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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.
VGX
Gas-Fired Residental
Boilers
Models 88-288 – Steam Only
Boiler Manual
Installation and
Operation Instructions
VGX2-213
22-VGX2
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Summary of Contents for HydroTherm VGX 88
- Page 1 VGX2-213 22-VGX2 Gas-Fired Residental Boilers Models 88-288 – Steam 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. Install, start and service the boiler only in the sequence and methods given in these in- structions.
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Page 2: Table Of Contents
INSTALLATION AND OPERATING INSTRUCTIONS MAINTENANCE TABLE OF CONTENTS A. GENERAL ........26 B. -
Page 3: Preinstallation
INSTALLATION AND OPERATING INSTRUCTIONS 1. PREINSTALLATION A. GENERAL C. ACCESSIBILITY CLEARANCES The boilers are supplied completely assembled as The following recommendations allow for reasonable packaged boilers. All items should be inspected for access to the boiler. Local codes or special conditions damage upon receipt and any damage reported to may require greater clearances. -
Page 4: Air Combustion And Ventilation
INSTALLATION AND OPERATING INSTRUCTIONS a. Combining spaces on the same floor: E. AIR FOR COMBUSTION AND Provide two permanent openings communicating VENTILATION with additional spaces that have a minimum free area of 1 in per 1000 Btu/hr (22 cm per 1000 W) 1. - Page 5 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
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 Placement & Assembly
INSTALLATION AND OPERATING INSTRUCTIONS 2. BOILER PLACEMENT & ASSEMBLY A. PACKAGED BOILER NOTICE 1. Remove the crate top and sides and remove any Be careful not to damage the burner tray when loose cartons. removing the boiler from the pallet. If necessary, remove the burner tray before moving the boiler. -
Page 8: Boiler Removal From Common Venting System
INSTALLATION AND OPERATING INSTRUCTIONS Figure 3.1: Venting Multiple Appliances a. Seal any unused openings in the common venting system. Sceller toute ouverture du système d’évacuation commun non utilisée. b. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition. - Page 9 INSTALLATION AND OPERATING INSTRUCTIONS d. Place in operation the appliance being inspected. g. Any improper operation of the common venting Follow the lighting instructions. Adjust thermostat so system should be corrected so that the installation conforms with the current edition of the National appliance will operate continuously.
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Page 10: Boiler Piping
INSTALLATION AND OPERATING INSTRUCTIONS 4. BOILER PIPING Use Threaded Fittings for Manifold Piping A. STEAM BOILER PIPING – SINGLE BOILERS 1. Install steam supply pipes as shown in Figure 4.3. The minimum quantity and size of supply pipes are indicated in Table 4.1. Use Threaded Fittings for Manifold Piping Figure 4.4: Steam Piping –... -
Page 11: Steam Boiler Indirect Water Heater Piping
INSTALLATION AND OPERATING INSTRUCTIONS 5. The use of a Hartford Loop in all installations is B. STEAM BOILER INDIRECT WATER recommended to ensure reliability of the system. A HEATER PIPING check is required on the pump discharge of all pumped return systems. 1. -
Page 12: Fuel Piping
INSTALLATION AND OPERATING INSTRUCTIONS 5. FUEL PIPING Table 5.1: Gas Input & Valve Inlet A. INSTALLATION Gas Input (CFH) Gas Valve Inlet (NPT) 1. Pipe gas to the boiler in accordance with local codes. Size Nat. Gas LP Gas Nat. Gat LP Gas In the absence of local regulations refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54. -
Page 13: Controls & Trim
INSTALLATION AND OPERATING INSTRUCTIONS 5. Refer to table 5.4 for minimum supply pressure for 6. Install the boiler such that the gas ignition system the purpose of input adjustment. components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap Table 5.4: Minimum Supply clean out, control replacement, etc.) - Page 14 INSTALLATION AND OPERATING INSTRUCTIONS 3. Low Water Cut-off (Level Control): 5. Pressure Gauge: a. Float Type: Install the float type low water cut- a. Install the operating limit control and pressure off (if provided) in conjunction with the gauge gauge in the 3/4" tappings located on the right glass as shown in Figure 6.3.
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Page 15: Electrical
INSTALLATION AND OPERATING INSTRUCTIONS 7. ELECTRICAL A. CONNECT SUPPLY WIRING B. MOUNT REMAINING CONTROLS 1. All electrical wiring must be done in accordance with 1. Steam Boilers – Mount the control transformer on local codes. In the absence of local codes use the junction box as shown in Figure 7.1. -
Page 16: Install Control Wiring
INSTALLATION AND OPERATING INSTRUCTIONS 2. Mount the blocked vent switch in the rear of the 4. Mount the ignition module as shown in Figure 7.4. boiler on the draft hood as shown in Figure 7.2. Figure 7.4 C. INSTALL CONTROL WIRING Figure 7.2 1. - Page 17 INSTALLATION AND OPERATING INSTRUCTIONS...
- Page 18 INSTALLATION AND OPERATING INSTRUCTIONS...
- Page 19 INSTALLATION AND OPERATING INSTRUCTIONS...
