HydroTherm R-180C, R-210C, R-250C, R-300B Installation, Operation & Maintenance Manual & Replacement Parts List

MMOODDEELL RR SSEERRIIEESS



IINNSSTTAALLLLAATTIIOONN,,

OOPPEERRAATTIIOONN &&

MMAAIINNTTEENNAANNCCEE

MMAANNUUAALL &&

RREEPPLLAACCEEMMEENNTT

PPAARRTTSS LLIISSTT

RRCC22--1100004

4

4422--99115599

GGaass--FFiirreedd WWaatteerr CCaasstt IIrroonn BBooiilleerrss

118800,,000000 ttoo 330000,,000000 BBttuuhh IInnppuut

SSttaannddiinngg PPiilloott,, IInntteerrmmiitttteenntt PPiilloott &

VVeenntt DDaammppeer

SSEECCTTIIOONN 11:: BBOOIILLEERR IINNSSTTAALLLLAATTIIOON

Introduction............................................................ 2

Step 1: Locating & Setting Boiler........................... 3

Step 2: Installing/Purging Water Piping................. 5

Step 3: Venting Boiler............................................ 8

Step 4: Installing/Testing Gas Piping..................... 10

Step 5: W

SSEECCTTIIOONN 22:: SSTTAARRTT--UUPP&& OOPPEERRAATTIIOON

Safety Controls......................................................

Start-Up & Adjustments.........................................

iring Boiler.............................................. 11

r

N

N

t

&

17
17

SSEECCTTIIOONN 33:: MMAAIINNTTEENNAANNCCE

Water Treatment.................................................... 20

Freeze Protection................................................... 20

Before Each Heating Season................................

o Change Orifices........................................

How T

Troubleshooting..................................................... 21

(French V

Appendix

Replacement Parts List.......................................... 23

A

E

20
21

ent Damper Translation)..... 22

TES: 260 NOR

A

UNITED

IN

IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONT. L4W IR3 [phone]/FAX [phone]

ST

TH ELM ST., WESTFIELD, MA 01085 [phone]/FAX [phone]

AANNSSII//AASSMMEE CCOODDEE CCOOMMPPLLIIAANNCCEE:

D

*LOCATED IN FRONT ON MODELS R-180C
AND R-210C

PRESS. RELIEF VALVE

TEMP./PRESS. INDICATOR

HI-LIMIT AQUASTAT

7"

GAS VALVE

*

2" SUPPLY

BOILER
MODEL

R-300B

R-250C

R-210C

R-180C 28-1/4" 58-5/8" 7"21-7/8"

DIMENSIONS

ABCD

28-1/4"

32-1/4"

28-7/8"

61-7/8"
65-5/8"7"7"

8"

32-1/4"

29-3/8" 66-1/8"

25-1/8"

B

2" RETURN

9-1/2"

9-1/2"

12"

SPILL SWITCH

ROLLOUT
SWITCH

NOTE: SPILL & ROLLOUT
SWITCHES USED ON
R-180 THRU R-250.

VENT DAMPER

3 5/8"

C

36 3/4"

21 1/4"

A

25 1/2"

:

Installation must
conform to requirements of authority having jurisdiction
or, in absence of such requirements, to National Fuel

as Code ANSI Z223.1-latest edition and to National

G
Electric Code NFPA-70-latest edition. Where required by
authority having jurisdiction, installation must also con­form to Standard for Controls and Safety Devices for

utomatically Fired Boilers, ANSI/ASME CSD-1.

A

BBOOIILLEERR SSHHIIPPMMEENNTT::

Each boiler is shipped in a single
carton. There is a vent damper packed separately with
the boiler (for model R-300 vent damper is optional)

WWAARRNNIINNGG:: IInnssttaalllleerrss mmuusstt ffoollllooww llooccaall rreegguullaattiioonns
wwiitthh rreessppeecctt ttoo tthhee iinnssttaallllaattiioonn ooff CCOO ddeetteeccttoorrss aannd
ffoollllooww tthhee mmaannuuffaaccttuurreerr''ss ssttaatteedd mmaaiinntteennaanncce
sscchheedduullee ffoorr tthhiiss bbooiilleerr!

!

s
d
e

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
Standard C.S.A. C22.1 Canadian Electrical Code, Part 1
and Part 2, and/or local codes.

AATTTTEENNTTIIOONN:: OObbsseerrvveerr lleess rrèègglleemmeennttss rrèèggiioonnaall àà ll''ee­ggaarrdd ddeess ddéétteecctteeuurrss ddee mmoonnooxxyyddee ddee ccaarrbboonnee eet
oobbsseerrvveerr eennttrreettiieenn ddee mmaannuuffaaccttuurriieerr ppoouurr cceetttte
cchhaauuddiièèrree!

!

­t

e

The following terms are used throughout this manual to bring attention to the presence of potential hazards or to
important information concerning the product:

DDAANNGGEERR:: IInnddiiccaatteess aann iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaa­ttiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh,, sseerrii­oouuss iinnjjuurryy oorr ssuubbssttaannttiiaall pprrooppeerrttyy ddaammaaggee.

WWAARRNNIINNGG:: IInnddiiccaatteess aa iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaa­ttiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn ddeeaatthh,, sseerrii­oouuss iinnjjuurryy oorr ssuubbssttaannttiiaall pprrooppeerrttyy ddaammaaggee.

MMOODDEELL RR BBOOIILLEERR DDIIMMEENNSSIIOONNSS

.

.

CCAAUUTTIIOONN:: IInnddiiccaatteess aa iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaa-

-

ttiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, mmaayy rreessuulltt iinn mmiinnoorr iinnjjuurry

-

oorr pprrooppeerrttyy ddaammaaggee.

NNOOTTEE:: UUsseedd ttoo nnoottiiffyy ooff ssppeecciiaall iinnssttrruuccttiioonnss oon

-

iinnssttaallllaattiioonn,, ooppeerraattiioonn oorr mmaaiinntteennaannccee wwhhiicchh aarre

-

iimmppoorrttaanntt ttoo eeqquuiippmmeenntt bbuutt nnoott rreellaatteedd ttoo ppeerrssoonnaal
iinnjjuurryy hhaazzaarrddss.

.

.

-

y

n
e

l

2

SSEECCTTIIOONN 11:: BBOOIILLEERR IINNSSTTAALLLLAATTIIOON

FRONT

ALCOVE

REAR

(6")

W/O CIRC.

24" WITH

CIRCULATOR

(RECOMMENDED

FOR SERVICING)

RECOMMEND
MORE FOR
ACCESS TO
VENT DAMPER
POSITION
INDICATOR

VENT
DAMPER

6" 6"

LEFT

6"

SIDE

VIEW

FRONT

VIEW

TOP

38"

RIGHT

6"

N

SSTTEEPP11:: LLOOCCAATTIINNGG && SSEETTTTIINNGG TTHHEE BBOOIILLEER

R

PPRROOCCEEDDUURREE AA:: CChheecckk tthhaatt pprroovviissiioonnss ffoorr ccoommbbuussttiioonn aaiirr aarree iinn aaccccoorrddaannccee wwiitthh NNaattiioonnaall FFuueell GGaass CCoodde

AANNSSII ZZ222233..11--llaatteesstt eeddiittiioonn aanndd aallll aapppplliiccaabbllee llooccaall ccooddeess.. IInn CCaannaaddaa,, ffoollllooww CCAANN//CCGGA
BB114499((..11 oorr ..22)) iinnssttaallllaattiioonn ccooddeess.

.

WWAARRNNIINNGG:: AAddeeqquuaattee ffrreesshh aaiirr mmuusstt bbee pprroovviiddeedd ffoor
ccoommbbuussttiioonn.. OOtthheerrwwiissee,, iimmpprrooppeerr bbooiilleerr ooppeerraattiioon
aanndd iinnaaddeeqquuaattee vveennttiinngg ooff ddeeaaddllyy fflluuee ggaasseess mmaay

.

rreessuulltt.

When communicating directly with the outside, each

r

opening must have a minimum free area of one square

n

inch per 4000 Btu/hr of gas input. When ventilation air is

y

provided by openings in doors, etc. to adjoining spaces

A

having adequate infiltration, each opening must have a

IIff bbooiilleerr iiss iinnssttaalllleedd iinn aann uunnccoonnffiinneedd ssppaaccee,

,

adequate

air will be available via normal infiltration.

IIff bbooiilleerr iiss iinnssttaalllleedd iinn aa ccoonnffiinneedd ssppaacce

e

(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 con­struction is unusually tight, adequate air for combustion
must be provided by two openings: one located about 6”

minimum free area of one square inch per 1000 Btu/hr of
gas input.

