HydroTherm HC-65 Owner's manual

HCD2-501
42-9156 REV. 1
AA
AA
AA
HYDROTHERM
IN UNITED STATES: 260 NORTH ELM ST., WESTFIELD, MA 01085 [phone]/FAX [phone]
IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONT. L4W 1R3 [phone]/FAX [phone]
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
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
SECTION 2: START-UP & OPERATION
Safety Controls........................................................15
Start-Up & Adjustments...........................................15
SECTION 3: MAINTENANCE
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
MEA# 90-77-E

2
ANSI/ASME CODE COMPLIANCE: Installation must
conform to requirements of authority having jurisdiction
or, in absence of such requirements, to National Fuel
Gas Code ANSI Z223.1-latest edition and to National
Electric Code NFPA-70-latest edition. Where required by
authority having jurisdiction, installation must also con-
form to Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1-latest
edition.
For Canada, the installation must be in accordance with
Standards CAN/CGA-B149.1 or .2 Installation Codes for
Gas Burning Appliances and Equipment and with Stan-
dard C.S.A. C22.1 Canadian Electrical Code, Part 1 and
Part 2, and/or local codes.
BOILER SHIPMENT: Each boiler is shipped in a single
carton. There is a vent damper packed separately with
the boiler.
MODEL HC-D BOILER DIMENSIONS
1 1/4"
RETURN
A
DIMENSIONS
BOILER
MODEL
HC-65
HC-85
HC-100
HC-120
HC-145
HC-165
A
19 1/2"
23 3/4"
27 1/4"
29"
23 3/4"
23 3/4"
B
12 3/4"
16"
12 3/4"
12 3/4"
12 3/4"
12 3/4"
C
16 1/2"
30 1/2"
33- /4"
32 1/2"
16 1/2"
16 1/2"
D
39 5/8"
43 7/8"
57 7/8"
64 1/8"
65 1/8"
43 7/8"
E
5"
5"
5"
6"
6"
7"
PRESS./RELIEF VALVE
HC-85, 100, 120
GAS VALVE
1 1/2" SUPPLY
HC-65, 145, 165
5 1/2"
1 1/2" SUPPLY
HC-85, 100,120
CIRCULATOR
(PACKAGED
BOILERS)
AIR ELIMINATOR
TAPPING
EXPANSION TANK
TAPPING
DRAIN
VALVE
HI-LIMIT AQUASTAT
TEMP./PRESS. INDICATOR
PRESS./RELIEF VALVE
HC-65, 145, 165
3 5/8"
VENT DAMPER
SPILL
SWITCH
ROLLOUT SWITCH
E
C
D
A
B21 3/4" 7 3/4"
DANGER: Indicates an imminently hazardous sit-
uation which, if not avoided, will result in death,
serious injury or substantial property damage.
WARNING: Indicates a imminently hazardous sit-
uation which, if not avoided, could result in
death, serious injury or substantial property dam-
age.
CAUTION: Indicates a imminently hazardous situa-
tion which, if not avoided, may result in minor
injury or property damage.
NOTE: Used to notify of special instructions on
installation, operation or maintenance which are
important to equipment but not related to personal
injury hazards.
The following terms are used throughout this manual to bring attention to the presence of potential hazards
or to important information concerning the product:
WARNING: Installers must follow local regulations
with respect to the installation of CO detectors and
follow the manufacturer's stated maintenance
schedule for this boiler!
ATTENTION: Observer les règlements règional à
l'egard des détecteurs de monoxyde de carbone et
observer entretien de manufacturier pour cette
chaudière!

3
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.
If boiler is installed in an unconfined space,adequate air
will be available via normal infiltration.
If boiler is installed in a confined space (a space with a
volume of less than 50 cubic feet per 1000 Btu/hr of gas
input for all fuel burning equipment) or building construc-
tion is unusually tight, adequate air for combustion must
be provided by two openings: one located about 6" below
the ceiling, the other about 6" above the floor. When
communicating directly with the outside, each opening
must have a minimum free area of one square inch per
4000 Btu/hr of gas input. When ventilation air is provided
by openings in doors, etc. to adjoining spaces having
adequate infiltration, each opening must have a minimum
free area of one square inch per 1000 Btu/hr of gas
input.
