HydroTherm HW Series Manual

HW2-805
ATU
IAL
STALLATI
INST
GAS
& E
CTION
LE
G
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.
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.
installation and service must be performed by a qualified installer,
service agency or the gas supplier.
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
CONSUMER, RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES.
TEL. (413) 564=5515 FAX [phone]
In Canada: 5211 Creekbank Road, Mississauga, Ont. L4W 1R3 (905) 625=2991 Fax [phone]

Page2 HWNATURALORPROPANEBOILER
iNSTALLATiONANDOPERATINGiNSTRUCTiONS
Ne pas entreposer ni utiliser d'essence ou ni d'autres vapeurs ou liquides inflammables
proximite de cet appareil ou de tout autre appareil.
QUE FAIRE Sl VOUS SENTEZ UNE ODEUR DE GAZ:
•Ne pas tenter d'allumer d'appareil.
•Ne touchez a aucun interrupteur; ne pas vous servir des telephones se trouvant darts
le b_timent.
•Appelez immediatement votre foumisseur de gas depuis un voisin. Suivez les
intructions du foumisseur.
•Si vous ne purvez rejoindre le foumisseur, appelez le service des incendies.
L'installation et I'entretien doivent _tre assures par un installateur ou un service
d'entretien qualifie ou par le foumisseur de gaz.
CONTENTS
Getting Started
Boiler Ratings & Capacities
Locating the Boiler
Combustible Floor Option
Air for Combustion
Chimney & Vent Pipe Connections
Heating System Piping
Gas Supply Piping
Electrical Wiring
Starting the Boiler
Operating the Boiler
Checking & Adjusting
Boiler Maintenance
Instructions to the Owner
Replacement Parts
Canadian Supplement
Health Warnings
page 2
page 3
page 3
page 5
page 5
page 6
page 8
page 11
page 12
page 18
page 20
page 23
page 24
page 25
page 26
page 28
page 30
BEFORE YOU START
These instructionscover the HW gas fired, low pressure,
sectional, cast iron hot water boiler. HW boilers have
been design certified by CSA under the latest revision of
ANSI-Z21.13 for gas fired low pressure steam and hot
water boilers, for use with natural and propane gas.
Each unit has been constructed and hydrostatically
tested for a maximum working pressure of 50 psi, 345
kPa in accordance with the A.S.M.E. Boiler and
Pressure Vessel Code, Section IV for cast iron boilers.
Each boiler has been equipped with a 30 psi pressure
relief valve.
This manual covers the application, installation,
operation and maintenance of a HW low pressure hot
water boiler,
To obtain the safe, dependable, efficient operation and
long life for which this boiler was designed, these
instructions must be read, understood and followed,

HWNATURALORPROPANEBOILER
iNSTALLATiONANDOPERATINGiNSTRUCTiONS Page3
Directall questionsto yourHydrothermdistributoror
writetotheCustomerServiceDepartment,260North
ElmStreet,Westfield,MA01085.Alwaysincludethe
modelandserialnumbersfromtheratingplateofthe
boilerinquestion.
Theownershouldmaintainarecordofallservicework
performedwiththedateandadescriptionofthework
done.Includethenameoftheserviceorganizationfor
futurereference.
Whererequiredbytheauthorityhavingjurisdiction,the
installationmustconformtotheStandardforControls
andSafetyDevicesfor AutomaticallyFiredBoilers,
ANSI/ASMECSD-1.
Theinstallationmustconformto therequirementsof
theauthorityhavingjurisdictionor,in theabsenceof
suchrequirements,to the NationalFuelGasCode,
ANSIZ223.1/NFPA54-latestrevision.In Canada,
installationmustbeinaccordancewiththerequirements
of CAN/CGAB149.1or 2 InstallationCodefor Gas
BurningAppliancesandEquipment.