NNOOTTEE:: BBooiilleerr eemmppllooyyss aattmmoosspphheerriicc ccoommbbuussttiioonn.
CCoommbbuussttiioonn aaiirr mmuusstt nnoott bbee ccoonnttaammiinnaatteedd wwiitthh hhaalloo­ggeennaatteedd hhyyddrrooccaarrbboonn vvaappoorrss,, aaeerroossooll pprrooppeellllaannttss oor

ffrreeoonn;; ootthheerrwwiissee,, hheeaatt eexxcchhaannggeerr wwiillll bbeessuubbjjeecctt tto
ccoorrrroossiioonn,, rreedduucciinngg bbooiilleerrlliiffee.

.

below the ceiling, the other about 6” above the floor.

e

.

-

r

o

PPRROOCCEEDDUURREE BB:: CChheecck
mmiinniimmuumm cclleeaarraanncceess tto
ccoommbbuussttiibblleess aarree pprrooppeer
aass sshhoowwnn.. LLooccaall rreeqquuiirree­mmeennttss mmaayy ssppeecciiffy
ggrreeaatteerr cclleeaarraanncceess && mmuusst
bbee aadd--hheerreedd ttoo.

BBooiilleerr sshhaallll bbee iinnssttaallll--eed
ssuucchh tthhaatt tthhee ggaass iiggnniittiioon
ssyysstteemm ccoommppoonneennttss aarre
pprrootteecctteedd ffrroomm wwaatteer
((ddrriippppiinngg,, sspprraayyiinngg,, rraaiinn,
eettcc..)) dduurriinngg aapppplliiaanncce
ooppeerraattiioonn aanndd sseerrvviiccee ((cciirr­ccuullaattoorr rreeppllaacceemmeenntt,, ccoonn­ddeennssaattee ttrraapp,, ccoonnttrrool
rreeppllaacceemmeenntt,, eettcc..)).

WWAARRNNIINNGG:: NNeevveerr iinnssttaallll bbooiilleerr oonn ccoommbbuussttiibbllee fflloooorr­iinngg oorr ccaarrppeettiinngg aass hheeaatt ddaammaaggee aanndd//oorr ffiirree mmaay
rreessuulltt.

.

.

.

k

o

r

-

y

t

d
n

e

r

,

e

-

­l

NNOOTTEE:: DDoo nnoott lloooosseenn ttiiee rrooddss oonn aabbssoorrppttiioonn uunniitt.

-

TThheeyy aaccccoommmmooddaattee tthheerrmmaall eexxppaannssiioonn.. LLoossss ooff bbooiill-

y

eerr ssttrruuccttuurraall iinntteeggrriittyy aanndd wwaatteerr lleeaakkss//ddaammaaggee mmaay

.

rreessuulltt.

CCAAUUTTIIOONN:: LLooccaattee bbooiilleerr ssoo hhoorriizzoonnttaall ccoonnnneeccttiinng
fflluuee ppiippee iiss aass sshhoorrtt aass ppoossssiibbllee.. MMaaxxiimmiizzee hheeiigghhtt oof
vveerrttiiccaall fflluuee ccoonnnneeccttoorr.

.

FIGURE 1.1

.

-

y

g

f

3

BAFFLE
GRID

DOME

6"

4

" HOLLOW CLAY TILE (TWO COURSES) OPENINGS THRU

B

LOCKS IN TOP COURSE TO BE AT 90 ANGLE TO OPENINGS

THRU BOTTOM COURSE

0

22 GAUGE
SHEETMETAL

FLOOR

6" OVERHANG
OF BLOCK AND
SHEETMETAL
A

LL AROUND

LEFT TOP PANEL

FRONT PANEL
(BOILER MOUNTED)

RIGHT SIDE PANEL

RIGHT TOP PANEL

LEFT SIDE PANEL

REAR PANEL

REMOVE KNOCK-OUT

ASSEMBLY SCREW

PPRROOCCEEDDUURREE CC:: CChheecckk ccoommppoonneenntt ppoossiittiioonniinngg..

1. Remove all packing material from boiler.

. Install boiler on non-combustible flooring only, unless

2
local codes permit use and fabrication of a recommend­ed fireproof base (see Figure 1.2A).

FIGURE 1.2A FIGURE 1.2B

3. Check that burners and controls are in the proper
position.

. Check proper seating of baffle grid inside of dome

4
opening (see Figure 1.2B).

PPRROOCCEEDDUURREEDD:: IInnssttaallll jjaacckkeett.

.

1. Unpack jacket parts from carton and check that quan­tity is correct: two side panels, one rear panel, one left
top panel and one right top panel (see Figure 1.3).

2. Stand left and right side panels in place and fasten to
front panel with screws provided. Fasten side panels to
rear panel in same manner.

3. Lock left and right halves of top panel together and fas­ten to side panels with screws provided.

FIGURE 1.3

4

SHUT-OFF
VALVE

VERTICAL EXPANSION TANK
ARRANGEMENT (PREFERRED)

DRAIN VALVE

SHUT-OFF
VALVE

PRESS.
RELIEF
VALVE

AIR VENT

SHUT-OFF
VALVE

PRESSURE
REDUCING
(FILL) VALVE

SHUT-OFF
VALVES

CIRCULATOR

DRAIN VALVE

HORIZONTAL EXPANSION
TANK ARRANGEMENT

DRAIN VALVE

SSTTEEPP22:: IINNSSTTAALLLLIINNGG && PPUURRGGIINNGG WWAATTEERR PPIIPPIINNG

PRESS. RELIEF VALVE

AIR
VENT

RELIEF VALVE DISCHARGE
PIPING

G

NNOOTTEE:: BBooiilleerr mmuusstt nnoott bbee uusseedd wwiitthhoouutt ffoorrccee cciirrccuu­llaattiioonn,, aass oovveerrhheeaattiinngg oorr ffaaiilluurree ooff ccaasstt iirroonn
sseeccttiioonnss mmaayy rreessuulltt.

PPRROOCCEEDDUURREE AA:: IInnssttaallll pprreessssuurree rreelliieeff vvaallvvee aannd
rreelliieeff vvaallvvee ddiisscchhaarrggee ppiippiinngg.. FFoorr MMooddeell RR--330000B
ssuuppppllyy oouuttlleett iiss aatt rreeaarr aanndd rreelliieeff vvaallvvee ppiippiinngg iiss aat
ffrroonntt ooff bbooiilleerr.

.

d

B

t

.

RReelliieeffVVaallvveeDDiisscchhaarrggeePPiippiinngg:: MMuusstt tteerrmmiinnaattee 66”
aabboovvee fflloooorr && bbee ssaammee ssiizzee oorr llaarrggeerr tthhaann vvaallvvee oouuttlleett.

WWAARRNNIINNGG:: NNoo vvaallvvee ooff aannyy ttyyppee mmaayy bbee iinnssttaalllleed
bbeettwweeeenn bbooiilleerr && rreelliieeff vvaallvvee ttoo pprreevveenntt aacccciiddeennttaal
eexxpplloossiioonn ffrroomm oovveerr--pprreessssuurree..

PPRROOCCEEDDUURREE BB:: IInnssttaallll ssuuppppllyy aanndd rreettuurrnn wwaatteer
ppiippiinngg.. FFoorr MMooddeellss RR--118800CC && 221100CC ssuuppppllyy oouuttlleett iis
aatt ffrroonntt ooff bbooiilleerr aanndd rreelliieeff vvaallvvee ppiippiinngg iiss aatt rreeaarr oof

.

bbooiilleerr.

-

”

.

CCAAUUTTIIOONN:: PPiippiinngg mmuusstt bbee iinnssttaalllleedd ffrroomm rreelliieeff vvaallvve

d

ddiisscchhaarrggee ssoo tthheerree wwiillll bbee nnoo ddaannggeerr ooff ssccaallddiinngg ppeerr-

l

ssoonnnneell.

r

IIff bbooiilleerr iiss iinnssttaalllleedd aabboovvee lleevveell ooff rraaddiiaattiioonn,, aa lloow

s

wwaatteerr ccuutt--ooffff mmuusstt bbee uusseedd.

.

.

f

AALLLLEEXXTTEERRNNAALLPPIIPPIINNGG MMUUSSTT BBEE SSUUPPPPOORRTTEEDD BBY
HHAANNGGEERRSS,, NNOOTT BBYYBBOOIILLEERR AACCCCEESSSSOORRIIEESS.

FIGURE 1.4

e

-

w

Y

.

FIGURE 1.5

5

S

UPPLY

R

ETURN

50%

120° F

100%

140° F

1

00%

160° F

50%

160° F

50%

160° F

SYSTEM
BYPASS

SUPPLY

RETURN

50%

120° F

100%

140° F

100%

160° F

50%

160° F

50%

160° F

PUMP AWAY

BYPASS

SUPPLY

RETURN

100%

120° F

200%

140° F

200%

160° F

100%

160° F

100%

160° F

PUMPED

BYPASS

CCAAUUTTIIOONN:: TToo pprreevveenntt ddaammaaggee dduuee ttoo eexxcceessssiivvee ccoonn­ddeennssaattiioonn,, oonnee ooff tthhee ffoolllloowwiinngg ppiippiinngg ooppttiioonnss sshhoouulld
bbee uusseedd.