NOTE: Boiler employs atmospheric combustion.
Combustion air must not be contaminated with halo-
genated hydrocarbon vapors, aerosol propellants or
freon; otherwise, heat exchanger will be subject to
corrosion, reducing boiler life.
FRONT
CLOSET
(6")
TOP
48"
AAAAA
SIDE
VIEW
REAR
(6")
W/O CIRC.
24" WITH
CIRCULATOR
(RECOMMENDED
FOR SERVICING)
6"
LEFT 6"
RIGHT
VENT
DAMPER
FRONT
VIEW RECOMMEND
MORE FOR
ACCESS TO
VENT DAMPER
POSITION
INDICATOR
6"
6" FIGURE 1.1
PROCEDURE B: Check mini-
mum clearances to com-
bustibles are proper as
shown. Local requirements
may specify greater clear-
ances & must be adhered to.
Boiler shall be installed such
that the gas ignition system
components are protected
from water (dripping, spray-
ing, rain, etc.) during appli-
ance operation and service
(circulator replacement, con-
densate trap, control replace-
ment, etc.).
NOTE: Do not loosen tie rods on absorption unit. They accommodate thermal expansion. Loss of boiler
structural integrity and water leaks/damage may result.
CAUTION: Locate boiler so horizontal connecting flue pipe is as short as possible. Maximize height of verti-
cal flue connector.
WARNING: Never install boiler on combustible flooring without combustible flooring pan or on carpeting as
heat damage and/or fire may result.
WARNING: This boiler must be supplied with com-
bustion air in accordance with Section 5.3, Air for
Combustion & Ventilation, of the latest revision of
the National Fuel Gas Code, ANSI Z223.1 and all
applicable local building codes. Failure to provide
adequate combustion air for this appliance can result
in severe personal injury or death!
PROCEDURE C: Check component positioning.
1. Remove all packing material from boiler.
2. Check that burners and controls are in the proper
position.
3. Check proper seating of baffle grid inside of dome
opening (see Figure 1.2).
BAFFLE GRID
DOME
TOP VIEW FIGURE 1.2

4
STEP 2: INSTALLING & PURGING WATER PIPING
PROCEDURE B: Install supply and return water pip-
ing. For Models HC-65, 145 & 165, supply outlet is
at rear of boiler and vent fitting assembly tapping is
at front of boiler.
If boiler is installed above level of radiation, a low
water cut-off must be used.
ALL EXTERNAL PIPING MUST BE SUPPORTED BY
HANGERS, NOT BY BOILER OR ACCESSORIES.
PRESS. REDUCING
(FILL) VALVE
DRAIN VALVE
SHUT-OFF
VALVE
SHUT-OFF VALVE
SHUT-OFF
VALVE
SHUT-OFF
VALVES
CIRCULATOR
FIGURE 1.4
NOTE: Boiler must not be used without forced circulation, as overheating or failure of cast iron sections may
result.
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"
above floor & be same size or larger than valve out-
let.
CAUTION: Piping must be installed from relief valve
discharge so there will be no danger of scalding per-
sonnel.
PRESS. RELIEF
VALVE
RELIEF VALVE
DISCHARGE
PIPING
VENT
FITTING
ASS'Y.
AIR VENT
MAY BE PIPED TO
EITHER SIDE OF BOILER
VERTICAL EXPANSION TANK
ARRANGEMENT (PREFERRED)
1/2" NPT TAPPING HORIZONTAL EXPANSION
TANK ARRANGEMENT
MAY BE SCREWED
INTO TAPPING
FIGURE 1.3
WARNING: No valve of any type may be installed
between boiler & relief valve to prevent accidental
explosion from over-pressure.

5
CAUTION: To prevent damage due to excessive con-
densation, one of the following piping options
should be used.
SYSTEM BYPASS
For systems using a circulator on the return as either a sin-
gle zone, or multiple zones with zone valves, install a sys-
tem bypass line between the supply and return on the suc-
tion side of the circulator (see Figure 1.5). Install a metering
valve in this bypass line to regulate the amount of flow that
will be diverted to the return. A plug valve offers the best
control for this application. Although other valves may be
less expensive, a plug valve will be easier to set accurately.
