HydroTherm HV-50 Installation & Operating Instructions Manual

Hydrotherm hv natural or propane gas hot water boiler

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User's information manual (8 pages)

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Summary of Contents for HydroTherm HV-50

Page 1 HV2-805R NATURAL OR PROPANE GAS BOILER INSTALLATION & OPERATING INSTRUCTIONS DESIGNED AND TESTED ACCORDING TO A.S.M.E. BOILER AND PRESSURE VESSEL CODE, SECTION IV FOR MAXIMUM ALLOWABLE WORKING PRESSURE OF 50 PSI, 345 kPa WATER NOTE TO INSTALLING CONTRACTOR: READ THESE INSTRUCTIONS CAREFULLY. THEY WILL SAVE YOU TIME IN ASSEMBLING BOILER PROPERLY.
Page 2: Table Of Contents
Boiler Maintenance ........... 20 Instructions to the Installer ........ 21 Direct all questions to your Hydrotherm distributor or write to the Customer Service Department, 260 North Elm Street, Replacement Parts ..........22 Westfield, MA 01085. Always include the model and serial numbers from the rating plate of the boiler in question.
Page 3: Boiler Ratings & Capacities
This boiler is designed for non- Include the name of the service organization for future reference. combustible floors only! A special base supplied by Hydrotherm must be used if the boiler is to be installed on a combustible Where required by the authority having jurisdiction, the floor.
Page 4: Combustible Floor Option
Thread a 4' length of 11/4" pipe designed for it by Hydrotherm. Do not alter in any way, into the elbow and carefully lift the front of the boiler. Slide a the special base supplied by Hydrotherm.
Page 5: Dimensions & Component Location
2. Vertical dimensions must be adjusted when using a base pan or concrete foundation under the boiler TABLE 1 Boiler Dimensions Boiler Size Dimension Dimension Vent Dia. Vent Dia. CATEGORY I CATEGORY III Single Wall Galv. Horizontal Vent HV-50 ⁄ ⁄ HV-75 ⁄ ⁄ HV-100 ⁄ ⁄ HV-125 ⁄...
Page 6: Combustion Air
Page 6 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS FIG. NO. 3 Special Base Installation TABLE 2 Combustion Air Duct Sizing INPUT BTUH Fresh Air 1⁄4" Wire Metal Wooden Duct Size Mesh Screen Louvers Louvers 3" x 12" 144,000 108,000 36,000 8"...
Page 7: Chimney & Vent Pipe Connection
Page 7 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS Any improper operation of the common venting system Insofar as is practical, close all building doors and windows should be corrected so the installation conforms with the and all doors between the space in which the appliances National Fuel Gas Code, ANSI Z223.1/NFPA 54.
Page 8: Vertical Venting
Page 8 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS Vent Connections to Chimneys Single Wall Metal Vent Use Type B1 or single wall metal vent pipe from the boiler to HV boilers may be vented vertically using single wall metal vent the chimney.
Page 9: Heating System Piping
Page 9 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS Horizontal vent systems shall terminate at least 4 ft, 1.3 m , HORIZONTAL VENTING below, 4 ft, 1.3 m , horizontally from or 1 ft, 0.23 m , above any Horizontal vent systems must be in compliance with UL 1738 door, window or gravity air inlet into any building.
Page 10 THE VALVE BODY. VALVE OUTLET. FOR DISCHARGE DO NOT RESTRICT FLOW. THROUGH ROOF CONSULT HYDROTHERM . 1" CLEARANCE MUST BE MAINTAINED BETWEEN HOT WATER PIPING AND COMBUSTIBLE CONSTRUCTION. DISCHARGE SO AS TO AVOID EXPOSURE OF PERSONS TO HOT LIQUID OR VAPOR. L E A V E O P E N E N D V I S I B L E F O R P E R I O D I C INSPECTION FOR SLOW LEAKAGE OR DRIPS.
Page 11 Page 11 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS Pumped Blend FIG NO. 9 115 volts An additional circulator can also be used to provide a return reverse water temperature blend. This method works well with systems aquastat with multiple zones with circulators, see FIG. NO. 8. The N.O.
Page 12: Gas Supply Piping