.

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d

SSYYSSTTEEMM BBYYPPAASSS

S

For systems using a circulator on the return as either a
single zone, or multiple zones with zone valves, install a
system bypass line between the supply and return on the
suction side of the circulator (see Figure 1.6). Install a

etering valve in this bypass line to regulate the amount

m
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 dia­gram 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 condensa­tion. 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 pack­aged with the boiler has enough capacity to feed the
baseboard distribution system and the bypass line.

PPUUMMPPAAWWAAYYBBYYPPAASSS

S

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 1.7). 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 1.6

PPUUMMPPEEDD BBLLEENND

D

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 1.8). 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 maxi
mize tankless coil output and increase the accuracy of
temperature sensing controls.

FIGURE 1.7

-

FIGURE 1.8

6

VALVE “C”

VALVE “B”

VALVE “A”

VALVE “D”

VALVE “E”

VALVE “F”

NOTE: VALVES "H" OPENED ON HEATING WITH "C" VALVES
CLOSED REVERSE PROCEDURE ON COOLING.

EXP. TANK

VENT

ROOM
UNIT

DRAIN

CHILLER

BOILER

HCP

UMP

RELIEF
VALVE

FILL
VALVE

DRAINCH

BOILER

reverse

aquastat

N.O.

T

T

t'stat

G

V

115 volts

24 volts

circulator

operating

aquastat

N.C.

REVERSE

AQUASTAT

SET AT 120° F

RREEVVEERRSSEE AACCTTIINNGG AAQQUUAASSTTAATTS

S

An alternative for existing systems experiencing conden­sation that does not require re-piping the boiler utilizes a
reverse acting aquastat, one that makes on temperature

ise. This approach works best in single zone systems.

r
Wired in series with the circulator, this control holds the cir­culator off until the boiler reaches an acceptable tempera­ture and then starts system circulation (see Figure 1.9).

he most commonly available reverse acting aquastat is

T
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 maximum (25­30°F) will minimize short cycling.

FIGURE 1.9

PPRROOCCEEDDUURREE CC:: FFoorr ccoommbbiinnaattiioonn hheeaattiinngg aanndd ccooooll­iinngg iinnssttaallllaattiioonnss oonnllyy.

.

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 1.10). When
boilers are connected to heating coils located in air han­dling units where they may be exposed to refrigerated air
circulation, such boiler piping system shall be equipped
with flow-control valves or other means to prevent gravi­ty circulation of the boiler water during the cooling cycle.

PPRROOCCEEDDUURREE DD:: CCoommpplleetteellyy ffiillll && ppuurrgge
hheeaattiinngg ssyysstteemm.. MMaakkee ssuurree tthhaatt aallll hheeaatt­iinngg ssyysstteemm mmaannuuaall aaiirr vveennttss aarree cclloosseedd.

e

­.

1. Check flow direction arrows on hydronic
components are facing in proper direction.

Attach hose to drain valve “B” and close

2.
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”.

-

FIGURE 1.10

4. Open valves “C” and “D”.

FFOORR WWAATTEERR TTRREEAATTMMEENNTT && FFRREEEEZZEE PPRROOTTEECCTTIIOONN RREEQQUUIIRREEMMEENNTTSS,,

SSEEEE ““SSEECCTTIIOONN 33:: MMAAIINNTTEENNAANNCCEE”” IINN TTHHIISS MMAANNUUAALL

FIGURE 1.11

7

SSTTEEPP33:: VVEENNTTIINNGG TTHHEE BBOOIILLEER

FLOW DIRECTION
ARROW POINTS UP

MOUNT
VENT DAMPER
OVER
DRAFTHOOD

MAKE SURE
MOTOR IS
LOCATED
ON LEFT SIDE

ATTACH LOWER
PORTION OF
VENT DAMPER
TO DRAFTHOOD
WITH 1/2" OR
SHORTER SCREWS
OR POP RIVETS

OPEN

OPEN

1

REMOVE
SHIPPING
CLIP

2

OBSERVE
DAMPER
ROTATES
TO OPEN
POSITION
WITHOUT
OBSTRUCTION

PLUG INTO MOLEX
RECEPTACLE ON FRONT
OF BOILER

PLUG INTO MOLEX
RECEPTACLE INSIDE
DAMPER MOTOR

VENT
DAMPER
WIRE
HARNESS

I

NSTALL

SWITCH

IN OPENING

ON DRAFTHOOD

C

ONNECT

WIRE

LEADS

I

NSTALL

MOUNTING

BRACKET

ON DRAFTHOOD

R

DDAANNGGEERR:: DDrraafftt hhoooodd aanndd vveenntt oouuttlleett mmuusstt nnoott bbe
aalltteerreedd,, aass pprrooppeerr ooppeerraattiioonn wwoouulldd bbee jjeeooppaarrddiizzeedd;
ffllaammee rroolllloouutt,, ffiirree oorr ccaarrbboonn mmoonnooxxiiddee ppooiissoonniinng
wwiillll rreessuulltt.

.

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;

g

PPRROOCCEEDDUURREE AA:: MMoouunntt ddrraafftt hhoooodd aanndd ssppiillll sswwiittcchh oon

.

bbooiilleerr.

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. R-C boilers are equipped with factory-mounted spill
switch harness/mounting bracket as-sembly; 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.

NNOOTTEE:: FFoorr bbooiilleerrss eeqquuiippppeedd wwiitthh iinntteerrmmiitttteenntt ppiilloot
iinnssttaallll pplluugg ssuupppplliieedd iinn ddaammppeerr ppaacckkaaggee iinnttoo ddaammppeer
vvaannee hhoollee.. FFoorr ssttaannddiinngg ppiilloott bbooiilleerrss ddiissccaarrdd pplluugg.
AAddddiittiioonnaall vveennttiinngg aanndd cchhiimmnneeyy rreeqquuiirreemmeennttss aarre
pprroovviiddeedd oonn ppaaggee 99.

.

n

4. Plug wiring leads from harness/bracket assembly onto
flat terminals on spill switch.

NNOOTTEE::BBooiilleerr wwiillll nnoott ooppeerraattee uunnlleessss wwiirriinngg lleeaaddss tto
ssppiillll sswwiittcchh aarree ccoonnnneecctteedd.

.

t
r

.

e

FIGURE 1.8

o

PPRROOCCEEDDUURREE BB:: IInnssttaallll vveenntt ddaammppeerr.. ((FFoorr FFrreenncchh vveerrssiioonn,, sseeee AAppppeennddiixx AAaatt rreeaarr ooff mmaannuuaall..)

)

DDAANNGGEERR:: OOnnllyy tthhee bbooiilleerr mmaayy bbee sseerrvveedd bbyy tthhee vveenntt ddaammppeerr.. DDoo nnoott uussee iitt ttoo vveenntt aann aaddddiittiioonnaall aapppplliiaannccee;
tthhiiss wwiillll ccaauussee ffiirree oorr ccaarrbboonn mmoonnooxxiiddee ppooiissoonniinngg.

11.. MMoouunntt ddaammppeerr oonn ttoopp ooff ddrraafftt hhoooodd.

FIGURE 1.13

33.. CChheecckk ddaammppeerr ooppeerraattiioonn.

.

.

.

22.. SSeeccuurree ddaammppeerr ttoo ddrraafftt hhoooodd.

44.. CCoonnnneecctt wwiirree hhaarrnneessss.

.

FIGURE 1.14

.

;

FIGURE 1.15

FIGURE 1.16

8

MAXIMUM

6-FT

APART

PITCH 1/4"

P

ER FOOT

S

ECURE
FLUE PIPE
TO VENT
DAMPER

USE VENT SUPPORT(S) AS REQUIRED TO PREVENT SAGGING

INSTALL

F

LUSH

WITH

I

NSIDE

CHIMNEY

LINER

SEAL
WITH

FURNACE

CEMENT

SINGLE WALL
OR TYPE B
FLUE PIPE
R

-180 = 7"
R-210 = 7"
R

-250 = 7"
R-300 = 8"

PPRROOCCEEDDUURREE CC:: IInnssttaallll fflluuee ppiippee bbeettwweeeenn vveenntt ddaammppeerr aannd

cchhiimmnneeyy ((66”” mmiinniimmuumm cclleeaarraannccee rreeqquuiirreed
bbeettwweeeenn fflluuee ppiippee aanndd ccoommbbuussttiibblleess)).

d

.

d

ing 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 windows and all doors between the
space in which the appliances remaining con-

1. Seal all unused openings in common vent-

ected to the common venting system are

n
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. Follow the lighting instructions. Ad-just ther­mostat so appliance 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.

FIGURE 1.17

AADDDDIITTIIOONNAALLVVEENNTTIINNGG RREEQQUUIIRREEMMEENNTTSS:

:

When connecting
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 mechanical 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 venting
system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it.
of removal of existing boiler

, following steps shall be followed

with each appliance remaining connected to the common vent-

ing system placed in operation, while other appliances remain­ing connected to common venting system are not in operation:

At time

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, windows, 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 system, 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.

