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CS300-IOM-1
MODEL CS300
NATURAL OR PROPANE GAS BOILER
INSTALLATION & OPERATING MANUAL
Designed and tested according to A.S.M.E. Boiler and Pressure Vessel Code, Section
IV for a maximum allowable working pressure of 80 psi US, 50 psi Canada water,
15 psi steam.
CAUTION: Do not use automotive anti-freeze in the boiler waterways. If the use of
antifreeze is necessary an anti-freeze specifically formulated for hydronic heating
systems must be used!
Water treatment is not recommended. This boiler uses gaskets made from ethylene
propylene, EPT, to seal the section ports. Consult a water treatment professional before
adding any chemicals to the boiler water to ensure that they are compatible with the
gaskets. Failure to comply with this caution can result in failure of the gaskets voiding
the warranty.
WARNING: If the information in this manual is not followed exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch. Do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call the fire department.
A qualified installer, service agency or the gas supplier, must perform installation
and service.
INSTALLER READ THESE INSTRUCTIONS CAREFULLY.
THEY WILL SAVE YOU VALUABLE TIME WHEN ASSEMBLING THE BOILER.
THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (413) 564-5515 • FAX (413) 568-9613
IN CANADA: 5211 CREEKBANK RD. • MISSISSAUGA, ONT. L4W 1R3 • (905) 625-2991 • FAX (905) 625-6610
www.hydrotherm.com
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Table of Contents
Related Manuals for HydroTherm CS300
Summary of Contents for HydroTherm CS300
- Page 1 CS300-IOM-1 MODEL CS300 NATURAL OR PROPANE GAS BOILER INSTALLATION & OPERATING MANUAL Designed and tested according to A.S.M.E. Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure of 80 psi US, 50 psi Canada water, 15 psi steam.
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Page 2: Table Of Contents
The owner should maintain a record of all service work This manual covers the application, installation, operation performed with the date and a description of the work and maintenance of a CS300 low pressure steam or hot done. Include the name of the service organization for water boiler. -
Page 3: Boiler Ratings & Capacities
3. Ensure that the floor is structurally sound and will support the weight of the boiler. Never install a CS300 on a concrete floor that contains wires, cables, water pipes or hoses. This boiler is designed for non combustible... -
Page 4: Combustion Air & Ventilation
The upper opening must be WARNING: Never operate a CS300 in an within 12 in, 300 mm of, but not less than 3 in, 80 mm environment subjected to a negative pressure from, the top of the enclosure. -
Page 5: Chimney & Vent Pipe Connections
1/4 inch/foot and and properly sized. Table 2 lists the equivalent breeching terminate flush with the inside of the chimney flue. and flue sizes required for the CS300 boilers. Fasten each connection with at least 3 corrosion resistant sheet metal screws. - Page 6 Page 6 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS COMMON VENT SYSTEMS Where it is practical, close all building doors and windows and all doors between the space in which If an existing boiler is removed from a common venting the appliances remaining connected to the common...
- Page 7 Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale. Figure 2A Vertical Venting Using A Metal Chimney System And Inside Air(CS300 Series) 2 FT .6 m 10 FT 3.4 m 3 FT 1 m...
- Page 8 2 FT .6 m 10 FT 3.4 m 3 FT 1 m 10 FT 3.4 m Figure 2C Vertical Venting Using A Masonry Chimney And Inside Air (CS300 Series) 10 FT 3.1 m 3 FT 1 m 5 FT 1.52 m...
- Page 9 Page 9 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 2D Dual Flue Outlets Using A Masonry Chimney And Inside Air (CS300 Series) 10 FT 3.1 m 3 FT 1 m 5 FT 1.52 m Figure 2E Common Vents And Inside Air (CS300 Series) 10 FT 3.1 m...
- Page 10 Page 10 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 2F Dual Flue Outlets With Two Boilers Using A Masonry Chimney And Inside Air (CS300 Series) 10 FT 3.1 m 3 FT 1 m 5 FT 1.52 m Figure 2G Horizontal Venting And Inside Air (CS300) BUILDING OVERHANG 4 FT 1.2 M MAX.