In the absence of a flow indicator, set the metering valve
using temperature as a guide. The accompanying dia-
gram suggests one scenario. This addition requires only
two tees, a plug valve, and a small amount of pipe and
offers the simplest approach to reliably control condensa-
tion. For this system and those that follow, be aware that
you are using a percentage of the pump capacity to
blend, but the friction loss for the entire pump flow has
been reduced. In most cases, the standard pump pack-
aged with the boiler has enough capacity to feed the
baseboard distribution system and the bypass line.
PUMP AWAY BYPASS
For systems that use a single circulator to pump away
from the boiler, the bypass should be installed on the dis-
charge side of the circulator (see Figure 1.6). Full tem-
perature water supplies the baseboard distribution sys-
tem as before. Half of the circulator’s volume moves
through the bypass, blending and heating the cooler
return water. Again, the cost of installing the bypass is
small and setting it by temperature can be accomplished
with a contact thermometer.
PUMPED BLEND
An additional circulator can also be used to provide a
return water temperature blend. This method works well
with systems with multiple zones with circulators (see
Figure 1.7). The dedicated bypass circulator provides a
strong blending flow without diminishing the flow avail-
able to any heating zone. Any residentially sized circula-
tor is adequate for this purpose.
Each of these bypass solutions also has the added ben-
efit of increasing circulation in the boiler which will maxi-
mize tankless coil output and increase the accuracy of
temperature sensing controls.
REVERSE ACTING AQUASTATS
An alternative for existing systems experiencing condensa-
tion that does not require re-piping the boiler utilizes a
reverse acting aquastat, one that makes on temperature
rise. This approach works best in single zone systems.
Wired in series with the circulator, this control holds the cir-
culator off until the boiler reaches an acceptable tempera-
ture and then starts system circulation (see Figure 1.8).
SUPPLY RETURN
50%
120°F
100%
140°F
100%
160°F
50%
160°F
50%
160°F
SYSTEM
BYPASS FIGURE 1.5
SUPPLY RETURN
50%
120°F
100%
140°F
100%
160°F
50%
160°F
50%
160°F
PUMP AWAY
BYPASS
FIGURE 1.6
SUPPLY RETURN
100%
120°F
200%
140°F
200%
160°F
100%
160°F
100%
160°F
PUMPED
BYPASS
FIGURE 1.7

6
PROCEDURE D: Completely fill & purge
heating system. Make sure that all heat-
ing system manual air vents are closed.
1. Check flow direction arrows on hydronic
components are facing in proper direction.
2. Attach hose to drain valve "B" and close
valve "A". Open valves "C", "D", "E" and "F"
and drain valve "B". Fill system with water
until water runs out of the hose in a steady
stream (no visible air bubbles).
3. Close valves "C" and "D". Open valve "A".
When water runs out of the hose in a steady
stream (no visible air bubbles), close drain
valve "B".
4. Open valves "C" and "D".
VALVE “B”
VALVE “C”
VALVE “A”
VALVE “D”
VALVE “E”
VALVE “F”FIGURE 1.10
FOR WATER TREATMENT & FREEZE PROTECTION REQUIREMENTS,
SEE "SECTION 3: MAINTENANCE" IN THIS MANUAL
If a hot water boiler is installed in connection with a water
chiller, the chilled water must be piped in parallel with the
boiler, using appropriate valves to prevent the chilled
medium from entering the boiler (see Figure 1.9). When
boilers are connected to heating coils located in air han-
dling units where they may be exposed to refrigerated air
circulation, such boiler piping system shall be equipped
with flow-control valves or other automatic means to pre-
vent gravity circulation of the boiler water during the cool-
ing cycle.
PROCEDURE C: For combination heating and cooling installations only.
NOTE: VALVES "H" OPENED ON HEATING WITH "C" VALVES
CLOSED REVERSE PROCEDURE ON COOLING.
EXP. TANK VENT ROOM
UNIT
DRAIN CHILLER
BOILER
H
C
PUMP
RELIEF
VALVE
FILL
VALVE
DRAIN
C
H
BOILER FIGURE 1.9
The most commonly available reverse acting aquastat is
a Honeywell L4006B. The aquastat should be mounted
in an immersion well directly installed in the boiler. The
use of heat conductive grease (Honeywell part #
972545) in the immersion well is strongly recommended
for fast and accurate temperature response. Set this
adjustable aquastat to make at no less than 130°F.