AADDDDIITTIIOONNAALLCCHHIIMMNNEEYYRREEQQUUIIRREEMMEENNTTSS:

:

Chimney condi­tion is of paramount importance for a safe and efficient 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 conversions.
Soot may have accumulated in chimney and/or degraded chim
ney 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.

DDAANNGGEERR:: AAcchhiimmnneeyy wwhhiicchh ddooeess nnoott mmeeeett mmooddeerrn
ssaaffeettyy ssttaannddaarrddss wwiillll rreessuulltt iinn aa ffiirree oorr ddeeaaddllyy ccaarrbboon
mmoonnooxxiiddee ppooiissoonniinngg ooff tthhee bbuuiillddiinngg rreessiiddeennttss.

9

-

n
n

.

SSTTEEPP44:: IINNSSTTAALLLLIINNGG && TTEESSTTIINNGG GGAASS PPIIPPIINNG

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 Liquefied

Petroleum Gases (at 11 Inches Water Column Inlet Pressure)

(Based on a Pressure 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"

G

PPRROOCCEEDDUURREE AA:: SSeelleecctt ggaass ppiippee ssiizzee wwhhiicchh wwiillll rreessuulltt iinn aa pprreessssuurree ddrroopp ooff lleessss tthhaann 00..33”” WW..CC.. ffoorr nnaattuurraal

l

ggaass oorr 00..55”” WW..CC.. ffoorr pprrooppaannee,, ffoolllloowwiinngg eexxaammppllee bbeellooww..

EExxaammppllee:

:

Boiler Model R-180C 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:

118800,,000000 BBttuu ppeerr hhoouur

r

= 176.4 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

FIGURE 1.18

PPRROOCCEEDDUURREEBB:: CCoonnnneecctt ggaass ppiippiinngg ffrroomm mmeetteerr tto

R

ISER TO OTHER

APPLIANCES

B

EAMPIPE CLAMP

GAS

METER

GAS
VALVE

UNION

SEDIMENT
TRAP

M

ANUAL MAIN
SHUT OFF
VALVE

bbooiilleerr ffoolllloowwiinngg ggoooodd ppiippiinngg pprraaccttiicceess.. PPiippee jjooiinnt
ccoommppoouunndd mmuusstt bbee ccoommppaattiibbllee wwiitthh tthhee ffuueell ((NNGG oor
LLPP)) bbeeiinngg uusseedd.. CChheecckk llooccaall ccooddeess aanndd uuttiilliittiieess ffoor
aannyy rreeqquuiirreemmeennttss..

o

t
r
r

AALLLLPPIIPPIINNGG MMUUSSTT BBEE SSUUPPPPOORRTTEEDD BBYYHHAANNGGEERRSS,
NNOOTT BBYYBBOOIILLEERR OORR AACCCCEESSSSOORRIIEESS.

PPRROOCCEEDDUURREECC::TTeesstt ggaass ppiippiinngg.

.

.

,

FIGURE 1.19

DDAANNGGEERR:: BBeeffoorree ppllaacciinngg ggaass ppiippiinngg iinnttoo sseerrvviiccee,, ccaarreeffuullllyy tteesstt iitt ttoo aassssuurree eevveerryy jjooiinntt iiss ggaass ttiigghhtt.
BBuubbbbllee tteesstt aallll jjooiinnttss wwiitthh aa ssooaapp ssoolluuttiioonn.. NNEEVVEERR TTEESSTT WWIITTHH AANN OOPPEENN FFLLAAMMEE AASS FFIIRREE OORR EEXXPPLLOO­SSIIOONN MMAAYYRREESSUULLT

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 sys­tem by closing its manual shutoff valve.

T

.

Minimum pressure required at the gas valve inlet is 5”
W.C. for natural gas and 11” W.C. for propane. Maximum
pressure allowable at the gas valve inlet is 12” W.C. If the
gas pressure is above this limit, a pressure regulator
must be installed. If the gas pressure is below these lim­its, contact the local utility.

.

-

WWHHEENN TTEESSTTIINNGG IISS CCOOMMPPLLEETTEEDD,, CCLLOOSSEE MMAAIINN GGAASS SSHHUUTT--OOFFFF VVAALLVVEE

&& SSEETT BBOOIILLEERR CCOOMMBBIINNAATTIIOONN GGAASS VVAALLVVEE IINN ““OOFFFF”” PPOOSSIITTIIOONN..

SSTTEEPP55:: WWIIRRIINNGG TTHHEE BBOOIILLEER

WWAARRNNIINNGG:: TTuurrnn ooffff eelleeccttrriicc ppoowweerr ssuuppppllyy bbeeffoorre
sseerrvviicciinngg.. CCoonnttaacctt wwiitthh lliivvee eelleeccttrriicc ccoommppoonneennttss ccaan
ccaauussee sshhoocckk oorr ddeeaatthh.

All electrical wiring must be in accordance with require­ments of authority having jurisdiction or, in absence of
such requirements, to National Electric Code NFPA-70­latest edition. If external source is utilized, boiler must be
electrically grounded in accordance with the require­ments of authority having jurisdiction or, in absence of
such requirements, with National Electric Code NFPA­70-latest edition. UL
almost universally approved for safety controls on heat­ing equipment, either internally or externally, without pro­tection of conduits or raceway

For Canada, all electrical connections are to be made in
accordance with Standard C.S.A. C22.1 Canadian
Electrical Code, Part 1 and Part 2 and/or local codes.

.

listed power limited circuit cable is

.

R

NNOOTTEE:: IIff aannyy oorriiggiinnaall wwiirree ssuupppplliieedd wwiitthh tthhee bbooiilleer

e

mmuusstt bbee rreeppllaacceedd,, uussee ssiimmiillaarr wwiirree ooff 110055 CC rraattiinngg.

n

OOtthheerrwwiissee,, iinnssuullaattiioonn mmaayy mmeelltt oorr ddeeggrraaddee,, eexxppoossiinng
bbaarree wwiirree.

NNOOTTEE:: BBooiilleerr ttrraannssffoorrmmeerr mmuusstt nnoott bbee uusseedd ttoo ppoowweer
eexxtteerrnnaall aacccceessssoorriieess ((ii..ee..,, zzoonnee vvaallvveess,, rreellaayyss,, eettcc..)).
OOtthheerrwwiissee,, bbooiilleerr ttrraannssffoorrmmeerr wwiillll bbee oovveerrllooaaddeedd aannd
wwiillll bbuurrnn oouutt.

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 dia­gram for your particular installation as shown in Figures

1.20 through 1.28.

.

.

r

.

g

r

.

d

11

FFIIGGUURREE 11..2200:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEEDD WWIITTH

IINNTTEERRMMIITTTTEENNTT PPIILLOOTT,, VVEENNTT DDAAMMPPEERR && LL88114488E

AAQQUUAASSTTAATT RREELLAAY

12

N

H

E

Y

FFIIGGUURREE 11..2211:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEEDD WWIITTH

IINNTTEERRMMIITTTTEENNTT PPIILLOOTT && VVEENNTT DDAAMMPPEERR &

HHIIGGHH LLIIMMIITT AAQQUUAASSTTAATT

N

H

&

FFIIGGUURREE 11::2222:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEEDD WWIITTHH IIIIDD,

VVEENNTT DDAAMMPPEERR && LL44008811BB DDUUAALLAAQQUUAASSTTAAT

N

,

T

13

CAUTION

THIS BOILER IS EQUIPPED WITH 24 VOLT

CONTROLS. DO NOT CONNECT GAS VALVE

TO LINE VOLTAGE.

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED

WITH THE BOILER MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE MTW(105¡C)

WIRE OR ITS EQUIVALENT.

115VAC,60H

Z

HN

115/24V

42-3902 Rev. 6

FIELD WIRING

FACTORY WIRING

TRANSFORMER

HI-LIMIT

AQUASTAT

THERMOSTAT

24VOLT
GAS VALVE

B

L

K

TH

TR

115V AC

115V, 60HZ PRI.
24V, 20VA SEC.

HI-LIMIT

T’STAT

THTR

B

L

K

CAUTION

T

HIS BOILER IS EQUIPPED WITH 24 VOLT

CONTROLS. DO NOT CONNECT GAS VALVE

TO LINE VOLTAGE.

42-5538 Rev. 4

115V ACL1L2

T’STAT

115/24V

1K1

C1

C2

CIRC.

MOTOR

JUMPER

1K

T

TV

Z

W

IF ANY OF THE ORIGINAL WIRE AS SUPPLIED

WITH THE BOILER MUST BE REPLACED,

IT MUST BE REPLACED WITH TYPE MTW(105¡C)

WIRE OR ITS EQUIVALENT.

FIELD WIRING
FACTORY WIRING

GAS VALVE

B

L

K

TH

TR

B

L

K

115V

CIRC.