BOILER RATINGS AND CAPACITIES
Before undertaking the installation of the HW check
the boiler rating plate to ensure that the boiler is the
proper size for the job. The "Net I=B=R Ratings" specify
the equivalent amount of direct cast iron radiation that
the boiler can handle under normal conditions. Also
ensure that the boiler has been set up for the type of
gas available at the installation site. Other important
considerations are the availability of an adequate
electrical supply, fresh air for combustion and a suitable
chimney or vent system.
NOTES:
1. For altitudes above 2000 ft, 610 m, ratings should
be reduced at the rate of 4% for each 1000 ft, 305
mabove sea level, 10% in Canada.
2. If ordering a boiler for use with LP gas add a P to
the model number, ie PHW.
BOILER LOCATION
.Locate the boiler in an area that provides good
access to the unit. Keep in mind that servicing may
require the removal of jacket panels. Accessibility
clearances must take precedence over fire
protection clearances.
2. An optimum site will be level, central to the piping
system, close to a chimney and have adequate
fresh air for combustion.
.Ensure that the floor is structurally sound and will
support the weight of the boiler. This boiler is
designed for non combustible floors only! A special
base supplied by Hydrotherm must be used if the
boiler is to be installed on a combustible floor.
NEVER USE A SUBSTITUTE BASE ON A
COMBUSTIBLE FLOOR! Never install this boiler on
carpeting!
.DO NOT install this boiler in a location that would
subject any of the gas ignition components to direct
contact with water or excessive moisture during
operation or servicing.
5. DO NOT place this boiler in a location that would
restrict the introduction of combustion air into the
boiler. NEVER store objects on or around the boiler.

Page4 HWNATURALORPROPANEBOILER
INSTALLATIONANDOPERATINGINSTRUCTIONS
,If the boiler is to be located in an alcove, closet or
other confined space the distances from the boiler
and it's vent system to all combustible construction
must be equal to or greater than the minimum
clearances in Figure 1. When installed in a closet or
confined space two permanent openings of equal
area adjoining another room or rooms having
sufficient volume to meet the requirements of an
unconfined space must be provided. Each opening
must have a minimum free area of one square inch
per 1000 Btu/hr, 2200 mm2/kWbased on the total
input rating of all gas utilization equipment in the
confined area. Each opening must be no less than
100 in 2, 64516 mm 2, in size. The upper opening
must be within 12 in, 305mm, of, but not less than
3 in, 76 mm, from the top of the enclosure. The
bottom opening must be within 12 in, 305 mm, of,
but not less than 3 in, 76 ram, from the bottom of the
enclosure.
Figure 1:Clearances to Combustible Construction
FRONT
A
B
C
D
E 7
F 4
AL = Alcove
CL = Closet
in
24
6
4
AL
mm
610
152
102
178
102
in
51
2
6
4
7
4
mm
1295
51
152
102
178
102
For
Servicing
in mm
N/A N/A
N/A N/A
6152
4 102
10 254
10 254
CL
*No Front Wall in Alcove

HW NATURAL OR PROPANE BOILER
INSTALLATION AND OPERATING INSTRUCTIONS
COMBUSTIBLE FLOOR OPTION
The HW boiler has been designed for use on
noncombustible floors only. If a HW boiler is to be
installed on combustible flooring of any type, it MUST
be installed using the Special Base designed by
Hydrotherm. Do NOT use any base other than the one
specifically designed for it if installing a HW boiler on
combustible flooring.
To order the Special Base contact the nearest
Hydrotherm distributor and ask for the "Noncombustible
Floor Pan" part number referenced in the Replacement
Parts List in back of the IOM.
Determine where the boiler will be located by following
the instructions in the Boiler Location section of this
manual. Place the Special Base in this location and
fasten it in place to prevent it from moving while the
boiler is being placed on it.
If the HW is being installed inan alcove or closet ensure
that the minimum distance to combustible construction
requirements, listed in Figure 1, are met.