While this method can cause the circulator to cycle more
frequently, setting the aquastat’s differential to the maxi-
mum (25-30°F) will minimize short cycling.
reverse
aquastat
N.O.
T
Tt'stat
GV
115 volts
24 volts
circulator
operating
aquastat
N.C.
REVERSE
AQUASTAT
SET AT 120° F FIGURE 1.8

7
STEP 3: VENTING THE BOILER
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. For standing pilot boilers discard plug.
PROCEDURE B: Install vent damper. (For French version, see Appendix A at rear of manual.)
FLOW DIRECTION
ARROW POINTS UP
MOUNT
VENT DAMPER
OVER
DRAFTHOOD
MAKE SURE
MOTOR IS
LOCATED
ON LEFT SIDE
1. Mount damper on top of draft hood.
FIGURE 1.12
ATTACH LOWER
PORTION OF
VENT DAMPER
TO DRAFTHOOD
WITH 1/2" OR
SHORTER SCREWS
OR POP RIVETS
2. Secure damper to draft hood.
FIGURE 1.13
PLUG INTO MOLEX
RECEPTACLE ON FRONT
OF BOILER
PLUG INTO MOLEX
RECEPTACLE INSIDE
DAMPER MOTOR VENT
DAMPER
WIRE
HARNESS
3. Connect wire harness.
FIGURE 1.14
PROCEDURE A: Mount draft hood and spill switch
on boiler.
1. Install draft hood on boiler. If draft hood shroud has a
hole near the relief opening, mount draft hood so hole
faces to the front of the boiler.
2. HC-D boilers are equipped with factory-mounted spill
switch harness/mounting bracket assembly; spill switch is
provided in bag on boiler front.
3. Install mounting bracket on outside surface of draft
hood shroud with the screws provided (HARNESS
MUST BE ON OUTSIDE OF SHROUD). Install spill
switch in hole in shroud (on outside surface) with the
screws provided.
INSTALL
SWITCH
IN OPENING
ON DRAFTHOOD
CONNECT
WIRE
LEADS
INSTALL
MOUNTING
BRACKET
ON DRAFTHOOD
FIGURE 1.11
4. Plug wiring leads from harness/bracket assembly onto
flat terminals on spill switch.
NOTE: Boiler will not operate unless wiring leads to
spill switch are connected.
DANGER: Only the boiler may be served by the vent damper. Do not use it to vent an additional appliance;
this will cause fire or carbon monoxide poisoning.
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.

8
ADDITIONAL VENTING REQUIREMENTS: When con-
necting to gas vents or chimneys, vent installations shall
be in accordance with Part 7, Venting of Equipment, of
the National Fuel Gas Code, ANSI Z223.1-latest edition,
or applicable provisions of the local building codes.
Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of mechani-
cal draft systems operating under positive pressure.
When two or more appliances vent into a common flue,
the area of the common flue should be at least equal to
the area of the largest flue plus 50% of the areas of the
additional flue or vent connectors.
When an existing boiler is removed from a common vent-
ing system, common venting system is likely to be too
large for proper venting of appliances remaining connect-
ed to it. At time of removal of existing boiler, following
steps shall be followed with each appliance remaining
connected to the common venting system placed in oper-
ation, while other appliances remaining connected to
common venting system are not in operation:
1. Seal all unused openings in common venting system.
2. 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.
3. Insofar as is practical, close all building doors and win-
dows and all doors between the space in which the appli-
ances remaining connected to the common venting sys-
tem are located and other spaces of the building. Turn on
clothes dryers and any appliance not connected to the
common venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a summer
exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being in-spected. Fol-
low the lighting instructions. Adjust thermostat so appli-
ance will operate continuously.
5. Test for spillage at draft hood relief opening after 5
minutes of main burner operation. Use the flame of a
match or candle, or smoke from cigarette, cigar or pipe.
6. After it has been determined that each ap-pliance
remaining connected to common venting system properly
vents when tested as outlined above, return doors, win-
dows, exhaust fans, fireplace dampers and any other
gas-burning appliance to previous conditions of use.