AQUASTAT

RELAY

TZTV

B

1B2

C

1

C2

L

1

L2

THERMOSTAT

TH

TR

1K2

B

R

B2

B1

FFIIGGUURREE 11..2233:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEEDD WWIITTH

SSTTAANNDDIINNGG PPIILLOOT

T

N

H

FFIIGGUURREE 11..2244:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEEDD WWIITTH

SSTTAANNDDIINNGG PPIILLOOTT && LL88114488EE AAQQUUAASSTTAATT RREELLAAY

N

H

Y

14

FFIIGGUURREE 11..2255:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEED

WWIITTHH IINNTTEERRMMIITTTTEENNTT PPIILLOOT

N

D

T

FFIIGGUURREE 11..2266:: WWIIRRIINNGG DDIIAAGGRRAAMM && OOPPEERRAATTIIOON

SSEEQQUUEENNCCEE FFOORR BBOOIILLEERRSS EEQQUUIIPPPPEEDD WWIITTH

IINNTTEERRMMIITTTTEENNTT PPIILLOOTT && LL88114488EE AAQQUUAASSTTAATT RREELLAAY

N

H

Y

15

T2: 24V TRANSF.
TH1: 24V T’STAT.
TH2: 24V T’STAT.

TH3: 24V T’STAT.
ZV1: ZONE VALVE
ZV2: ZONE VALVE

ZV3: ZONE VALVE
R1: AQUASTAT RELAY - L8148E
GV: GAS VALVE

TH1

TH2

N

H

115V

T

H3

ZV1

ZV2

ZV3

T2

YEL

R

ED

Y

EL RED

R1

TV T

2

W

B

1B2

TH

TR

C

1C2

L1 L2

GV

N

H

115V

TO CIRC.

RED

R

ED

RED

RED

YEL

YEL

YEL

YEL

FFIIGGUURREE 11..2277:: WWIIRRIINNGG DDIIAAGGRRAAMM FFOORR ZZOONNIINNGG WWIITTHH ZZOONNEE VVAALLVVEES

C2

C1

2

31

4

T

T

2

3

14

X

X

T

X

T

X

TH1

TH2

ZR1

ZR2

N

H

115V

TH

TR

GV

T1

TO

ADDITIONAL

ZONES

H1

C1: ZONE CIRCULATOR

TH1: ZONE T’STAT

C2: ZONE CIRCULATOR

TH2: ZONE T’STAT

ZR1: ZONE RELAY (RA832A
OR EQUIVALENT)

ZR2: ZONE RELAY (RA832A
OR EQUIVALENT)

H1: HI-LIMIT AQUASTAT
GV: GAS VALVE
T1: 24V TRANSFORMER

T2,T3: TRANSF. (IN RELAYS)

1R-1, 1R-2: ZR1 CONTACTS
2R-1, 2R-2: ZR2 CONTACTS

FACTORY WIRING

FIELD WIRING

T1

115V

1R-2

2R-2

H1

BOILER CIRCUIT

1R-1

T2

2R-1

T3

TH2

TH1

ZR1 ZR2

CIRC.

1

CIRC.

2

115V

BLACK

WHITE

EXTERNAL CIRCUIT

GAS VALVE
COIL

FFIIGGUURREE 11..2288:: WWIIRRIINNGG DDIIAAGGRRAAMM FFOORR ZZOONNIINNGG WWIITTHH CCIIRRCCUULLAATTOORRS

16

S

S

SSEECCTTIIOONN 22:: SSTTAARRTT--UUPP&& OOPPEERRAATTIIOON

SPILL SWITCH

ROLLOUT
SWITCH

DAMPER POSITION INDICATOR
MUST BE IN VISIBLE LOCATION
FOLLOWING INSTALLATION.

OPEN

CLOSED

FLOW DIRECTION

N

SSAAFFEETTYY CCOONNTTRROOLLSS

Spill switch (see
Figure 2.1) detects the
escape of combustion
products through the

raft hood relief open-

d
ing and interrupts the
power to the gas valve
preventing unsafe boil­er operation. Escape
of flue products could
be caused by a
blocked or collapsed
chimney or by inade­quate chimney draft.

TThhiiss iiss aa mmaannuuaall rree­sseett--ttyyppee ddeevviiccee aannd
ccaann bbee rreeaaccttiivvaatteedd bby
ddeepprreessssiinngg tthhee ssppiilll
sswwiittcchh rreesseett bbuuttttoonn.

Flame rollout switch
(see Figure 2.1) pre­vents flame rollout from the boiler combustion chamber,
caused by blocked boiler flue passageways, by interrupt­ing power to the gas valve to prevent unsafe boiler oper-

TThhiiss iiss aa ssiinnggllee uussee ddeevviiccee aanndd mmuusstt bbee rree-

ation.

ppllaacceedd iiff iitt iiss ttrriippppeedd.

ed by a qualified installer if problem occurs, prior to
switch replacement.

DDAANNGGEERR:: IIff ffllaammee rroolllloouutt sswwiittcchh oorr ssppiillll sswwiittcchh ttrriipps
rreeppeeaatteeddllyy dduurriinngg ssttaarrtt--uupp oorr ooppeerraattiioonn,, iitt iinnddiiccaatteess a
hhaazzaarrddoouuss ccoonnddiittiioonn ttoo bbee ccoorrrreecctteedd iimmmmeeddiiaatteellyy.

WWAARRNNIINNGG:: IIff bbooiilleerr ccaannnnoott bbee rreessttoorreedd ttoo nnoorrmmaal
ooppeerraattiioonn aafftteerr rreesseettttiinngg ooff ssppiillll sswwiittcchh,, oorr iiff ffllaamme
rroolllloouutt sswwiittcchh hhaass ttrriippppeedd,, ddoo nnoott aatttteemmpptt ttoo ppuutt tthhe
bbooiilleerr iinn ooppeerraattiioonn.. IImmmmeeddiiaatteellyy ccoonnttaacctt aa qquuaalliiffiieed
sseerrvviiccee pprrooffeessssiioonnaall.

­d
y

l

.

FIGURE 2.1

.

Flue passages must be inspect-

.

.

floor. Open vents one at a time until water squirts out.
Close vent and repeat procedure with remaining vents.

2. Make sure boiler combination gas valve is in OFF
position. Then, open main gas shutoff valve, allowing gas
to flow to boiler.

3.Set thermostat heat anticipator at .8 amp when therm­ostat is controlling boiler directly. When zone controlled,
set heat anticipator to amp draw of zone valve or circu­lator pump relay.

4. Set thermostat to call for heat and turn on electrical
power to boiler.
Observe that vent
damper position indi­cator has rotated to
open position (see
Figure 2.2).

mmuusstt bbee iinn ooppeen
ppoossiittiioonn wwhheenn bbooiill­eerr mmaaiinn bbuurrnneerr iis
ooppeerraattiinngg.. IInn ccaasse
ooff aa ddaammppeerr mmaall­ffuunnccttiioonn,, tthhe
ddaammppeerr bbllaaddee mmaay
bbee mmaannuuaallllyy ppllaacceed

-

iinn tthhee ffuullll ooppeen

DDaammppeer

r

n

­s
e

­e
y

d
n

FIGURE 2.2

ppoossiittiioonn ttoo ppeerrmmiitt bbuurrnneerr ooppeerraattiioonn.. TToo aaccccoommpplliissh
tthhiiss,, ffiirrsstt ddiissccoonnnneecctt eelleeccttrriiccaall ppoowweerr aanndd tthheenn sseeppaa­rraattee tthhee vveenntt ccoonnnneeccttoorr ffrroomm tthhee ddaammppeerr.. MMaannuuaalllly

s

((uussiinngg hhaanndd ttoooollss iiff rreeqquuiirreedd)) rroottaattee tthhee bbllaaddee uunnttiil

a

tthhee eenndd sswwiittcchh cclloosseess.. RReeppoossiittiioonn aanndd rreeccoonnnneecctt tthhe
vveenntt ccoonnnneeccttoorr ttoo tthhee bbooiilleerr bbeeffoorree ttuurrnniinngg oonn tthhe
eelleeccttrriiccaall ppoowweerr.

l

e

5. Allow circulator to run 15 to 30 minutes, which should

e

purge any leftover air from system. Check automatic air

d

vent for the proper operation and entire system for any

.

leaks. Make sure all air is purged from system before
lighting boiler

.

h

-

y

l
e
e

SSTTAARRTT--UUPP && AADDJJUUSSTTMMEENNTTSS

Safe lighting and other performance criteria were met
with the gas manifold and control assembly provided on
the boiler when the boiler underwent tests specified in
ANSI Z21.13-1991.

WWAARRNNIINNGG:: KKeeeepp bbooiilleerr aarreeaa cclleeaarr aanndd ffrreeee ffrroomm ccoomm­bbuussttiibbllee mmaatteerriiaallss,, ggaassoolliinnee aanndd ootthheerr ffllaammmmaabblle
vvaappoorrss aanndd lliiqquuiiddss.. OOtthheerrwwiissee,, ffiirree oorr eexxpplloossiioonn mmaay
rreessuulltt.