Figure 2: Special Base installation on
Combustible Flooring
FRONT SUPPORT
GRILL CHANNEL
Remove the sheet metal base pan attached to the
boiler. Position the boiler in front of the Special Base. It's
suggested that two lengths of 3" pipe the width of the
boiler, or longer, be placed under the boiler base side
panels.
COMBUSTION AiR
CAUTION: Be careful not to damage the burners,
pilot assembly or any other gas train components
during this procedure, if a component is damaged,
replace it!
Carefully roll the boiler up to the front of the Special
Base. Align the boiler base side panels with the Special
Base support channels. Using great care, slide the boiler
onto the Special Base.
CAUTION: Never lift the boiler by the jacket panels
or flue collector/draft diverter or severe damage to
the boiler may result!
Center the boiler from side to side on the Special Base.
Ensure that the back of the burner base side panels
are flush with the back of the Special Base support
channels. Install the front grill supplied with the Special
Base. Complete the installation in accordance with the
instructions set forth in this manual.
Table 1: Vent and Chimney Dimensions
HW HW HW HW HW HW HW
Boiler Size 50 75 1O0 125 150 175 200
Vent Pipe 5566778
Dia. (In.)
Chimney 8x8 8x12
Flue Size
Chimney 18 18 18 17 17 17 16
Height (Ft.)
Page 5

Page 6 HW NATURAL OR PROPANE BOILER
iNSTALLATiON AND OPERATING iNSTRUCTiONS
To operate properly and safely this boiler requires a
continuous supply of air for combustion. Oxygen is used
by the burners in the boiler to burn the gas. In addition,
air is also used to assist in the safe disposal of the
products of combustion. This air is known as dilution
air and mixes with the products of combustion to assist
in it's exit through the flue pipe and chimney. An
adequate supply of outside air must be available to
replace that used by these processes.
Older houses often have enough "leakage" to provide
an adequate amount of combustion air provided that
the demand for combustion air is not too great. Homes
that are relatively new or "tight" will most likely require
the installation of a fresh air duct or other means of
providing air for combustion. Any home utilizing other
gas burning appliances, a fireplace, wood stove or any
type of exhaust fan must be checked for adequate
combustion air when all of these devices are in operation
at one time. Sizing of an outside air duct must be done
to meet the requirements of all such devices.
Table 2: Combustion Air Duct Sizing
Input Btuh Input Btuh 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"x 8" 256,000 192,000 64,000
8"x 12" 384,000 288,000 96,000
8-1/2" x 16" 512,000 384,000 128,000
If the boiler will be located in an alcove, closet or any
confined space refer to item 6 in the Boiler Location
section of this manual.
VENT CONNECTIONS
Always use a type B or C vent pipe of the proper
diameter for the boiler. Use the shortest, straightest
vent system possible for the particular application. The
vent system should be sloped up toward the chimney
at a rate of 1/4 in/ft, 2 mm/m. Ensure that the flue pipe
is properly supported and each connection securely
fastened with at least 3 corrosion resistant sheet metal
screws. The termination of the vent pipe should be
flush with the inside of the chimney flue.
Always provide a minimum clearance of 6 in, 152 mm,
between type C vent pipe and any combustible
materials. Type B1 vent may be used, clearance
between it and any combustible material must be as
listed.
CHIMNEY & VENT PIPE CONNECTIONS
Chimney inspection & Sizing
if this boiler will be connected to a masonry chimney, a
thorough inspection of the chimney must be performed.
Ensure that the chimney is clean, properly constructed
and properly sized. Table 1 lists the flue size and
chimney height required for this boiler.
When more than one appliance is connected to the
same chimney flue, the flue must be large enough to
handle both appliances.
The vent installation must be in accordance with Part 7
of the latest revision of the National Fuel Gas Code,
ANSI Z223.1/NFPA 54.
