Table of Contents
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MODEL HC-D SERIES
INSTALLATION,
OPERATION &
MAINTENANCE
MANUAL & REPLACE-
MENT PARTS MANUAL
Gas-Fired Cast Iron Water Boilers
65,000 to 165,000 Btuh Input
Intermittent Pilot & Vent Damper
Introduction ...............................................................2
Step 1: Locating & Setting the Boiler ........................3
Step 2: Installing/Purging Water Piping.....................4
Step 3: Venting the Boiler..........................................6
Step 4: Installing/Testing Gas Piping ........................8
Step 5: Wiring the Boiler ...........................................9
Safety Controls...................................................... ..15
Start-Up & Adjustments...........................................15
MEA# 90-77-E
IN UNITED STATES: 260 NORTH ELM ST., WESTFIELD, MA 01085 (413) 564-5515/FAX (413) 568-9613
IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONT. L4W 1R3 (905) 625-2991/FAX (905) 625-6610
Water Treatment ......................................................18
Freeze Protection ....................................................18
Before Each Heating Season.................................. 18
How To Change Orifices..........................................19
Troubleshooting....................................................... 19
Appendix A (French Vent Damper Translation)....... 20
Replacement Parts List ......................................... 21
HCD2-501
42-9156 REV. 1
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Summary of Contents for HydroTherm HC-65
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Page 1: Table Of Contents
HCD2-501 42-9156 REV. 1 MODEL HC-D SERIES INSTALLATION, OPERATION & MAINTENANCE MANUAL & REPLACE- MENT PARTS MANUAL Gas-Fired Cast Iron Water Boilers 65,000 to 165,000 Btuh Input Intermittent Pilot & Vent Damper SECTION 1: BOILER INSTALLATION SECTION 3: MAINTENANCE Introduction ...............2 Water Treatment ............18 Step 1: Locating &... -
Page 2: Dimensions
TAPPING SPILL EXPANSION TANK SWITCH 1 1/2" SUPPLY TAPPING HC-85, 100,120 1 1/4" RETURN 1 1/2" SUPPLY CIRCULATOR HC-65, 145, 165 (PACKAGED GAS VALVE BOILERS) PRESS./RELIEF VALVE HC-65, 145, 165 HI-LIMIT AQUASTAT TEMP./PRESS. INDICATOR ROLLOUT SWITCH DRAIN VALVE 21 3/4"... -
Page 3: Section 1: Boiler Installation
SECTION 1: BOILER INSTALLATION STEP 1: LOCATING & SETTING THE BOILER PROCEDURE A: Check that provisions for combustion air are in accordance with National Fuel Gas Code ANSI Z223.1-latest edition and all applicable local codes. In Canada, follow CAN/CGA B149.1 or .2 installation codes. be provided by two openings: one located about 6"... -
Page 4: Step 2: Installing/Purging Water Piping
PROCEDURE A: Install vent tapping assembly, components and relief valve discharge piping. For Models HC-65, 145 & 165, supply outlet is at rear of boiler and vent fitting assembly tapping is at front of boiler. Relief Valve Discharge Piping: Must terminate 6"... - Page 5 CAUTION: To prevent damage due to excessive con- densation, one of the following piping options should be used. SUPPLY RETURN SYSTEM BYPASS 120° F For systems using a circulator on the return as either a sin- 160° F gle zone, or multiple zones with zone valves, install a sys- tem bypass line between the supply and return on the suc- 160°...
- Page 6 115 volts The most commonly available reverse acting aquastat is a Honeywell L4006B. The aquastat should be mounted reverse aquastat in an immersion well directly installed in the boiler. The use of heat conductive grease (Honeywell par t # N.O. 972545) in the immersion well is strongly recommended circulator for fast and accurate temperature response.
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Page 7: Step 3: Venting The Boiler
STEP 3: VENTING THE BOILER DANGER: Draft hood and vent outlet must not be altered, as proper operation would be jeopardized; flame rollout, fire or carbon monoxide poisoning will result. NOTES: Additional venting and chimney requirements are provided on page 8. For boilers equipped with intermittent pilot install plug supplied in damper package into damper vane hole. - Page 8 (6" minimum clearance required between flue pipe and combustibles). MAXIMUM 6-FT SINGLE WALL APART OR TYPE B FLUE PIPE HC-65 = 5" HC-85 = 5" HC-100 = 5" PITCH 1/4" INSTALL HC-120 = 6" PER FOOT FLUSH HC-145 = 6"...
