HydroTherm HVX 70 Installation And Operation Instructions Manual
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HydroTherm HVX 70 Installation And Operation Instructions Manual

Gas-fired residental boilers
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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
instructions. 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.
HVX
Gas-Fired Residental Boilers
Models 70-175
Boiler Manual
Boiler Manual
Installation and
Installation and
Operation Instructions
Operation Instructions
HVX2-0313
22-HVX2

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Summary of Contents for HydroTherm HVX 70

  • Page 1 HVX2-0313 22-HVX2 Gas-Fired Residental Boilers Models 70-175 Boiler Manual Boiler Manual Installation and Installation and Operation Instructions 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.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS USING THIS MANUAL 6. ELECTRICAL A. INSTALLATION SEQUENCE ... . .3 A. WIRING ......20 B.

  • Page 3: Using This Manual

    USING THIS MANUAL USING THIS MANUAL A. INSTALLATION SEQUENCE DANGER Follow the installation instructions provided in this Indicates a condition or hazard which will cause manual in the order shown. The order of these severe personal injury, death or major property instructions has been set in order to provide the installer damage.

  • Page 4: Preinstallation

    PREINSTALLATION 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 Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code .

  • Page 5: Air For Combustion And Ventilation

    PREINSTALLATION 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. Adequate combustion air and ventilation air must be Provide two permanent openings communicating provided in accordance with section 5.3, Air for with additional spaces that have a minimum free...
  • Page 6 PREINSTALLATION 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).
  • Page 7 PREINSTALLATION 5. Combination Indoor and Outdoor Combustion Air: b. Motorized dampers shall be interlocked with the If the required volume of indoor air exceeds the equipment so that they are proven in the full available indoor air volume, outdoor air openings or open position prior to ignition and during ducts may be used to supplement the available operation of the main burner.

  • Page 8: Planning The Layout

    PREINSTALLATION D. PLANNING THE LAYOUT The above requirements do not apply if the ° exhaust vent termination is seven (7) feet or Prepare sketches and notes of the layout to minimize the more above finished grade in the area of the possibility of interferences with new or existing venting, including but not limited to decks equipment, piping, venting and wiring.

  • Page 9: Water Piping And Controls

    WATER PIPING AND CONTROLS 3. WATER PIPING AND CONTROLS 3. Supply Piping: A. BOILER SUPPLY AND RETURN Pipe the supply to the 1-1/2 NPT supply tapping at the top of the boiler. 1. Size the supply and return to suit the system. A typical piping arrangement is shown in Figure 3.1.

  • Page 10: Safety Relief Valve

    WATER PIPING AND CONTROLS 6. 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.). 7. If this boiler and distribution system is used in conjunction with a refrigeration system, pipe the chilled medium in parallel with the boiler and install the proper valve to prevent the chilled medium from...

  • Page 11: Piping For Zoned Systems

    WATER PIPING AND CONTROLS 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. If required, provide means to isolate and drain each zone separately.

  • Page 12: Expansion Tank

    WATER PIPING AND CONTROLS 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 13: Venting

    VENTING 4. VENTING 3. Locate fan adapter, silicone, hardware and fan A. GENERAL adapter gasket in boiler miscellaneous parts box and attach to blower outlet flange. Refer to Fig. 4.1 1. Install vent system in accordance with the “Venting for details. of Equipment”...
  • Page 14 VENTING Figure 4.1: Chimney Venting d. Vent terminal shall not be located over public • Horizontal portions of the vent pipe must be walkways where condensate could create a supported at intervals no greater than four nuisance or hazard. feet to prevent sagging/separation. Parties horizontales du conduit d'évacuation e.
  • Page 15 VENTING i. The only approved vent termination is a 3" (76 7. Refer to Figure 4.2 for vertical offset option. The mm) 90° elbow. Refer to Figure 4.4. Vent pipe maximum offset is 5 feet. With the exception of the must be sealed to the thimble (or outside wall if- last 90°...

  • Page 16: Direct Exhaust Vertical Venting

    VENTING Figure 4.4: Direct Exhaust; Sidewall Venting D. DIRECT EXHAUST; VERTICAL VENTING 1. This vent system will operate with a positive pressure in the vent pipe. Follow vent pipe manufacturer’s instructions for proper assembly of vent pipe and fittings. 2. Refer to Table 4.2 for minimum and maximum vent length allowed.

  • Page 17: Boiler Removal From Common Venting System

    VENTING d. Place in operation the appliance being inspected. E. 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 inspecter. Suivre les steps with each appliance remaining connected to the instructions concernant l’allumage.

  • Page 18: Gas Piping

    GAS PIPING 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. 2. Determine the volume of gas to be provided to the boiler in cubic feet per hour.
  • Page 19 GAS PIPING Table 5.1: Natural Gas Input Input Size (Cubic Ft/Hr) (Cubic Meter/Hr) Based on 1000 Btu/Cubic Ft. Table 5.2: LP Gas Input Input Size (Cubic Ft/Hr) (Cubic Meter/Hr) Based on 2500 Btu/Cubic Ft. Table 5.3: 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 kPa] and a specific gravity of 0.60.

  • Page 20: Electrical

    ELECTRICAL 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 21 ELECTRICAL Figure 6.2: Wiring Diagram, Spark Ignited Pilot, Becket 7600 Limit Control Figure 6.3: Wiring Diagram, Spark Ignited Pilot, Hydrolevel 3200 Limit control...