Common Vent Systems
If an existing appliance is removed from a common
venting system, the common venting system may then
be too large for the proper venting of the remaining
appliances connected to it. At the time of removal of
an existing boiler, the following steps shall be followed
with each appliance remaining connected to the
common venting system placed in operation, while the
other appliances remaining connected to the common
venting system are not in operation.
Au moment du retrait d'une chaudi_re existante, les
mesures suivantes doivent _tre prises pour chaque
appareil toujours raccorde au syst_me d'evacuation
commun et qui fonctionne alors que d'autres appareils
toujours raccordes au syst_me d'evacuation ne fonction-
nent pas: syst_me d'evacuation.

HWNATURALORPROPANEBOILER
INSTALLATIONANDOPERATINGINSTRUCTIONS Page7
a)
b).
c)
d)
e)
Seal all unused openings in the common vent
system and repair any leaks.
Sceller toutes les ouvertures non utilisees du sys-
t_me d'evacuation.
Visually inspect the vent system to ensure that it is
properly pitched and sized and that there are no
structural deficiencies such as blockages,
restrictions, leakage, or corrosion that could cause
an unsafe condition.
Inspecter de fagon visuelle le syst_me d'evacu-ation
pour determiner la grosser et I'inclinaison horizontale
qui conviennent et s'assurer que le syst_me est
exempt d"obstruction, d"etranglement de fruite, de
corrosion et autres defaillances qui pourraient
presenter des risques.
As far as is practical close all doors and windows
common to the space in which the vent system and
appliances connected to the common vent system
are contained. Turn on all exhaust fans, clothes
dryers, range hoods and appliances requiring air for
combustion that are not connected to the common
vent system. Ensure that all appliances operate at
maximum speed. Do not operate a summer
exhaust fan. Close all fireplace dampers.
Dans la mesure du possible, fermer toutes les portes
et les fen_tres du b&timent et toutes les portes entre
I'espace oQ les appareils toujours raccordes du
syst_me d'evacuation sont installes et les autres
espaces du b&timent. Mettre en marche les
secheuses, tousles appareils non raccordes au
syst_me d'evacuation commun ettousles ventilateurs
d'extraction comme les hottes de cuisin_re et les
venfilateurs des salles de bain. S'assurer que ces
ventilateurs fonctionnent & la vitesse maximale. Ne
pas faire fonctionner les ventilateurs d'ete. Fermer
les registres des cheminees.
Place in operation the appliance being inspected.
Follow the lighting instructions. Adjust thermostat so
appliance will operate continuously.
Mettre I"appareil inspecte en marche. Suivre les
instructions d'allumage. Regler le thermostat de
fagon que I'appareil foncfionne de fa£on continue.
Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of
a match or candle, or smoke from a cigarette, cigar or
pipe.
Fake fonctionner le brOleur principal pendant 5 min
ensuite, determiner si le coupe-tirage deborde &
I'ouverture de decharge. Utiliser la flamme d'une
allunette ou d'une chandelle ou la fumee d'une ciga-
rette, d'un cigare ou d'une pipe.
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers
and any other gas-burning appliance to their previ-
ous condition of use.
Une fois qu"il a ete d etermine, selon la metode
indiquee ci-dessus, que chaque appareil raccorde
au syst_me d'evacuation est mis & I'air libre de fagor
adequate. Remettre les portes et les fen_tres, les
ventilateurs, les registres de cheminees et les
appareils au gaz & leur position originale.
g) Any improper operation of the common venting sys-
tem should be corrected so the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/
NFPA 54. When resizing any portion of the common
venting system, the common venting system should
be resized to approach the minimum size as deter-
mined using the appropriate tables in Appendix F in
the National Fuel Gas Code, ANSI Z223.1/NFPA 54
and or CSA B149 Installation Codes.