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Page 9: Step 4: Installing/Testing Gas Piping
STEP 4: INSTALLING & TESTING GAS PIPING PROCEDURE A: Select gas pipe size which will result in a pressure drop of less than 0.3" W.C. for natural gas or 0.5" W.C. for propane, following example below. Example: Boiler Model HC-120D is to be installed. Distance from existing gas meter to installation site is 20 ft. What pipe size must be used? Local utility indicates heating value of natural gas being supplied is 1020 Btu per cu.ft. -
Page 10: Step 5: Wiring The Boiler
PROCEDURE B: Connect gas piping from meter to RISER TO OTHER boiler following good piping practices. Pipe joint BEAM APPLIANCES compound must be compatible with the fuel (NG or LP) being used. Check local codes and utilities for any requirements. PIPE CLAMP METER MANUAL MAIN... -
Page 11: Wiring Diagram Iid/Vent Damper/L8148E Aquastat Relay
FIGURE 1.19: WIRING DIAGRAM & OPERATION FIGURE 1.18: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS WITH IID, SEQUENCE FOR BOILERS WITH IID & VENT DAMPER & L8148E AQUASTAT RELAY VENT DAMPER... - Page 12 FIGURE 1.20: WIRING DIAGRAM & OPERATION FIGURE 1.21: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS WITH IID, VENT DAMPER SEQUENCE FOR BOILERS WITH IID, VENT DAMPER, & DUAL AQUASTAT L4081A R8285 CONTROL CENTER & DUAL AQUASTAT L4081A...
- Page 13 FIGURE 1.22: WIRING DIAGRAM & OPERATION SEQUENCE FOR BOILERS WITH IID, VENT DAMPER, & DUAL AQUASTAT L4081B...
- Page 14 115V TO CIRC. 115V T2: 24V TRANSF. ZV1: ZONE VALVE R1: AQUASTAT RELAY - L8148E TH1: ZONE T'STAT ZV2: ZONE VALVE GV: GAS VALVE TH2: ZONE T'STAT ZV3: ZONE VALVE TH3:ZONE T'STAT FIGURE 1.23: WIRING DIAGRAM FOR ZONING WITH ZONE VALVES FACTORY WIRING GAS VALVE FIELD WIRING...
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Page 15: Section 2: Start-Up & Operation
SECTION 2: START-UP & OPERATION Safety Controls 2. Make sure boiler combination gas valve is in OFF Spill switch (see Figure position. Then, open main gas shutoff valve, allowing gas 2.1) detects the escape to flow to boiler. of combustion products through the draft hood 3. - Page 16 If this is the case, the local utility or Hydrotherm may recom- 9. Boilers are shipped from the factory with the primary mend the orifices be changed. When changing orifices, air shutters on the main burner wide open.
- Page 17 WARNING If you do not follow these instructions exactly, a fire or explosion may result with property damage, personal injury, or loss of life. A. This appliance is equipped with an ignition device which phone. Follow the gas supplier's instructions. automatically lights the pilot.
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Page 18: Section 3: Maintenance
SECTION 3: MAINTENANCE This boiler has been designed to provide years of trou- examine all flue passageways. ble free performance in normal installations. Examina- a. If passageways are free of soot and obstructions, tion by the homeowner at the beginning of each heating replace dome and seal with furnace cement or high season, and in mid-heating season, should assure con- temperature silicone adhesive/sealant. -
Page 19: How To Change Orifices
1. Shut off power supply and gas supply to the boiler. MODEL DRILL SIZE DRILL SIZE 2.60MM HC-65 2. Remove burner access panel. To remove burners, lift HC-85 up & to rear until burners are disengaged from orifices. HC-100 1.65MM HC-120 1.55MM... - Page 20 APPENDIX A MÈTHODE D' INSTALLATION B: pour le volet motorisé de ventilation. DANGER: Le volet de ventilation doit servir seulement à la chaudière. Ne pas l utiliser pour ventiler d'autres appareils; sinon cela pourrait provoquer un incendie ou causer un empoisonnement par le monoxyde de carbone.
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Page 21: Parts List
MODEL HC-D REPLACEMENT PARTS LIST ORDERING INFORMATION When ordering replacement parts, provide the model and serial number shown on the unit rating plate as well as the part number and name as shown in the parts list. Parts may be obtained from your local Hydro-therm heating contractor. - Page 22 NAME OF PART PART NO. 100D 120D 145D 165D Rear Tie Plate, Insulated BM-3322 Rear Tie Plate, Insulated BM-3327 Rear Tie Plate, Insulated BM-3331 Bracket, Manifold - L.H. 03-7153 Bracket, Manifold - R.H. 03-7154 Front Tie Bar 03-7873 Front Tie Bar 03-7874 Base Door, Insulated BM-3324...
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Page 23: General Assembly
18 & 19 41 (MOUTED ON REAR JACKET PANEL) FIGURE 1: HC-D GENERAL ASSEMBLY... - Page 24 Jacket - Complete 03-1017 Vent Damper w/ Harness Ass'y. 02-5865 Vent Damper w/ Harness Ass'y. 02-5867 Vent Damper w/ Harness Ass'y. 02-5854 ORIFICE PART NUMBERS ORIFICE HYDROTHERM ORIFICE HYDROTHERM ORIFICE HYDROTHERM SIZE PART NO. SIZE PART NO. SIZE PART NO.
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