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This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these in-
structions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of
the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation with
contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualified
service technician, and to follow all guidelines in the User' s Information Manual.
HWX
Gas-Fired Residental Boilers
Models 70-195 – Water Only
Boiler Manual
Installation and
Operation Instructions
HWX2-0114
22-HWX2
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Summary of Contents for ATH HWX Series
- Page 1 HWX2-0114 All manuals and user guides at all-guides.com 22-HWX2 Gas-Fired Residental Boilers Models 70-195 – Water Only Boiler Manual Installation and Operation Instructions This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler.
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Page 2: Table Of Contents
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS TABLE OF CONTENTS USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE A. INSTALLATION SEQUENCE ..... . .2 Follow the installation instructions provided in this B. -
Page 3: Preinstallation
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 1. PREINSTALLATION Read carefully, study these instructions before beginning work. This boiler must be installed by a qualified contractor. The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly. NOTICE The equipment must be installed in accordance with those installation requirements of the authority having jurisdiction or, in the absence of such requirements, to the current edition of the National Fuel Gas Code , ANSI... -
Page 4: Air For Combustion And Ventilation
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 3. Indoor Air Opening Size and Location: Openings C. AIR FOR COMBUSTION AND connecting indoor spaces shall be sized and located VENTILATION as follows: a. Combining spaces on the same floor: 1. - Page 5 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 4. Outdoor Combustion Air: Outdoor combustion air is ii. Where communicating with the outdoors to be provided through one or two permanent through horizontal ducts, each opening shall openings. The minimum dimension of these air have a minimum free area of 1 in per 2000 openings is 3 inches (76 mm).
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Page 6: Planning The Layout
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 5. Combination Indoor and Outdoor Combustion Air: If iii. Nonmotorized dampers shall be fixed in the the required volume of indoor air exceeds the open position. available indoor air volume, outdoor air openings or ducts may be used to supplement the available b. -
Page 7: Boiler Set-Up
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 2. BOILER SET-UP 1. Provide a sound, level foundation. Locate boiler as 4. Separate the wood shipping pallet from the boiler near to the chimney or outside wall as possible and base by removing two (2) hold-down bolts at each centralized with respect to the heating system. -
Page 8: Safety Relief Valve
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 5. Install this boiler so that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacements, etc.). 6. -
Page 9: Piping For Zoned Systems
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS C. PIPING FOR ZONED SYSTEMS 1. See Figures 3.5 and 3.6 for basic zoned system layouts. 2. Run each zone pipe down then up to zone to prevent air accumulation in piping. 3. -
Page 10: Expansion Tank
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS D. EXPANSION TANK FREEZE PROTECTION For new or existing systems that must be freeze- 1. Consult the tank manufacturer’s instructions for protected: specific information relating to tank installation. Size the expansion tank for the required system volume WARNING and capacity. -
Page 11: Venting
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 4. VENTING A. INTEGRAL DRAFT HOOD B. VENT DAMPER INSTALLATION – GENERAL 1. The boiler is equipped with a built-in draft hood. This device is designed to: 1. Do not use one vent damper to control two or more heating appliances. -
Page 12: Vent Piping And Chimney
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 4. Before connection of joints, inspect the vent pipe C. VENT PIPING AND CHIMNEY interior for foreign objects such as tools, equipment, rags, etc. and remove if present. 1. Install vent piping in accordance with Venting of Equipment part of the National Fuel Gas Code, 5. -
Page 13: Boiler Removal From Common Venting System
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS d. Place in operation the appliance being inspected. D. BOILER REMOVAL FROM COMMON Follow the lighting instructions. Adjust thermostat so VENTING SYSTEM appliance will operate continuously. At the time of removal of an existing boiler, follow these Mettre en service l’appareil à... -
Page 14: Gas Piping
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 5. GAS PIPING 1. Size and install the gas supply piping properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the meter and the boiler. - Page 15 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Table 5.1: Natural Gas Input Size Cubic Feet / Hour Cubic Meters / Hour Table 5.2: LP Gas Input Size Cubic Feet / Hour Cubic Meters / Hour Table 5.4: Pipe Capacity Capacity of pipe of different diameters and lengths in cubic feet per hour [cubic meter per hour] with a pressure drop of 0.3 inches of water (75 Pa) and specific gravity of 0.60.
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Page 16: Electrical
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 6. ELECTRICAL Install all electrical wiring in accordance with the National Electrical Code and local requirements. NOTICE This unit when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the current edition of the National Electrical Code , ANSI/NFPA 70 and/or the Canadian Electrical Code , Part 1 CSA C22.1, Electrical Code. - Page 17 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS...
- Page 18 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS...
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Page 19: Sequence Of Operation
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS D. SEQUENCE OF OPERATION Figure 6.4: Intermittent Ignition System Operating Sequence... -
Page 20: Start-Up Procedures
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 7. START-UP PROCEDURES A. COMPLETING THE INSTALLATION 1. Confirm that all water, gas and electricity are turned off. 2. Inspect the boiler combustion chamber for foreign objects and remove if present. 3. - Page 21 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Figure 7.3: Operating Instructions...