Tout mauvais fonctionnement du systeme d'evacu-
tion commun devrait etre corrig_ de fagor que
I'installation soit conforme au National Fue Gas
Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d'in-
stallation CSA-B149. Si la grosseur d'une section du
syst_me d"evacuation doit etre modifiee, le syst_me
devrait etre modifie pour respecter les valeurs
minimales des tableaux pertinents de I'appendice F
du National Fuel Gas Code, ANSI Z223.1/NFPA 54
et (ou) des codes d'installation CSA-B149.
Vent Dampers
This boiler comes from the factory equipped with a
vent damper specifically engineered for it. The vent
damper must be properly installed to obtain the high
performance for which this boiler was designed. If the
damper is damaged or missing do not install the boiler
without it! Contact the nearest Hydrotherm distributor
to obtain the proper vent damper.
Vent dampers are designed for use with only one
appliance. NEVER connect more than one appliance
to a single vent damper.
Locate the vent damper so that it is accessible and the
damper position indicator is visible. Maintain a minimum
of 6 inches between the damper and any combustible
materials!

Page8 HWNATURALORPROPANEBOILER
INSTALLATIONANDOPERATINGINSTRUCTIONS
Fastentheventdampertothefluecollarandventpipe
usingatleast3corrosionresistantsheetmetalscrews
perjoint.Connectthedamperharnesstothetoppanel
with the BXconnectorsupplied. Plugthe Molex
connectoronthedamperharnessintothematingplug
ontheharnesslocatedinsidethecontrolcompartment.
Theventdamperisoperatingproperlywhenit opens
completelyuponacallforheatandclosescompletely
whenthecallforheatends.Theventdampermustbe
intheopenpositionwhentheboilersmainburnersare
inoperation.
Figure3: Vent Damper Location
_ .... '4_'
DAMPER BLADE POSiTiONED
FRONT TO BACK OF BOILER
MOTOR TO FACE
FRONT OF BOILER
FRONTOF
BOILER
Figure 4: Heating System Piping
DISCHARGE PIPE
SIZE TO EQUAL
VALVE OUTLET.
DO NOT RESTRICT
FLOW.
SUPPORT DISCHARGE PIPING
SO AS TO AVOID STRAIN ON
THE VALVE BODY.
/
.... FOR DISCHARGE
THROUGH ROOF
CONSULT
HYDROTHERM.
1" CLEARANCE MUST BE
MAINTAINED BETWEEN
HOT WATER PIPING
AND COMBUSTIBLE
__ CON STRUCTION.
_j oo
0
/J
/
DISCHARGE SO AS TO AVOID EXPOSURE OF PERSONS TO
HOT LIQUID OR VAPOR. LEAVE OPEN END VISIBLE FOR
PERIODIC INSPECTION FOR SLOW LEAKAGE OR DRIPS.
HEATING SYSTEM PIPING
CAUTION: All piping must be installed by a qualified
technician in accordance with the provisions set
forth in the applicable ANSI/ASME standards and
local building codes and regulations, improper
piping of this boiler can cause flooding, extensive
property damage, heating system damage or
damage to the boiler.
The HW hot water boiler comes from the factory ready
to be piped to the heating system. Each boiler is
equipped with a safety relief valve. This valve must be
piped in accordance with the ANSl/ASME Boiler and
Pressure Vessel Code, Section IV. Figure 4 provides a
pictorial description of the boiler and piping components.

HWNATURALORPROPANEBOILER
INSTALLATIONANDOPERATINGINSTRUCTIONS
Theboilershouldbeplacedinthelocationselectedfor
it. Referto the BOILERLOCATIONsectionin this
manual.Ensurethatthe boileris levelfromfrontto
backandfromsideto side.Usemetalshimsto level
the boiler. NEVERuse wood, plastic or other
combustiblematerialsasshims.
All heating system piping must be installed in
accordancewiththeANSI/ASMEBoilerandPressure
VesselCode,SectionIV,andANSI/ASMECSD-1,
Standard for Controls and Safety Devicesfor
AutomaticallyFiredBoilers.Allapplicablelocalcodes
andordinancesmustalsobefollowed.
