2
USING THIS MANUAL
2
A. INSTALLATION SEQUENCE . . . . . . . . . . . . . . . . . . . . . . .2
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . . . . . . . . . .2
1.
PREINSTALLATION
3
A. ACCESSIBILITY CLEARANCES . . . . . . . . . . . . . . . . . . . .3
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
C. AIR FOR COMBUSTION AND VENTILATION . . . . . . . . .3
D. PLANNING THE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . .6
2.
BOILER SET-UP
6
3.
WATER PIPING AND CONTROLS
7
A. BOILER SUPPLY AND RETURN . . . . . . . . . . . . . . . . . . . .7
B. SAFETY RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8
C. PIPING FOR ZONED SYSTEMS . . . . . . . . . . . . . . . . . . . .9
D. EXPANSION TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
E. INDIRECT-FIRED WATER HEATER . . . . . . . . . . . . . . . . .10
F.
FREEZE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.
VENTING
11
A. INTEGRAL DRAFT HOOD . . . . . . . . . . . . . . . . . . . . . . . .11
B. VENT DAMPER INSTALLATION GENERAL . . . . . . . . . .11
C. VENT PIPING AND CHIMNEY . . . . . . . . . . . . . . . . . . . .12
D. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.
GAS PIPING
13
6.
ELECTRICAL
15
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
B. ZONED SYSTEM WIRING . . . . . . . . . . . . . . . . . . . . . . .15
C. CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
D. SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . .16
7.
START-UP PROCEDURES
20
A. COMPLETING THE INSTALLATION . . . . . . . . . . . . . . . .20
B. CONTROL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . .24
C. ADJUSTMENT OF GAS PRESSURE REGULATOR . . . .24
D. ADJUSTMENT OF PILOT GAS FLOW . . . . . . . . . . . . . .24
E. CHECKING BURNER INPUT . . . . . . . . . . . . . . . . . . . . . .25
F.
CHECK-OUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . .25
8.
TROUBLESHOOTING
27
A. SHUT-DOWN CAUSED BY PILOT OUTAGE,
BLOCKED VENT SHUT-OFF SWITCH OR
FLAME ROLL-OUT SAFETY SHUT-OFF
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
B. TROUBLESHOOTING GUIDES . . . . . . . . . . . . . . . . . . . .27
9.
MAINTENANCE
30
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
B. DAILY (WITH BOILER IN USE) . . . . . . . . . . . . . . . . . . . .31
C. WEEKLY (WITH BOILER IN USE) . . . . . . . . . . . . . . . . . .31
D. MONTHLY (WITH BOILER IN USE) . . . . . . . . . . . . . . . .31
E. ANNUALLY (BEFORE START OF HEATING
SEASON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
10. BOILER DIMENSIONS & RATINGS
33
11. REPAIR PARTS
34
A. BASE/COMBUSTIBLE FLOOR PAN . . . . . . . . . . . . . . . .34
B. MANIFOLD/GAS TRAIN . . . . . . . . . . . . . . . . . . . . . . . . .35
C. BLOCK/DRAFT HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . .37
D. JACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
E. CONTROLS/CIRCULATOR/VENT DAMPER . . . . . . . . . .39
TABLE OF CONTENTS
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this
manual in the order shown. The order of these
instructions has been set in order to provide the
installer with a logical sequence of steps that will
minimize potential interferences and maximize safety
during boiler installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual you will see special attention
boxes intended to supplement the instructions and
make special notice of potential hazards. These
categories mean, in the judgment of Hydrotherm.:
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
USING THIS MANUAL
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING
INSTALLATION AND OPERATING INSTRUCTIONS