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Page 11: Boiler Assembly
Figure 1. Align the hollow blocks so air can flow through them. WARNING: Never install a CS300 boiler on top of combustible flooring! Failure to comply with this warning may result in a fire causing property... - Page 12 Page 12 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Burner Base Assembly 5 through 12 Sections Figure 8 Burner Base Rear Panel Detail, 5 - 12 Sect Loosely attach the base baffle to the side panels using 4 5/16 stainless steel nuts. Install the burner base front,...
- Page 13 Page 13 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Temporarily attach the manifold brackets and manifold, Locate the Burner Box. It is marked with a number from Figures 11 and 12. 72724 to 72731. Install three burner tubes in the base, one on each end and one in the middle.
- Page 14 Page 14 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Ceramic Blanket Installation Figure 17 Ceramic Blanket Placement Before installing the cast iron sections a ceramic blanket gasket must be installed on the burner base. Locate the roll of ceramic blanket and can of spray adhesive supplied in the X1 box.
- Page 15 Page 15 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 19 Marking Burner Base Rear Midpoint Figure 21 Ceramic Rope Application Apply two coats of the spray adhesive supplied with the Figure 22 Trimming Ceramic Rope boiler to the rope seal grooves, Figure 20. Allow time for the first coat to become tacky before applying the second coat.
- Page 16 Page 16 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS To ensure that the assembled sections will be centered Figure 26 Front View - Odd Numbered Models on the burner base the cast iron sections should be assembled from the midpoint of the burner base outward.
- Page 17 Page 17 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 29 Lower Port Seal Placement Install the draw rods, nuts and washer and slightly tighten the nuts. Only one washer is to be placed on each draw rod, Figure 31, to torque sections together.
- Page 18 Page 18 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Make sure that the sections are square with the burner Figure 33 Flue Collector Box 63203 to 63210 base. Align the bottom front edge of the sections so they’re flush with the face of the burner base front panel, Figure 32.
- Page 19 Page 19 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 36 “J” Bolt Installation Figure 37 Flue Collector Bracket Installation CAST IRON PRESSURE TEST NOTE: All assembled boiler sections shall pass the hydrostatic tests prescribed in Section IV of the ASME Boiler and Pressure Vessel Code.
- Page 20 Page 20 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS FLUE COLLECTOR INSTALLATION Position the flue collector on the boiler sections with the draft hood opening at the rear of the boiler. The sides of A single draft hood is used on the 5 through 12 section the flue collector should lie along the center of each end boilers.
- Page 21 Page 21 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Clean Out Covers Figures 44 Clean Out Cover Bolt Location The clean out covers and mounting hardware are packaged in the Burner Box with a number from 72724 to 72731 on it, Figure 42 Figure 42 Clean Out Cover &...
- Page 22 Page 22 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS MANIFOLD, BURNER AND PILOT INSTALLATION Figure 49 Burner Tube w/ Pilot Bkt. and Pilot Box 63273, Base Panel Sides, contains the manifold brackets. Bolt the left and right manifold brackets to the front burner base side panel flanges, Figures 11 and 49.
- Page 23 Page 23 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Install the supplied 1/8” stainless steel bleed line on con- Pull the tubes forward over the brass orifices in the tinuous pilot boilers equipped with V88A gas valves. The manifold engaging the notch in the flattened part of the bleed line must be located in a fixed position relative to burners with rear panel, Figures 53 and 54.
- Page 24 Page 24 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS When all of the burner tubes are in place adjust the NOTE: Before installing the jacket, any nipples, steam manifold so the burner tube orifice brackets are positioned risers or short pieces of pipe that will penetrate the midway along the cylindrical portion of the orifice, Figure jacket should be installed in the cast iron sections.
- Page 25 Page 25 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS The jacket should be assembled using the black screws Fasten the rear jacket panel to the inner draft hood and provided. On 5 through 12 section models slide the rear flue collector flanges using the holes provided, Figure panel behind the draft hood flanges with the grill side on the floor, Figures 58, 59 &...
- Page 26 Page 26 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Slip the rear flange of one of the side panels between Locate the top jacket panel(s), Figure 65. the rear panel and the jacket-mounting bracket, Figure Figure 65 Top Jacket Panel Figure 63...
- Page 27 Page 27 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Install the front jacket top panel(s), Figure 67. Install the front access panels as shown in Figure 69. Figures 67 Front Top Jacket Panel, 5 through 12 Figure 69 Front Access Panel 5 - 12 Sect...
