for Hydrotherm were free of defects in material and
workmanship when shipped, and will remain free of defects under normal usage from the date of original installation, for a period of
ten years. In the event that the cast iron section is found to be defective in material or workmanship during this period, Hydrotherm
will repair or replace, at its option, the defective section.
Eleventh Year and Above
Hydrotherm warrants that the cast iron sections of its residential water boilers will remain free of defects in material and workmanship
under normal usage for the lifetime of the original owner at the original place of installation. Should any sections be found to be
defective, Hydrotherm will repair or replace, at its option, the original cast iron sections upon the payment of a proportionate charge
based on the time the defective section was in service. The proportionate charge will be equal to the appropriate percentage of the
retail price of the section at the time the warranty claim is made, determined as follows:
Year
% of
Retail Price
1lth
12th
13th
14th
15th
16th
17th
18th
19th
20th
21 st
23nd
24th
25th & above
5
10
15
20
25
30
35
40
45
50
55
60
65
75
Procedure for Obtaining Warranty Service
The homeowner should perform the following in order to insure prompt warranty service:
1. Notify the installer, who in turn should notify the distributor, promptly upon discovery of a condition believed to be caused by a
defect in manufacture. Failing this, the owner should notify Hydrotherm, 260 North Elm St., Westfield, MA 01085 in writing, giving
full particulars in support of the claim.
2. Make available for inspection to Hydrotherm or its representative the parts alleged to be defective, and if requested by
Hydrotherm, ship said parts prepaid to Hydrotherm, 47 Westfield Industrial Park Road, Westfield, MA 01085 for inspection or
repair.
3. The homeowner is required to complete and mail the Warranty card attached hereto within ten days after the installation of the
boiler before coverage under the Warranty commences.
Exceptions and Exclusions
1. This Warranty covers cast iron boiler sections only. Other cast iron parts such as but not limited to grates and grate parts are
specifically not warranted. The burner, jacket, controls and other auxiliary equipment furnished by Hydrotherm, but purchased
from others shall be limited to that manufacturer's warranty, if any.
2. This Warranty does not include expenses for removal or re-installation. The user will be responsible for the cost of replacement of
the defective part and labor and material necessary to the exchange. Replacement material will be invoiced to the Distributor in
the usual manner and will be subject to adjustment upon proof of defect.
3. Nothing herein shall be construed as a guaranty of workmanship of any installer in installing Hydrotherm boilers, or as imposing on
the Company any liability of any nature for unsatisfactory performance caused by faulty workmanship in installation, which liability
is expressly disclaimed.
4. This Warranty will not apply if the boiler is structurally altered; is used or operated at over its rated capacity; or is not maintained
in accordance with Hydrotherm's recommendations or the accepted good practice of the industry as defined by the Hydronics
Institute, A.S.M.E. or other accepted authority.
5. This Warranty will not apply if the boiler has been damaged a result of: fire or other casualties; flooding or exposure to the
elements; settlement, distortion, collapse or cracking of any foundation area, beams or pipes surrounding the boiler; improper
or negligent installation, service or operation (including but not limited to the following - operated with insufficient water, allowed
to freeze; subject to flood conditions; or operated with water conditions and/or fuels or additives which have caused unusual
deposits or corrosion in or on the cast sections).
6. This Warranty applies only to boilers installed within the United States and Canada.
7. In order for this Warranty to be effective:
A. The boiler must have been properly installed in a single or two-family residential dwelling. Warranty does not apply to boilers
installed in apartments, commercial or industrial installations.
B. The boiler must have been assembled in strict accordance with Hydrotherm installation instructions furnished with the boiler.
C. Boiler sections must not have been damaged in handling during shipment or installation. The determination of damage in
handling or installation is a considered judgement of Hydrotherm and decision shall be final.
D. The boiler must have been serviced annually by a licensed contractor and proof of such service must be provided with warranty
claim. This service must include but is not limited to fireside cleaning and proper burner adjustment with combustion testing.