1. Bleed all heating system air vents, starting on lowest

.

6. Set thermostat to no longer call for heat. Observe that
damper position indicator rotated to closed position.

7. Set thermostat to lowest setting and light boiler follow­ing lighting instructions in Figures 2.4, 2.5, 2.6 & 2.7.
Boiler is equipped with flame rollout switch to shut down
boiler in case of sustained flame roll-out or excessive

-

heat behind front panel. If switch opens, see the infor

e

mation on “Safety Controls” on this page.

y

8. Observe pilot and main burner flame (see Figure 2.3).
All burner ports should be ignited and burn with a steady
blue flame.

17

-

used per hour). Multiply this figure by the heating

N

ORMAL PILOT FLAME

Q314ALB

STANDING

PILOT

MODELS

L

IFTING

(TOO MUCH AIR)

Y

ELLOW

TIPPING

(MARGINAL)

MAIN BURNER FLAMES

N

ORMAL

(HARD FLAME)

Y

ELLOW

FLAME

(TOO LITTLE AIR)

Q345ALB

INTERMITTENT

IGNITION

P

ILOT

MODELS

Q314ALB

STANDING PILOT

M

ODELS

value of the gas to obtain Btu input per hour.

Example: An R-300B boiler takes 2 minutes to use 10

ubic feet of natural gas. Local utility indicated heating

c
value of the natural gas being supplied is 1020 Btu/cu
ft. Therefore:

(2x60) = 120 seconds

CCAAUUTTIIOONN:: NNeevveerr lleeaavvee tthhee jjoobb wwiitthh yyeellllooww bbuurrnniinng
ffllaammeess.. TThhiiss ccoonnddiittiioonn iinnddiiccaatteess ppoooorr ccoommbbuussttiioon
aanndd wwiillll qquuiicckkllyy ccaarrbboonniizzee tthhee bbooiilleerr,, rreedduucciinngg eeffffii­cciieennccyy aanndd bbooiilleerr lliiffee.. IItt mmaayy aallssoo bbee aann iinnddiiccaattiioonn oof
iimmpprrooppeerr vveennttiinngg oorr ccoommbbuussttiioonn aaiirr ssuuppppllyy.. IIff uunnaabblle
ttoo aaddjjuusstt ffllaammee pprrooppeerrllyy,, ccoonnssuulltt yyoouurr llooccaall uuttiilliittyy.

9. Boilers are shipped from the factory with the primary
air shutters on the main burner wide open. It is recom­mended these air shutters be left in the wide open posi­tion unless there is lifting of the flame above the burner
ports. If there is lifting, the air shutters should be gradu­ally closed until the lifting is eliminated. It may also be
necessary to adjust the primary air shutters if the input
rate is reduced by a change in the orifices.

10. After burner has been in operation for about 10 min­utes, check gas input rate to boiler as follows:

a. Make sure that all appliances served by meter are
turned off during timing of gas input rate to the boiler.

b. Measure the time in seconds it takes for the boiler
to use10 cubic feet of gas. Divide 36,000 by the num­ber of seconds (this is the number of cubic feet of gas

FIGURE 2.3

36,000

x 1020 = 306,000 Btu/hr

120

Therefore, the boiler input is correct.

NNOOTTEE:: BBeeffoorree ccaallccuullaattiinngg tthhee iinnppuutt ooff tthhee hheeaattiinng
eeqquuiippmmeenntt,, oobbttaaiinn tthhee hheeaattiinngg vvaalluuee ooff tthhee ggaass ffrroom

g

m

tthhee llooccaall uuttiilliittyy..

11. If boiler input needs to be corrected, adjust the com­bination gas valve pressure regulator. (Regulator is fac­tory set at 3.5” W.C. for natural gas or 10” W.C. for
propane.) Turn adjusting screw clockwise to increase gas
flow (increase input). Turn adjusting screw counterclock­wise to decrease gas flow (decrease input). In no case,
should final manifold pressure setting vary more than .2”
from factory-set pressures. If rated input cannot be
obtained with regulator adjustment, gas supply pressure

g

or orifice size may be the cause. Consult your local utili-

n

ty and Hydrotherm.

­f

12. The gas burner orifices supplied with the boiler have

e

.

been carefully designed to provide the correct gas input
rate for most gas conditions typically found in the U.S.
Occasionally, however, the local gas characteristics may
not allow the unit to be properly adjusted for input. If this
is the case, the local utility or Hydrotherm may recom­mend the orifices be changed. When changing orifices,
follow the procedures in Section 3 of this manual.

13. Start and stop burners several times by raising and
lowering the thermostat setting.

14. After the boiler has been firing long enough to raise
the boiler water temperature to above the minimum set­ting of the high limit, check the high limit by turning its set­ting from maximum to minimum setting. This should turn
the boiler off. Return high limit to desired setting.

15. W

ith the boiler firing, disconnect the wire connected
to the “PV” terminal on Honeywell S8600 control. Gas
valve should close.

18

WWAARRNNIINNGG:

INLET

GAS CONTROL KNOB
SHOWN IN "OFF" POSITION

GAS

O

N

OFF

RESET BUTTON

P

ILOT

INLET

GAS CONTROL KNOB
SHOWN IN "OFF" POSITION

GAS

ON

OFF

IIff yyoouu ddoo nnoott ffoollllooww tthheessee iinnssttrruuccttiioonnss eexxaaccttllyy,, aa ffiirree oorr eexxpplloossiioonn mmaayy rreessuulltt wwiitthh pprrooppeerrttyy ddaammaaggee,, ppeerrssoonnaall iinnjjuurryy,, oorr lloossss ooff lliiffee.

AA.. BBEEFFOORREE OOPPEERRAATTIINNG

area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.

WWHHAATT TTOO DDOO IIFF YYOOUU SSMMEELLLLGGAAS

Do not try to light any appliance.

•

• Do not touch any electrical switch; do not use any phone
in your building.

Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire

G

smell all around the appliance

S

:

.

BB.

Use only your hand to push in or turn the gas control
knob, don’t try to repair it, call a qualified service tech­nician. Force or attempted repair may result in a fire or
explosion.

.

CC.

o not use this appliance if any part has been under

D
water. Immediately call a qualified service technician to
inspect the appliance and to replace any part of the
control system and any gas control which has been
under water.

department.

LLIIGGHHTTIINNGG CCOONNTTIINNUUOOUUSS PPIILLOOTT IINNSSTTRRUUCCTTIIOONNSS

SSttaannddiinngg PPiilloott HHoonneeyywweellll VVRR8833000

NNaattuurraall oorr PPrrooppaannee GGaas

0

s

.

TThhiiss aapppplliiaannccee hhaass aa ppiilloott wwhhiicchh mmuusstt bbee lliitt bbyy hhaanndd.. WWhheenn lliigghhttiinngg tthhee ppiilloott,, ffoollllooww tthheessee iinnssttrruuccttiioonnss eexxaacctt-

11.. SSTTOOPP!

page.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

4. Remove control access panel (If applicable).

5. Turn gas control knob clockwise to “OFF”.

6. Wait five (5) minutes to clear out any gas. Then smell
for gas, including near the floor. If you then smell gas,

SSTTOOPP!

!

Read the safety information above on this

!

Follow “A” in the safety information above. If you

• If button does not pop up when released, stop immedi­ately and call your service technician or gas supplier.

• If the pilot will not stay lit after several tries, turn the gas
control knob to “OFF” and call your service technician or
gas supplier.

11. Replace the base door.

12. Turn gas control knob counterclockwise to “ON”.

13. Turn on all electric power to the appliance.

14. Set thermostat to desired setting.

don’t smell gas, go to the next step.

7. Remove the base door covering the top of the burners
and enclosing the pilot.

8. Find pilot – Follow metal tube from gas control. The
pilot is between the central burner tubes behind the base
door.

9. Turn knob on gas control counterclockwise to “Pilot”.

10. Push down and hold the red button next to the control
knob. Immediately light the pilot with a match.
Continue to hold the red button down for about one (1)
minute after the pilot is lit.
Release button and it will pop back up. Pilot should
remain lit. If it goes out, repeat steps 5 through 10.

OOPPEERRAATTIINNGG IINNSSTTRRUUCCTTIIOONNS

HHoonneeyywweellll VVRR8833004

HHoonneeyywweellll VVRR8833000

S

4

0

-

1.

Read the safety information above.

!

SSTTOOPP!

2. Set the thermostat to lowest setting.
3 Turn off all electric power to the appliance.

4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to light the
pilot by hand.
5 Remove control access panel, (if applicable)

6. Rotate gas control knob clockwise to “OFF”
ait five (5) minutes to clear out any gas.

7. W

Then smell for gas, including near the floor.

!

If you then smell gas

SSTTOOPP!

Follow “A” in the safety infor-

mation above. If you don’t smell gas, go to next step.