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Page 20: Boiler Operation
INSTALLATION AND OPERATING INSTRUCTIONS 8. BOILER OPERATION d. The control will spark for 90 seconds (trial for A. SYSTEM INSPECTION ignition), then shut down for a 5 to 6 minute wait 1. Confirm that all water, gas, and electricity are period before attempting another ignition. -
Page 21: Controls Check
INSTALLATION AND OPERATING INSTRUCTIONS WARNING d. NOTE: If the pressure is adjusted to set the nameplate input to the boiler, do not set it more than 0.3 inches plus or minus from the specified Cleaning the boiler requires the use of very hot water settings. -
Page 22: Boiler Shut-Down
INSTALLATION AND OPERATING INSTRUCTIONS CAUTION H. TO SHUT DOWN THE BOILER Before servicing the boiler: 1. Open main line power disconnect switch to boiler. • Turn off all electrical power to the boiler. 2. Close Main and Pilot gas shut-off valves. •... -
Page 23: To Turn Off Gas To Appliance
INSTALLATION AND OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. A. This appliance is equipped with an ignition device Immediately call your gas supplier from a which automatically lights the pilot. - Page 24 INSTALLATION AND OPERATING INSTRUCTIONS Figure 8.3:...
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Page 25: Maintenance
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 fibers, when inhaled, have been classified by the International Agency for Research on Cancer (IARC), as a possible carcinogen to humans. After the RCF materials have been exposed to temperatures above 1800°F, they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans. -
Page 26: General
INSTALLATION AND OPERATING INSTRUCTIONS A. GENERAL D. MONTHLY MAINTENANCE (WITH BOILER OPERATING) 1. Disconnect this boiler from the gas supply piping during any pressure testing of the gas system. 1. Check boiler room floor drains for proper functioning. 2. Check pipes adjacent to cold walls or in unheated spaces. -
Page 27: As Required Maintenance
INSTALLATION AND OPERATING INSTRUCTIONS d. Remove the vent pipe, vent damper, top jacket 2. Inspect entire venting system for corrosion, support panels and flue collector. and joint integrity. Repair as necessary. e. Brush flueways with wire brush. 3. Check the pilot and main burner flame. See Figure f. -
Page 28: Troubleshooting
INSTALLATION AND OPERATING INSTRUCTIONS 10. TROUBLESHOOTING – SERVICE TIPS Table 10.1: Boiler Troubleshooting Problem Possible Cause Suggested Remedy Heavy Draft Blowing across Pilot Redirect Air Movement or Eliminate Plugged Pilot Orifice Replace Orifice Check Manual Pilot Valve Pilot Outage Check Main Gas Shut-Off Valve No Gas Check Manual Meter Valve Consult Gas Company... -
Page 29: Installation And Operating Instructions
INSTALLATION AND OPERATING INSTRUCTIONS Table 10.1 (cont’d): Boiler Troubleshooting Problem Possible Cause Suggested Remedy Sags in Steam Piping or not enough Pitch Correct Piping Condition Concentric reducers causing condensate pooling Correct Piping Drip trap failed closed Replace Trap or Trap Element Water Hammer On Start-Up (Steam Boilers) Dry returns wetted due to new boiler water line... - Page 30 INSTALLATION AND OPERATING INSTRUCTIONS Table 10.1 (cont’d): Boiler Troubleshooting Problem Possible Cause Suggested Remedy Install Boiler Feed System with Receiver Tank New boiler water content smaller than old boiler Large enough for Condensate Boiler water feed rate or pump rate too fast System or Boiler Overfilling or Flooding causing water level to collapse (due to collapse of Reduce Feed Rate...
- Page 31 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 32: Boiler Dimensions & Ratings
INSTALLATION AND OPERATING INSTRUCTIONS 11. BOILER DIMENSIONS & RATINGS Figure 11.1: Dimensions and Tapping Locations Table 11.1: Tapping Sizes & Functions Tap ID Size NPT Steam 1-1/4" Skim Tapping 1" Tank Supply/Limit 1" Tank Return 3/4" Boiler Drain 3" Supply 2-1/2"... - Page 33 INSTALLATION AND OPERATING INSTRUCTIONS Table 11.3: Boiler Ratings Water Approx. Heating Capacity³ Net Ratings¹ AFUE² Content Shipping Steam, Weight, Boiler Input, Steam, Steam, Steam, Steam, Sizes sqft 88.5 83.0 118.0 82.6 147.5 82.6 10.8 177.0 82.4 10.8 206.5 82.3 12.4 236.0 82.2 12.4...
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Page 34: Repair Parts
INSTALLATION AND OPERATING INSTRUCTIONS 12. REPAIR PARTS Note: Remember to include boiler model number and serial number when ordering parts. Figure 12.1... - Page 35 INSTALLATION AND OPERATING INSTRUCTIONS Table 12.1 Quantity Stock Quantity Stock Description Description Required Code Required Code Pilot Assembly NAT Intermediate Section – w/out Draw Lugs – 90028 – 50558 Honeywell Q348A-1002 Right Hand Section – 90030 Pilot Assembly LP – 51814 Left Hand Section –...
- Page 36 OWNER OF THE INSTALLATION SITE SPECIFIC LEGAL RIGHTS. YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY BY EACH JURISDICTION. IN UNITED STATES: IN CANADA: 260 NORTH ELM ST. 7555 TRANMERE DRIVE WESTFIELD, MA 01085 MISSISSAUGA, ONT. L5S 1L4 www.hydrotherm.com TEL (413) 564-5515 TEL (905) 672-2991 FAX (413) 568-9613 FAX (905) 672-2883...
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