- Page 22 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Figure 7.4: Operating Instructions...
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Page 23: Control Descriptions
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS B. CONTROL DESCRIPTIONS D. CHECKING BURNER INPUT See Figure 6.1 in Section 6 (Electrical) for locations of 1. Refer to rating label mounted on the jacket top panel these devices. to obtain the rated BTU per hour input. -
Page 24: Check-Out Procedure
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Table 7.1b: Meter Conversion – Natural Gas 3. Low Water Cut-Off (if used) – Consult the (SI Metric Units) manufacturer’s instructions for the low water cut-off operational check procedure. Burner inputs in kW for for various meter timings and heat values. -
Page 25: Troubleshooting
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 8. TROUBLESHOOTING DANGER A. SHUT-DOWN CAUSED BY PILOT OUTAGE, BLOCKED VENT SHUT-OFF When servicing or replacing items that communicate SWITCH OR FLAME ROLL-OUT SAFETY with the boiler water, be certain that: SHUT-OFF SWITCH There is no pressure on the boiler. - Page 26 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Table 8.1: Boiler Troubleshooting Guide PROBLEM POSSIBLE CAUSES CORRECTIVE ACTIONS Burners not functioning. 1. No power. 1. Check line voltage wiring and fuses. 2. Limit not working. 2. Check wiring and contacts, relay, temperature setting.
- Page 27 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS START BEFORE TROUBLESHOOTING, NOTE: “CALL FOR HEAT” 24 VAC SUPPLY IS CONNECTED TO THE 24 V TERMINAL ON THE CONTROL. FAMILIARIZE YOURSELF WITH THE STARTUP AND CHECKOUT PROCEDURES. TURN GAS SUPPLY OFF, TURN THERMOSTAT (CONTROLLER) TO “CALL FOR HEAT.”...
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Page 28: Maintenance
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 9. MAINTENANCE WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers (RCF). Airborne RCF, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. -
Page 29: General
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS A. GENERAL D. MONTHLY (WITH BOILER IN USE) 1. Disconnect this boiler from the gas supply piping 1. Check boiler room floor drains for proper during any pressure testing of the gas system. functioning. - Page 30 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS c. Remove burners and brush orifice spuds lightly using a soft bristle brush. d. Remove the vent pipe, vent damper, top jacket panels and flue collector/draft diverter. e. Brush flueways with wire brush. f.
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Page 31: Boiler Dimensions & Ratings
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 10. BOILER DIMENSIONS & RATINGS Figure 10.1: Boiler Views Table 10.1: Boiler Dimensions BOILER DIMENSIONS Jacket Rear of Jacket Left of Jacket Vent Size Diame- Length (Depth) Width Height to c/l of Vent to c/l of Vent “A”... -
Page 32: Repair Parts
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS 11. REPAIR PARTS REPAIR PARTS Note: Remember to include boiler model number and serial number when ordering parts. Figure 11.1: Base/Combustible Floor Pan Table 11.1: Base/Combustible Floor Pan Quantity Stock Description Required... -
Page 33: Manifold, Gas Valve & Pilot
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Figure 11.2: Manifold Figure 11.3: Gas Valve and Pilot (Intermittent Ignition) - Page 34 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Table 11.2: Manifold, Gas Valve and Pilot Quantity Stock Description Required Code Steel Burner – 70 51537 Steel Burner – 105 51537 Steel Burner – 140 51537 Steel Burner – 175 51537 Steel Burner –...
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Page 35: Block/Draft Hood & Jacket
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Figure 11.4: Block/Draft Hood Figure 11.5: Jacket... - Page 36 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Table 11.3: Block/Draft Hood & Jacket Quantity Stock Description Required Code Block Assembly – 70 – 90419 Block Assembly –105 – 90420 Block Assembly – 140 – 90421 Block Assembly – 175 –...
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Page 37: Controls/Circulator/Vent & Damper
All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Figure 11.6: Controls/Circulator/Vent Damper... - Page 38 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS Table 11.4: Controls/Circulator/Vent Damper Quantity Stock Description Required Code Limit Beckett 7600B – 50335 Well Beckett 7600TW03B – 50341 Sensor Beckett 7600P06B – 50339 Limit w/ Sensor Hydrolevel 3200 –...
- Page 39 All manuals and user guides at all-guides.com INSTALLATION AND OPERATING INSTRUCTIONS...
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Page 40: Lifetime Limited Warranty
All manuals and user guides at all-guides.com LIFETIME LIMITED WARRANTY Residential Cast Iron Water Boilers First Through Tenth Year The “Manufacturer” warrants to the original owner at the original installation site that the cast iron sections of the Residential Cast Iron Water Boilers (the “Product”) will be free from defects in material or workmanship for ten (10) years from the date of installation.
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