  • Page 22: Boiler Sequence Of Operation

    ELECTRICAL 7. Pilot flame detected. D. BOILER SEQUENCE OF OPERATION a. Ignitor off. 1. Thermostat calls for heat. b. Main gas on, igniting main burners. 2. Limit control energizes circulator. Note: If pilot flame is not detected within 90 seconds, the igniter and pilot are turned off for 5 minutes.
  • Page 23 START-UP PROCEDURES Figure 7.1: Gas Valve, Manifold and Burner Assembly – Intermittent Ignition Figure 7.2: Valve Tapping and Adjustment Screw Locations...
  • Page 24 START-UP PROCEDURES Figure 7.3: Operating Instructions...
  • Page 25 START-UP PROCEDURES Figure 7.4: Operating Instructions...

  • Page 26: Control Descriptions

    START-UP PROCEDURES 3. In no case should the final manifold pressure vary B. CONTROL DESCRIPTIONS more than ±0.3 inches water column (0.07 kPa) See Figure 6.1 in Section 6 (Electrical) for locations of from the above specified pressures. Any necessary these devices.

  • Page 27: Check-Out Procedure

    START-UP PROCEDURES Table 7.1a: Meter Conversion Natural Gas Table 7.1b: Meter Conversion Natural Gas (U.S. Customary Units) (SI Metric System) Burner inputs in kW for various meter timings and Burner inputs in Btu/hr for various meter timings and heating values. (Tables based on 2 cubic feet of gas heating values.
  • Page 28 START-UP PROCEDURES 3. Low Water Cut-Off (if used) – Consult the 7. Check the general condition of the system including manufacturer’s instructions for the low water cut-off piping support, joints, etc. Check cleanliness of the operational check procedure. radiators, baseboard units and/or convectors. Clean them to the extent possible.

  • Page 29: Troubleshooting

    TROUBLESHOOTING 8. TROUBLESHOOTING DANGER A. SHUT-DOWN CAUSED BY PILOT OUTAGE, PRESSURE SWITCH OR When servicing or replacing items that communicate FLAME ROLL-OUT SAFETY with the boiler water, be certain that: SHUT-OFF SWITCH There is no pressure on the boiler. ● In the event of a shut-down caused by a pilot outage, The boiler is not hot.
  • Page 30 TROUBLESHOOTING SEE TABLE 7 Figure 8.1: Procedure For Measuring Fan Suction Pressure Table 8.2: Boiler Troubleshooting Guide (Burners Functioning) Problem Possible Causes Corrective Actions Burners not functioning, 1. Flame rollout switch open. 1. Replace switch. Locate cause and correct. blower running. 2.
  • Page 31 TROUBLESHOOTING 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.” CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING ALSO.

  • Page 32: Maintenance

    MAINTENANCE 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. After the RCF materials have been exposed to temperatures above 1800°F (980°C), they can change into crystalline silica, which has been classified by the IARC as carcinogenic to humans.

  • Page 33: General

    MAINTENANCE A. GENERAL C. WEEKLY (WITH BOILER IN USE) 1. Disconnect this boiler from the gas supply piping 1. Flush float-type low-water cut-off (if used) to remove during any pressure testing of the gas system. sediment from the float bowl as stated in the manufacturer’s instructions.

  • Page 34: Annually (Before Start Of Heating Season)

    MAINTENANCE 2. Inspect entire venting system for corrosion, support E. ANNUALLY (BEFORE START OF HEATING and joint integrity. Repair as necessary. Inspect vent SEASON) termination for any obstruction that may hinder proper venting. DANGER 3. Check the pilot and main burner flame. See Figure 9.1.

  • Page 35: Boiler Dimensions & Ratings

    BOILER DIMENSIONS & RATINGS 10. BOILER DIMENSIONS & RATINGS Figure 10.1: Boiler Views Table 10.1: Boiler Ratings BOILER RATINGS Seasonal DOE Heating Net Ratings Efficiency³ Water Water¹ , ² Input Capacity³ AFUE Content Boiler Size Gallon Liter 82.1 4.72 17.87 82.0 6.00 22.71...

  • Page 36: Repair Parts

    REPAIR PARTS 11. REPAIR PARTS REPAIR PARTS Use the figures and tables on pages 37-38 to assist in ordering parts. Note: Remember to include boiler model number and serial number when ordering parts. Figure 11.1: Block/Base/Floor Pan/Jacket/Flue Collector...
  • Page 37 REPAIR PARTS Table 11.1: Repair Parts – Block/Base/Floor Pan Jacket/Flue Collector (see note) Quantity Stock Description Required Code Block Assembly – 70 – 90419 Block Assembly – 105 – 90420 Block Assembly – 140 – 90421 Block Assembly – 165 –...

  • Page 38: Base/Burners/Manifold

    REPAIR PARTS Figure 11.2: Base/Burners/Manifold Table 11.2: Repair Parts – Base/Burners/Manifold (see note) Quantity Stock Description Required Code – Honeywell VR8204A-2013 Spark Gas Valve – LP Gas – 70 thru 140 – 50584 – Honeywell VR8304M-4010 Spark Gas Valve – LP Gas – 165 –...
  • Page 40 THE ORIGINAL OWNER OF THE PRODUCT 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) 670-5888 FAX (413) 568-9613 FAX (905) 670-5782...

This manual is also suitable for:

Hvx 175Hvx-105Hvx-140Hvx-165

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