8. Turn gas control knob counterclockwise to “ON”.

9. Replace control access panel.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting.

12. If the appliance will not operate, follow the instructions
“To Turn Off Appliance” and call your service technician or
gas supplier.

19

TTOOTTUURRNNOOFFFF GGAASS TTOOAAPPPPLLIIAANNCCE

1. Set the thermostat to lowest setting.
. Turn off all electric power to the appliance if service is

2

to be performed.

E

3. Turn gas control knob counterclockwise to “OFF” Do
ot force.

n

SSEECCTTIIOONN 33:: MMAAIINNTTEENNAANNCCE

This boiler has been designed to provide years of trouble
free performance in normal installations. Examination by
the homeowner at the beginning of each heating season,
and in mid-heating season, should assure continued
good performance. In addition, the boiler should be
examined by a qualified service professional at least
once every year.

DDAANNGGEERR:: TToo aavvooiidd ffiirree aanndd eexxpplloossiioonn hhaazzaarrddss:: DDo
nnoott ssttoorree aannyytthhiinngg aaggaaiinnsstt bbooiilleerr oorr aallllooww ddiirrtt//ddeebbrriis
ttoo aaccccuummuullaattee iinn aarreeaa iimmmmeeddiiaatteellyy ssuurrrroouunnddiinngg bbooiill­eerr.. KKeeeepp bbooiilleerr aarreeaa cclleeaarr aanndd ffrreeee ffrroomm ccoommbbuussttiibblle
mmaatteerriiaallss,, ggaassoolliinnee aanndd ootthheerr ffllaammmmaabbllee vvaappoorrss aannd
lliiqquuiiddss.. DDoo nnoott aallllooww lliinntt,, ppaappeerr oorr rraaggss ttoo aaccccuummuu­llaattee nneeaarr bbuurrnneerrss.. DDoo nnoott ppllaaccee ccllootthhiinngg oonn bbooiilleerr tto

.

ddrryy.

NNOOTTEE:: BBooiilleerr iiss nnoott ffoorr uussee iinn ssyysstteemmss wwhheerree wwaatteer
iiss rreepplleenniisshheedd.. DDoo nnoott ddrraaww wwaatteerr ffrroomm ssyysstteemm ffoor
cclleeaanniinngg.. MMiinneerraallss iinn wwaatteerr ccaann bbuuiilldd uupp oonn hheeaat
ttrraannssffeerr ssuurrffaacceess aanndd ccaauussee oovveerrhheeaattiinngg aanndd ssuubbssee­qquueenntt ffaaiilluurree ooff ccaasstt iirroonn sseeccttiioonnss.

NNOOTTEE:: DDoo nnoott oobbssttrruucctt tthhee ffllooww ooff ccoommbbuussttiioonn aannd
vveennttiillaattiioonn aaiirr.

.

.

E

BBEEFFOORREE EEAACCHH HHEEAATTIINNGG SSEEAASSOONN

. Remove and inspect draft hood and vent piping (con-

1
necting draft hood to chimney or vent) for obstructions,
soot accumulation, rust or corrosion. Clean and replace
as necessary. Check tightness of joints; seal all joints
where necessary.

2. Check boiler flue passageways in the boiler sections

o

for any blockage or soot accumulation. Remove draft

s

hood, jacket top and cast iron dome. Using a flash light,

-

examine all flue passageways.

e
d

-

o

r
r

t

-

d

a. If passageways are free of soot and obstructions,
replace dome and seal with furnace cement or high
temperature silicone adhesive/sealant.

b. If passageways need cleaning, remove burners as
described in paragraph 3 below. Insert long-handle
bristle flue brush down between section tubes and
upward through sections from combustion chamber in
both diagonal directions to remove carbon from fin­ned surfaces. Vacuum debris. Replace dome and seal
with furnace cement or high temperature silicone
adhesive/sealant.

c. Reinstall jacket top panel and draft hood.

NNOOTTEE:: IIff bbooiilleerr iiss eeqquuiippppeedd wwiitthh aa llooww wwaatteerr ccuuttooffff,
ffoollllooww mmaannuuffaaccttuurreerr’’ss mmaaiinntteennaannccee iinnssttrruuccttiioonnss..

WWAATTEERR TTRREEAATTMMEENNTT

ater treatment is recommended in areas where water

W
quality is a problem. A local water treatment company
should be consulted to determine the requirements for
your particular system and locality

.

FFRREEEEZZEE PPRROOTTEECCTTIIOONN

Where absolutely necessary, system antifreeze can be
utilized. It must be compatible with hydronic heating sys­tems. System must be designed to accommodate nec­essary changes in heat transfer, pump head, flow rate &
expansion. For more information, consult The Hydronics
Institute Technical Topics Number 2A publication.

NNOOTTEE:: NNeevveerr uussee aann RRVV--ttyyppee aannttiiffrreeeezzee pprrootteeccttiioon
ssoolluuttiioonn nnoorr aann aauuttoommoottiivvee--ttyyppee aannttiiffrreeeezzee aass ddaamm­aaggee ttoo tthhee bbooiilleerr aanndd ootthheerr ssyysstteemm ccoommppoonneennttss mmaay

.

rreessuulltt.

3. Check and clean burner assembly. Remove burner

,

access panel. To remove burners, lift up and to rear until
burners are disengaged from orifices. Brush top of burn­ers with soft bristle brush; blow out with air or vacuum.

4. Check gas manifold for proper position and reassem
ble burners to the manifold. Line up holes in burners with
the orifices and slide assembly back into position. BE
SURE
TOP SURFACE (UPRIGHT).

5. When a low water cut-of
manufacturer’s maintenance instructions. As a minimum,
test electronic control operation at least once a year.
Float type controls should be flushed twice a year

6. Lubricate circulator motor according to manufacturer’s
instructions.
ing on the pump frame.

n

-

7. Follow “System Start-Up & Adjustments” procedures in

y

Section 2 of this manual.

TO REINSTALL BURNER WITH PORTS ON THE

f has been utilized, follow the

This information may be contained in label

-

.

-

20

HHOOWW TTOO CCHHAANNGGEE OORRIIFFIICCEESS

DRILL SIZE

MODEL

M

ANIFOLD

PRESSURE

N.G. L.P.

N

AT. GAS

1000 BTU

CU. FT .60 SG.

L.P. GAS

2500 BTU

C

U. FT 1.5 SG

TYPE OF GAS

R-180C
R-210C
R-250C
R-300B

3.5

3.5

3.5

3.5

10.0

10.0

10.0

10.0

52
51
51
49

39
35
35
31

1. Shut off power supply and gas supply to the boiler.

2. Remove burner access panel. To remove burners, lift
up & to rear until burners are disengaged from orifices.

3. Check orifices for proper drill size. Size is stamped
onto the body of the brass orifice. The size can also be

hecked by using a pin gauge (see Figure 3.1). All ori-

c
fices are screwed into the manifold and may be removed
by using a 5/8” wrench or socket.

4. Reverse above procedures to install orifices & burn-

FIGURE 3.1

ers. BE SURE TO INSTALL BURNERS WITH BURNER
PORTS ON TOP SURFACE (UPRIGHT).

EEQQUUIIVVAALLEENNTT OORRIIFFIICCEE SSIIZZEESS AATT HHIIGGHH AALLTTIITTUUDDEESS ((IINNCCLLUUDDEESS 44%% IINNPPUUTT RREEDDUUCCTTIIOONN FFOORR EEAACCHH 11,,000000 FFEEEET

OOrriiffiiccee SSiizzee

MMooddeell ## FFuueell TTyyppee OOrriiffiiccee QQttyy.. SSeeaa LLeevveell 22000000 fftt.. 33000000 fftt.. 44000000 fftt.. 55000000 fftt.. 66000000 fftt.. 77000000 fftt.. 88000000 fftt.. 99000000 fftt.. 1100000000 fftt..

R-180C NG 6 39 40 41 41 42 42 43 43 44 44
R-180C LP 6 52 52 53 53 53 53 53 54 54 54
R-210C NG 6 35 36 36 37 37 38 39 40 41 42
R-210C LP 6 51 51 52 52 52 52 53 53 53 54
R-250C NG 7 35 36 36 37 37 38 39 40 41 42
R-250C LP 7 51 51 52 52 52 52 53 53 53 54
R-300B NG 7 31 32 32 32 33 34 35 36 37 38
R-300B LP 7 49 50 50 50 51 51 51 52 52 52

OORRIIFFIICCEE PPAARRTT NNUUMMBBEERRSS

SSIIZZE

E

E

HHYYDDRROOTTHHEERRM

PPAARRTT NNOO.

OORRIIFFIICCE

31 25-1118
32 25-1132
33 25-1130
34 25-1119
35 25-1126
36 25-1120
37 25-1121

M

OORRIIFFIICCE

.

SSIIZZE

E

E

HHYYDDRROOTTHHEERRM

PPAARRTT NNOO.