- Page 28 Page 28 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Gas Train Assemblies Pilot Assembly All threaded gas train connections must be made using a pipe compound that is resistant to the actions of The pilot assembly must be performed after the liquefied petroleum gases.
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Page 29: Heating System Piping
Page 29 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS HEATING SYSTEM PIPING Figure 74 Steam Control Tapings NOTE: The boiler jacket must be installed before connecting the heating system piping and controls. All heating system piping must be installed by a qualified... - Page 30 Page 30 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 75 Typical Single Boiler Steam Piping Stop Valve Steam Main Pres. ASME Controls Safety Valve F & T Trap LWCO Steam Gage Stop Valve Gage Glass Check Valve Blowoff Valve Figure 76...
- Page 31 Page 31 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 77 Typical Steam Piping - Pumped Return for Multiple Boilers Stop Valve ASME Safety Valve Stop Valve F & T Trap ASME High Level “Spill” Safety Valve To Receiver Tank LWCO Pres.
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Page 32: Gas Supply Piping
Always use a pipe sealant that is suitable for use with LP gas. The CS300 boiler comes from the factory ready to be piped to the gas supply. If for any reason the boiler is... -
Page 33: Electrical Wiring
Page 33 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS ELECTRICAL WIRING Use the factory supplied wiring schematic booklet to connect power to the boiler. The schematic booklet also depicts how to interconnect the boiler controls, using the Electrical Power Connections supplied wire harness. Before connecting any harnesses,... -
Page 34: Boiler Operation
Page 34 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS BOILER OPERATION C. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the... - Page 35 Page 35 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS 14. The burners should light with proper boiler operation. 11. The pilot(s) should automatically light. Do not try to light the pilot(s) by hand! 15. A boiler designed for use with natural gas should have a manifold gas pressure of 3.5"...
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Page 36: Boiler Checking & Adjustment
Page 36 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Gas Pressure Adjustment BOILER CHECKING & ADJUSTMENT PILOT ADJUSTMENT NATURAL GAS: Optimum results are obtained when The pilot burner flame should envelope 3/8" to 1/2" of the boiler is operated at its full input rating, with 3.3" WC the thermocouple tip or flame-sensing probe, depending to 3.7"... -
Page 37: Boiler Maintenance
Page 37 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Input Rate BOILER MAINTENANCE Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 feet. CAUTION: Servicing, inspection and adjustment At elevations above 2000 feet, input ratings should be must be done by a trained technician in accordance reduced by 4% for each 1000 feet above sea level. - Page 38 Page 38 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Heat Exchanger Cleaning 3. The relief valve should vent water when the test lever is lifted. It should not weep or discharge water at normal The burners should be removed to protect them from falling rust and scale.
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Page 39: Repair Parts
Page 39 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS... - Page 40 Page 40 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Number of Sections with Item Quantities Below Ref # Name of Part Part # Jacket Less Sides Panels, (Figure 8) 55177 55178 55179 55180 55181 55182 55183 55184 Jacket Side Panels, 55176 Left &...
- Page 41 Page 41 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Number of Sections with Item Quantities Below Ref # Name of Part Part # Robertshaw 7000 DERHC, Natural Gas, 1" 51186 Robertshaw LP Conversion Kit 51083 Honeywell V88A, Natural Gas, 1" 72733 Honeywell V8943B, Natural Gas, 1"...
- Page 42 Page 42 CS300 BOILER INSTALLATION AND OPERATION INSTRUCTIONS Number of Sections with Item Quantities Below Ref # Name of Part Part # Burner Base Front Channel, 63216 (see Figure 2) Burner Base Intermediate Channel, 63217 (see Fig. 2) Burner Base Rear Channel,...
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Page 43: Health Warnings
Your home should also be adequately ventilated, particularly if you have insulated your home. ONLY QUALIFIED, LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK ON YOUR HYDROTHERM BOILER! WARNING: Install, operate and maintain unit in accordance with manufacture’s instructions to avoid exposure to fuel substances or substances from incomplete combustion which can cause death or serious illness. - Page 44 IN UNITED STATES: 260 NORTH ELM ST. • WESTFIELD, MA 01085 • (413) 564-5515 • FAX (413) 568-9613 IN CANADA: 5211 CREEKBANK RD. • MISSISSAUGA, ONT. L4W 1R3 • (905) 625-2991 • FAX (905) 625-6610 www.hydrotherm.com...
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