Iftheboilerisinstalledaboveanyradiationelementsit
mustbefittedwithalowwatercutoffdevice,L.W.C.O.,
installedabovethenormalboilerwaterlevel.
Circulators
ATACO007circulatorhasbeensuppliedasstandard
equipmentwiththeboiler.The007issizedforuseina
closedheatingsystemwitha30 psi, 207kPa, maximum
operating pressure. If the 007 circulator furnished with
this boiler does not have the required capacity for the
system in which it is to be installed, an extra zone
circulator must be provided. A circulator with a higher
capacity may also be used. Figure 5 depicts the
performance curve for the TACO 007 circulator.
Piping For Use With Cooling Units
The boiler, when used in connection with a refrigeration
system, must be installed so the chilled medium is piped
in parallel with the boiler. Appropriate valves must be
used to prevent the chilled water from entering the
boiler. See Figure 6 for the proper piping layout.
When a boiler is connected to a heating coil that may
be exposed to refrigerated air from an air handling
device, the piping system must be equipped with flow-
control valves or some other automatic means of
preventing gravity circulation of the boiler water during
the cooling cycle.
Figure 5: TACO 007 Performance Curve
10
rr
LU
_6
F-
uJ
g4
<
LU
7-
10 15 20 25
FLOW - GPM
Figure 6: Chiller Schematic
NOTE
FOR HEATING:VALVES"H"OPEN, VALVES"C"CLOSED.
FOR COOLING:VALVES"H"CLOSED, VALVES"C"OPEN.
Page 9
CAUTION: To prevent damage due to excessive
condensation, one of the following piping options
should be used.

Page10 HWNATURALORPROPANEBOILER
iNSTALLATiONANDOPERATINGiNSTRUCTiONS
SystemBypass
Forsystemsusinga circulatoronthereturnaseithera
singlezone,ormultiplezoneswithzonevalves,install
a systembypasslinebetweenthesupplyandreturn
on the suctionsideof the circulator,see Figure7.
Installa meteringvalveinthisbypasslineto regulate
theamountofflowthatwillbedivertedtothereturn.A
plugvalveoffersthebestcontrolforthisapplication.
Althoughothervalvesmaybelessexpensive,a plug
valvewillbeeasiertosetaccurately.
In theabsenceof a flow indicator,setthemetering
valveusingtemperatureasaguide.Theaccompanying
diagramsuggestsonescenario.Thisadditionrequires
onlytwotees,aplugvalve,anda smallamountofpipe
andoffersthe simplestapproachto reliablycontrol
condensation.Forthissystemandthosethatfollow,
beawarethatyouareusinga percentageofthepump
capacityto blend,butthefrictionlossfor theentire
pumpflow has beenreduced.In mostcases,the
standardpumppackagedwiththeboilerhasenough
capacitytofeedthebaseboarddistributionsystemand
thebypassline.
Figure7:SystemBypass
SUPPLY RETURN
50%
160°F
50%
120° F
100% 100%
160°F 140°F
SYSTEM
BYPASS
Pump Away Bypass
For systems that use a single circulator to pump away
from the boiler, the bypass should be installed on the
discharge side of the circulator, see Figure 8. Full
temperature water supplies the baseboard distribution
system 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.
Figure 8: Pump Away Bypass
SUPPLY RETURN
50%
160° F
50%
120 ° F
100%
160 ° F100%
140° F
PUMP AWAY
BYPASS
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 9. The dedicated bypass circulator provides
a strong blending flow without diminishing the flow
available to any heating zone. Any residentially sized
circulator is adequate for this purpose.
Each of these bypass solutions also has the added
benefit of increasing circulation in the boiler which will
maximize tankless coil output and increase the accuracy
of temperature sensing controls.
Figure 9: Pumped Bypass
_ _ SUPPLY
100%
160°F
160°F
200%
160°F
PUMPED
BYPASS
RETURN
120° F
200%
140° F