7. Any improper operation of the common venting system
should be corrected so installation conforms with the
National Fuel Gas Code, ANSI Z223.1-latest edition.
When resizing any portion of the common venting sys-
tem, the common venting system should be resized to
approach the minimum size as determined using the
appropriate tables in Appendix G in the National Fuel
Gas Code, ANSI Z223.1-latest edition. For Canada, the
provisions of CAN/CGA B149.1 or .2 shall apply.
ADDITIONAL CHIMNEY REQUIREMENTS: Chimney
condition is of paramount importance for a safe and effi-
cient boiler installation. All installations must include a
chimney inspection by a qualified individual or agency.
Chimney construction materials must be compatible with
the fuel being used.
Particular attention should be paid on all oil-to-gas con-
versions.Soot may have accumulated in chimney and/or
degraded chimney liner. Most utilities require complete
chimney cleaning. Others may require installation of new
liner, spill switches or other chimney upgrades. Check
with local utility for required safety precautions.
AAAAA
MAXIMUM
6-FT
APART
PITCH 1/4"
PER FOOT
SECURE
FLUE PIPE
TO VENT
DAMPER
USE VENT SUPPORT(S) AS REQUIRED TO PREVENT SAGGING
INSTALL
FLUSH
WITH
INSIDE
CHIMNEY
LINER
SEAL
WITH
FURNACE
CEMENT
SINGLE WALL
OR TYPE B
FLUE PIPE
HC-65 = 5"
HC-85 = 5"
HC-100 = 5"
HC-120 = 6"
HC-145 = 6"
HC-165 = 7"
PROCEDURE C: Install flue pipe between vent
damper and chimney (6" minimum clearance
required between flue pipe and combustibles).
FIGURE 1.15
DANGER: A chimney which does not meet modern
safety standards will result in a fire or deadly carbon
monoxide poisoning of the building residents.

9
STEP 4: INSTALLING & TESTING GAS PIPING
Maximum Capacity of Pipe in Cubic Feet of Natural Gas per Hour for Gas Pressures of
0.5 Psig or Less and a Pressure Drop of 0.3 Inch Water Column
(Based on a 0.60 Specific Gravity Gas)
Nominal
Iron Pipe
Size,
Inches
Internal
Diameter
Inches
Length of Pipe, Feet
10
32
72
132
278
520
1,050
1,600
3,050
4,800
8,500
17,500
20
22
49
92
190
350
730
1,100
2,100
3,300
5,900
12,000
30
18
40
73
152
285
590
890
1,650
2,700
4,700
9,700
40
15
34
63
130
245
500
760
1,450
2,300
4,100
8,300
50
14
30
56
115
215
440
670
1,270
2,000
3,600
7,400
60
12
27
50
105
195
400
600
1,150
1,850
3,250
6,800
70
11
25
46
96
180
370
560
1,500
1,700
3,000
6,200
80
11
23
43
90
170
350
530
990
1,600
2,800
5,800
90
10
22
40
84
160
320
490
930
1,500
2,600
5,400
100
9
21
38
79
150
305
460
870
1,400
2,500
5,100
125
8
18
34
72
130
275
410
780
1,250
2,200
4,500
150
8
17
31
64
120
250
380
710
1,130
2,000
4,100
175
7
15
28
59
110
225
350
650
1,050
1,850
3,800
200
6
14
26
55
100
210
320
610
980
1,700
3,500
1/4"
3/8"
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
2-1/2"
3"
4"
.326
.493
.622
.824
1.049
1.380
1.610
2.067
2.469
3.026
4.026
Maximum Capacity of Pipe in Thousands of Btu per Hour of Undiluted Liquifi
Petroleum Gases (at 11 Inches Water Colum Inlet Pressure)
(Based on aPressure Drop of 0.5 Inch Water Column)
Nominal
Iron Pipe
Size,
Inches
Length of Pipe, Feet
10
275
567
1071
2205
3307
6221
20
189
393
732
1496
2299
4331
30
152
315
590
1212
1858
3465
40
129
267
504
1039
1559
2992
50
114
237
448
937
1417
2646
60
103
217
409
834
1275
2394
70
96
196
378
771
1180
2205
80
89
185
346
724
1086
2047
90
83
173
322
677
1023
1921
100
78
162
307
630
967
1811
125
69
146
275
567
866
1606
150
63
132
252
511
787
1498
1/2"
3/4"
1"
1-1/4"
1-1/2"
2"
FIGURE 1.16
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. Determine cubic feet of gas per hour for above boiler model:
120,000 Btu per hour = 117.6 cu.ft. per hour
1020 Btu per cu.ft.
1. Find 20 ft. in upper portion of the table for natural gas under "Length of Pipe, Feet" heading.
2. Moving down the column, match required capacity. Higher capacity acceptable. In our case it is 190 cu.ft.
3. Move to left-hand column "Nominal Iron Pipe Size, Inches"; read required pipe size. In our case it is 3/4".
10 20 30 40 50 60 70 80 90 100 125 150 175 200
10 20 30 40 50 60 70 80 90 100 125 150
Maximum Capacity of Pipe in Thousands of Btu per Hour of Undiluted Liquefied
Petroleum gases (at 11 Inches of Water Column Inlet Pressure)
(Based of a Pressure Drop of 0.5 Inch Water Column)

10
DANGER: Before placing gas piping into service, carefully test it to assure every joint is gas tight. Bubble
test all joints with a soap solution. NEVER TEST WITH AN OPEN FLAME AS FIRE OR EXPLOSION MAY
RESULT.
For any pressure testing in excess of 1/2 psi, the boiler
and its individual shutoff valve must be isolated from the
piping system by disconnecting them and capping the
outlet(s). For any pressure testing equal to or less than
1/2 psi, the boiler must be isolated from the piping sys-
tem by closing its manual shutoff valve.
Minimum pressure required at the gas valve inlet is 5"
W.C. for natural gas and 11" W.C. for propane. Maxi-
mum pressure allowable at the gas valve inlet is 12" W.C.
If the gas pressure is above this limit, a pressure regula-
tor must be installed. If the gas pressure is below these
limits, contact the local utility.
PROCEDURE C: Test gas piping.
WHEN TESTING IS COMPLETED, CLOSE MAIN GAS SHUT-OFF VALVE
& SET BOILER COMBINATION GAS VALVE IN "OFF" POSITION.
PROCEDURE B: Connect gas piping from meter to
boiler following good piping practices. Pipe joint
compound must be compatible with the fuel (NG or
LP) being used. Check local codes and utilities for
any requirements.
All piping must be supported by hangers, not by
boiler or accessories.
AAAAAAAAA
RISER TO OTHER
APPLIANCES
BEAM
PIPE CLAMP GAS
METER
GAS
VALVE
UNION
SEDIMENT
TRAP
MANUAL MAIN
SHUT OFF
VALVE
FIGURE 1.17
STEP 5: WIRING THE BOILER
All electrical wiring must be in accordance with require-
ments of authority having jurisdiction or, in absence of
such requirements, to National Electric Code NFPA-70-
latest edition. If external source is utilized, boiler must be
electrically grounded in accordance with the require-
ments of authority having jurisdiction or, in absence of
such requirements, with National Electric Code NFPA-
70-latest edition. UL listed power limited circuit cable is
almost universally approved for safety controls on heat-
ing equipment, either internally or externally, without pro-
tection of conduits or raceway.
For Canada, all electrical connections are to be made in
accordance with Standard C.S.A. C22.1 Canadian Elec-
trical Code, Part 1 and Part 2 and/or local codes.
NOTE: If any original wire supplied with the boiler
must be replaced, use similar wire of 105 C rating.
Otherwise, insulation may melt or degrade, exposing
bare wire.
NOTE: Boiler transformer must not be used to power
external accessories (i.e., zone valves, relays, etc.).
Otherwise, boiler transformer will be overloaded and
will burn out.
A separate 115V (60Hz) power supply is recommended
for the boiler. Use standard 15-amp fuse and 14-gauge
wire from power supply to boiler. Follow the wiring dia-
gram for your particular installation as shown in Figures
1.18 through 1.24.
WARNING: Turn off electric power supply before ser-
vicing. Contact with live electric components can
cause shock or death.