HydroTherm HV-100, Installation & Operating Instructions Manual

Page 1: ...TED ACCORDING TO A S M E BOILER AND PRESSURE VESSEL CODE SECTION IV FOR MAXIMUM ALLOWABLE WORKING PRESSURE OF 50 PSI 345 kPa WATER NOTE TO INSTALLING CONTRACTOR READ THESE INSTRUCTIONS CAREFULLY THEY WILL SAVE YOU TIME IN ASSEMBLING BOILER PROPERLY INSTALLER THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES 260 NORTH ELM STREET...

Page 2: ...r Maintenance 20 Instructions to the Installer 21 Replacement Parts 22 Health Warnings 24 BEFORE YOU START WARNING This manual must be read and fully understood before installing operating or servicing this boiler Failure to follow these instructions could result in a fire or explosion causing extensive property damage personal injury or death These instructions cover the HV gas fired induced draf...

Page 3: ...ate fresh air for combustion 3 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 install this boiler on carpeting 4 Do not install this boiler in a location that would subject any of the gas igni...

Page 4: ... are squarely under the boiler base side panels Carfully slide the boiler and base into position Center the boiler from side to side and 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 boiler installation in accordance with the instructions set forth in this manual C...

Page 5: ...al Vent in mm in mm in mm in mm HV 50 107 8 276 27 16 62 4 102 4 102 HV 75 135 8 346 313 16 97 4 102 4 102 HV 100 163 8 416 53 16 132 4 102 4 102 HV 125 191 8 486 69 16 167 5 127 4 102 HV 150 217 8 556 715 16 202 5 127 4 102 GAS VALVE TEMP CONTROL JUNCTION BOX CONTROL CENTER INDUCER RELAY FRONT VIEW A 2 11 16 2 11 16 FLAME ROLL OUT SWITCH 6 1 2 B 6 3 4 13 1 4 27 5 8 5 5 8 13 1 2 11 1 2 30 GAS INLE...

Page 6: ... for proper size and horizonal pitch and determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition Inspecter de façon visuelle le système d évacu ation pour déterminer la grosser et l inclinaison horizontale qui conviennent et s assurer que le système est exempt d obstruction d étranglement de fruite de corrosion et autres déf...

Page 7: ...s registres de cheminées et les appareils au gaz à leur position originale 7 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...

Page 8: ...passes through the roof In addition the vent pipe must be at least 2 ft 0 6 m higher than any portion of the building within a horizontal distance of 10 ft 3 m Single Wall Metal Vent HV boilers may be vented vertically using single wall metal vent pipe sized per Table 1 Galvanized sheet metal pipe must have a minimum wall thickness of 26 gauge In Canada pipe constructed of 025 in 0 63 mm thick alu...

Page 9: ...from front to back and from side to side Use metal shims to level the boiler Never use combustible materials for shims CAUTION To prevent damage due to excessive conden sation one of the following piping options should be used OUTSIDE WALL THIMBLE VENT SYSTEM 8 BOILER 18 MIN 4 MIN HORIZONTAL VENTING Horizontal vent systems must be in compliance with UL 1738 for installations in the United States U...

Page 10: ...ow has been reduced In most cases the standard pump packaged with the boiler has enough capacity to feed the baseboard distribution system and the bypass line FIG NO 6 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 FIG NO 7 Full temperature water supplies the baseboard distribution sy...

Page 11: ...tly 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 SUPPLY R...

Page 12: ...ly 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 sediment trap drip leg 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 us...

Page 13: ... 1 Canadian Electrical Code Part I if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler A shut off switch should be located at the boiler The boilermust be grounded in accordance with the authority having jurisdiction or if none the latest edition of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of controls and other devices must conform to the tem...

Page 14: ...FIG NO 13 Fenwal Honeywell Hot Surface Ignition Page 14 ...

Page 15: ...W 1 3 BK R8285D FIG NO 15 Multi Zone Diagram FIG NO 16 Multi Zone Diagram LINE VOLTAGE LOW VOLTAGE CIRCULATOR ZONE 1 R8230B ZONE 1 THERMOSTAT CIRCULATOR ZONE 2 R8230B ZONE 2 THERMOSTAT CIRCULATOR ZONE 3 R8230B ZONE 3 THERMOSTAT 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED 2 AS MANY AS FOUR R8230B RELAYS MAY BE POWERED BY THE R8285A ADDITIONAL GROUPS OF 4 REQUIRE AN ADDITIONAL TRA...

Page 16: ... information on previous page 2 Set the thermostat to lowest setting 3 Turn off all electric power to the appliance 4 This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand 5 Remove control access panel 6 Turn the gas control knob clockwise to the full OFF position on the White Rodgers 36E push the knob before turning it 7 Wa...

Page 17: ...N utilisez pas cet appareil s il a été plongé dans l eau même partiellement Faites inspecter l appareil par un tecnicien qualifié et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l eau 1 ARRÊTEZ Lisez les instructions de sécurité sur la portion supérieure de cette étiquette 2 Mette le thermostat à la température la plus basse 3 Coupez l alimentation élect...

Page 18: ...olenoid should close with an audible noise The ignitor should glow and an attempt at ignition take place After unsuccessfully attempting to light the main burners the ignition module should lock out Open the manual shutoff valve in the gas supply line Reset the ignition control system by interrupting then restoring electrical power to the boiler A normal ignition sequence should take place BOILER ...

Page 19: ...HECKING ADJUSTMENT 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 pr...

Page 20: ...re to properly inspect the vent system on a regular basis may leave problems undetected that can result in excessive levels of carbon monoxide which can cause severe personal injury or death BOILER MAINTENANCE WARNING The ceramic combustion chamber in the burner box and its gasket contain crystalline silica Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and ...

Page 21: ...E INSTALLER The installer must give this copy of the INSTALLATION AND OPERATING INSTRUCTIONS to the boiler owner and 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 po...

Page 22: ... Sections Ref Name of Part Part No HV 50 HV 75 HV 100 HV 125 HV 150 1 Top Rear Inner Front and Front Panels BM 8796 1 BM 8797 1 BM 8798 1 BM 8799 1 BM 8800 1 2 Left Side Panel BM 8749 1 1 1 1 1 3 Right Side Panel BM 8750 1 1 1 1 1 4 Floor Pan BM 8826 1 BM 8827 1 BM 8828 1 BM 8829 1 BM 8830 1 ...

Page 23: ...1 14 High Limit L4080B 1253 BM 8782 1 1 1 1 1 15 Control Center R8285D 1026 BM 8783 1 1 1 1 1 16 Roll Out Switch 262 deg F 404257A BM 8784 1 1 1 1 1 17 Pressure Switch Set 0 45 W C BM 8810 1 1 Pressure Switch Set 0 51 W C BM 8811 1 Pressure Switch Set 0 58 W C BM 8812 1 Pressure Switch Set 0 65 W C BM 8813 1 18 Pressure Relief Valve 30 psi 22 1203 1 1 1 1 1 19 Temp Pressure Gauge 20 1019 1 1 1 1 1...

Page 24: ...es 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 CO poisoning occur or if any of the signs of carbon monoxide are present vacate the premises imme diately and contact a qualfied heating service company the gas company or th...