8. In no case shall Hydrotherm's liability exceed the original selling price of the product found to be defective.
9. THIS WARRANTY IS IN LIEU OF ALL EXPRESS WARRANTIES OF ANY KIND. THE REMEDIES UNDER THIS WARRANTY
ARE EXCLUSIVE AND HYDROTHERM NEITHER ASSUMES NOR AUTHORIZES ANYONE TO ASSUME FOR IT ANY
OTHER OBLIGATIONS. IN NO EVENT SHALL HYDROTHERM BE LIABLE UNDER THIS WARRANTY OR OTHERWISE IN
ANY MANNER FOR ANY INCIDENTAL, REMOTE OR CONSEQUENTIAL DAMAGES RESULTING FROM BREACH OF THIS
WARRANTY
OR CONDITION
IMPLIED BY LAW OR OTHERWISE,
INCLUDING
ANY IMPLIED WARRANTY
OF
MERCHANTABILITY OR FITNESS, FOR A PARTICULAR PURPOSE. SOME STATES DO NOT ALLOW THE EXCLUSION
OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY
NOT APPLY TO YOU.
10. This Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Page 29
Any appliance that burns natural gas, propane gas, fuel oil, wood or coal is capable of producing
monoxide (CO).
carbon
Carbon Monoxide (CO) is a gas which is odorless, colorless and tasteless but is very toxic.
If your Hydrotherm boiler is not working properly, or is not vented properly, dangerous levels of CO may
accumulate. CO is lighter than air and thus may travel throughout the building. BRIEF EXPOSURE TO NIGH
CONCENTRATIONS OF CO, OR PROLONGED EXPOSURE TO LESSER AMOUNTS OF CO MAY RESULT iN
CARBON MONOXIDE POiSONiNG.
EXPOSURE CAN BE FATAL AND EXPOSURE TO HiGH CONCENTRATIONS
SUDDEN ONSET OF SYMPTOMS iNCLUDiNG UNCONSCIOUSNESS.
MAY RESULT
iN THE
Symptoms of CO poisoning include the following:
dizziness
headaches
nausea
vision problems
loss of muscle control
weakness
shortness of breath
unclearthinking
unconsciousness
The symptoms of CO poisoning are often confused with those of influenza, and the highest incidence of poisoning
occurs at the onset of cold weather or during flu season. A victim may not experience any symptoms, only one
symptom, or a few symptoms. Suspect the presence of carbon monoxide if symptoms tend to disappear when
you leave your home.
The following signs may indicate the presence of carbon monoxide:
Hot gases from appliance, venting system, pipes or chimney, escaping into the living space.
Flames coming out around the appliance.
Yellow colored flames in the appliance.
Stale or smelly air.
The presence of soot or carbon in or around the appliance.
Very high unexplained humidity inside the building.
If any of the symptoms of CO poisoning occur, or if any of the signs of carbon monoxide are present, VACATE
THE PREMISES iMMEDiATELY AND CONTACT A QUALiFiED HEATING SERVICE COMPANY OR THE GAS
COMPANY OR THE FiRE DEPARTMENT.
To reduce the risk of CO poisoning, have your heating system "tuned up" by a licensed heating contractor or the
gas company -- preferably before each heating season. Also have the service company check your chimney or
vent pipes for blockage.
Your home should also be adequately ventilated, particularly if you have insulated your home.
ONLY QUALIFIED,
SHOULD PERFORM
LICENSED
SERVICE
CONTRACTORS
WORK ON YOUR HYDROTHERM
BOILER.
Install, operate and maintain unit in accordance with manufacturer's instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness. The State of
California has determined that these substances may cause cancer, birth defects, or other reproductive harm.
Also, install and service this product to avoid exposure to airborne particles of glasswool fibers and/or ceramic
fibers known to the State of California to cause cancer through inhalation.
Page30
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
HWNATURAL
ORPROPANE
BOILER
iNSTALLATiON
ANDOPERATING
iNSTRUCTiONS
Page31
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LP BH_I_
in Canada: 5211 Creekbank
2°°.o.T.E.M
ST.EET
WESTF,E.O,
MA
OlO_
TEL. (413) 564=5515 FAX (413) 568=9613
Road, Mississauga, Ont. L4W 1 R3 (905) 625=2991 Fax (905) 625=6610
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