If for any reason the boiler is not for the type of gas available at it’s manual shut off valve, see FIG. NO. 8. If the test pressure the installation site, call the nearest Hydrotherm distributor to is greater than 1/2 psig 3.5 kPa , disconnect the boiler and it’s resolve the problem.
Page 13: Electrical Wiring
Page 13 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS TABLE 3 Maximum Gas Pipe Capacity in ft The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest edition Nominal Iron Pipe length of the National Electrical Code, ANSI/NFPA-70.
Page 14 Page 14 FIG. NO. 13 Fenwal/Honeywell Hot Surface Ignition...
Page 15 Page 15 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS FIG. NO. 15 Multi-Zone Diagram FIG. NO. 16 Multi-Zone Diagram T87F ZONE 1 T87F ZONE 2 T87F ZONE 3 V8043F V8043F V8043F END SWITCH END SWITCH END SWITCH TO ADDITIONAL LINE VOLTAGE R845A RELAYS LOW VOLTAGE TH-TR...
Page 16: Lighting Instructions
Page 16 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING 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 that •...
Page 17 Page 17 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS POUR VOTRE SÉCURITÉ LISEZ AVANT DE METTRE EN MARCHE AVERTISSEMENT. Quinconque ne respecte pas à la lettre les instructions dans la présente notice risque de déclencher un incendie ou une explosion entraînant des dommages, des blessures ou la mort.
Page 18: Boiler Operation
Page 18 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS BOILER SET-UP Direct Ignition Systems Connect a manometer having a minimum capacity of Note: Before starting the boiler, turn off the electrical supply 10 in, 254 mm , WC to the outlet pressure port of the gas valve. going to it.
Page 19: Checking & Adjusting
Page 19 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS CHECKING & ADJUSTMENT If the computed rate deviates by more than 5% from the rated input value of the unit adjust the gas valve pressure Gas Pressure Adjustment accordingly. Do not adjust the manifold pressure by more than 5%.
Page 20: Boiler Maintenance
Page 20 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS BOILER MAINTENANCE Heat Exchanger Cleaning Remove the burners to protect them from falling rust and scale by following the Burner Removal instructions. WARNING: The ceramic combustion chamber in the Remove the vent pipe, front access and top panels. burner box and its gasket contain crystalline silica.
Page 21: Instructions To The Installer
Page 21 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS Controls/Burners INSTRUCTIONS TO THE INSTALLER Refer to the BOILER OPERATION and CHECKING and The installer must give this copy of the INSTALLATION AND ADJUSTMENT sections in this manual. OPERATING INSTRUCTIONS to the boiler owner and make Check the thermostat for proper operation.
Page 22: Replacement Parts
Page 22 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS HV SERIES REPLACEMENT PARTS Number of Sections Ref # Name of Part Part No. HV-50 HV-75 HV-100 HV-125 HV-150 Top, Rear, Inner Front and Front Panels BM-8796 BM-8797 BM-8798 BM-8799 BM-8800 Left Side Panel...
Page 23 Page 23 HV BOILER INSTALLATION & OPERATING INSTRUCTIONS Number of Sections Ref # Name of Part Part No. HV-50 HV-75 HV-100 HV-125 HV-150 Flue Collector/Drafthood BM-8801 BM-8802 BM-8803 BM-8804 BM-8805 Flue Baffle BM-8806 Heat Exchanger/Assembled Block BM-8765 BM-8766 BM-8767 BM-8768...
Page 24: Health Warnings
Carbon monoxide (CO) is a gas which is odorless, colorless and tasteless but is very toxic. If your Hydrotherm boiler is not working properly, or is not vented properly, dangerous levels of CO may accumulate. CO is lighter than air and thus may travel throughout the building. Brief exposure to high concentrations of CO, or prolonged exposure to lesser amounts of CO, may result in carbon monoxide poisoning.

This manual is also suitable for:

Hv-75 Hv-100 Hv-125 Hv-150