38 25-1137
39 25-1125
40 25-1136
41 25-1135
42 25-1111
43 25-1112

M

OORRIIFFIICCE

.

SSIIZZE

E

E

HHYYDDRROOTTHHEERRM

PPAARRTT NNOO.

M

.

49 25-1127
50 25-1123
51 25-1124
52 25-1129
53 25-1128
54 25-1115

44 25-1113

T

NNOO HHEEAAT

T

1. Blown fuse or circuit breaker.

2. Power switch turned of

f.

3. IID system malfunction.

4. Vent damper not open.

5. Circulator not running.

6. Air in lines and radiation.
ripped rollout switch.

T

7.
ripped spill switch.

T

8.

IINNSSUUFFFFIICCIIEENNTT HHEEAAT

1. Incorrect t’

stat anticipator setting.

T

2. Hi-limit control setting too low.

3. Boiler undersized or underfired.

4. Insuf

CCAAUUTTIIOONN:
LLaabbeell aallll wwiirreess pprriioorr ttoo ddiissccoonnnneeccttiioonn wwhheenn sseerrvviicciinngg ccoonnttrroollss.. WWiirriinngg eerrrroorrss ccaann ccaauussee iimmpprrooppeerr aanndd ddaannggeerr­oouuss ooppeerraattiioonn.. VVeerriiffyy pprrooppeerr ooppeerraattiioonn aafftteerr sseerrvviicciinngg.

ficient radiation.

:

TTRROOUUBBLLEESSHHOOOOTTIINNG

G

5. Air traps in lines or radiation.

OOVVEERRHHEEAATTIINNG

G

1. Wrong thermostat anticipator set­ting.

2. Bad thermostat location.

3. Bad thermostat.

OODDOORR,, EEXXCCEESSSSIIVVEE MMOOIISSTTUURREE IIN
BBUUIILLDDIINNG

G

1. Leak in piping.

2. Carbon build-up in flueways.

3. Blocked chimney.

4. Downdrafts- incorrect termination

.

21

YYEELLLLOOWW FFLLAAMMEE,, CCAARRBBOON
BBUUIILLDD--UUP

P

1. Unit overfired.

2. Air shutter misadjustment

3. Wrong orifices.

4. Burning in burner mixing tube.

5. Inadequate combustion air.

6. Inadequate draft (flue blockage).

N

E

NNOOIISSE

Ignition-incorrect air shutter

1.
adjustment.

2. Whistle due to burr on orifices.

3. Burner “fluteing” -air shutter open-

ing too wide.

N

-

APPENDIX A

1. Monter le volet de ventilation sur la partie
supérieure du coupe-tirage.

MONTER LE VOLET
DE VENTILATION
AU-DESSUS DU COUPE­TIRAGE.

LA FLÈCHE DE DIRECTION
DE L'ÉCOULEMENT POINTE
VERS LE HAUT

FIGURE 1.9

MÉTHODE D' INSTALLATION B: pour le volet motorisé de ventilation.

DANGER: Le volet de ventilation doit servir seulement á la chaudière. Ne pas l'utiliser

pour ventiler d'autres appareils; sinon cela pourrait provoquer un incendie ou causer un

empoisonnement par le monoxyde de carbone.

2. Fixer le volet de ventilation au coupe-tirage.

FIGURE 1.10

ATTACHER LA PARTIE
INFÉRIEURE DU VOLET
DE VENTILATION AU
COUPE-TIRAGE À L'AIDE
DE VIS DE 1/2 po OU PLUS
COURTES OU DES RIVETS
AVEUGLES.

FIGURE 1.12

3. Verifier le fonctionnement du volet de ventilation.

'

FAISCEAU DE FILS
DU VOLET DE
VENTILATION.

FIGURE 1.11

OUVERT

OUVERT

1

2

4. Brancher le faisceau de fils.

S'ASSURER QUE
LE VOLET DE
VENTILATION
TOURNE VERS
LA POSITION
OUVERTE
SANS
OBSTRUCTION.

ENLEVER L ATTACHE
D'EXPÉDITION.

ENFICHER DANS LA PRISE
MOLEX SUR LE DEVANT
DE LA CHAUDIÈRE.

ENFICHER DANS LA PRISE
MOLEX À L'INTÉRIEUR DU
MOTEUR DU VOLET DE
VENTILATION.

S'ASSURE QUE
LE MOTEUR SOIT
SITUÉ A GAUCHE

LE REGISTRE DOIT ETRE EN
POSITION OUVERTE LORSQUE
LE BRULEUR PRINCIPAL EST EN
MARCHE.

OUVERTE

CLOS

SENS DE DEBIT

^

^

FIGURE 2.2

22

M

ODDEELLRR

M

O

SSEERRIIEES

RREEPPLLAACCEEM

PPAARRTTSS LLIISST

S

MEENNTT

T

ORDERING INFORMATION

When ordering replacement parts, provide
the model and serial number shown on the
unit rating plate as well as the part number
and name as shown in the parts list. Parts
may be obtained from your local Hydro­therm heating contractor

F

RREEF
NNOO..NNAAMMEE OOFF PPAARRT

1 Absorption Unit BM-3105 1 1

Absorption Unit BM-3106 1 1
2 Section, Base BM-9686 1 1 11
3 Section, Middle BM-9689 2 2 3 3

Section, Middle (1/2" Tap) BM-9690 1 1 1 1
4 Section, Top BM-9691 1 1

Section,
5 Push Nipple 53-1373 4 4 5 5
6 Tie Rod - 5/16X16 1/2" with N. & W. 44-1116 2 2

ie Rod - 5/16X20" with N.& W.

T

T

T

op BM-9692 1

.

NNUUMMBBEERR RREEQQUUIIRREEDD PPEERR BBOOIILLEERR

PPAARRTT NNOO.

44-1105 2 2

.

RR--118800C

C

RR--221100C

1

C

RR--225500C

C

RR--330000B

B

7 Base Side Plate - L.H. - Insulated BM-3333 1 1 1 1

Base Side Plate - R.H. - Insulated BM-3334 1 1 1 1

8
9 Front Tie Bar 03-3024 1 1 1 1

10 Rear Tie Plate - Insulated BM-3335 1 1 1 1

Base Door - Insulated BM-3336 1 1 1 1

1

1
12 Bracket, Manifold - L.H. 55-1606 1 1 1 1
13 Bracket, Manifold - R.H. 55-1607 1 1 1 1

Bracket, Burner

14

Bracket, Burner 55-1031 1 1

15 Reflector Shield 03-3219 1 1 1 1

Burner (Nat.) 03-7112 5 5 6 6

16

Burner (Prop.) 03-7114 5 5 6 6

Burner w/Pilot Bracket (Nat.) 03-7117 1 1 1 1

Burner w/Pilot Bracket (Prop.)

55-1030 1 1

03-7118 1 1 1 1

23

F

RREEF
NNOO..NNAAMMEE OOFF PPAARRT

7 Burner Orifice#39 (Nat.) (R Only) 25-1125 6

1

T

PPAARRTT NNOO.

.

NNUUMMBBEERR RREEQQUUIIRREEDD PPEERR BBOOIILLEERR

RR--118800C

C

RR--221100C

C

RR--225500C

C

RR--330000B

Burner Orifice #35 (Nat.) R Only 25-1126 6 7

urner Orifice #31 (Nat.) 25-1118 7

B

Burner Orifice # 52 (Prop.) 25-1129 6

Burner Orifice # 51 (Prop.) 25-1124 6 7

Burner Orifice # 49 (Prop.) 25-1127 7

18 Manifold 24-1109 1 1

Manifold 24-1110 1 1

19 Pilot Ass'y-Nat.Q314A w/Q309A&BCR18 BM-8072 1 1 1 1

Pilot Ass'y-Prop.Q314A w/Q309A&BBR10 BM-8073 1 1 1 1

20 Pilot Orifice - Nat. (BCR18) 62-3326 1 1 1 1

Pilot Orifice - Prop. (BBR10) 62-3327 1 1 1 1

22 Thermocouple - (Q309A) 04-1302 1 1 1 1
23 Pilot Line with Fittings BM-3318 1 1 1 1
24 Gas Valve - Nat. VR8300C 4043 02-1552 1 1 1 1

Gas Valve - Prop. VR8300C 4035 02-1553 1 1 1 1

25 Hi-Limit Aquastat-L4006A BM-4897 1

Hi-Limit Aquastat-L4080B 02-2700 1 1 1

Aquastat Relay-R8148E

02-2406 1 1 1 1
26 Well - 1/2" 02-3413 1 1 1 1
27 Temp./Press. Indicator (For 30 # R.V.) 20-1014 1 1 1 1

Temp./Press. Indicator (For 50 # R.V.) 20-1003 1 111
Temp./Press. Indicator (For 75/100 # R.V.) 20-1011 1 1 1 1

29 Grid Ass'y. BM-9614 1

Grid Ass'y. BM-9615 1
Grid Ass'y. BM-9616 1
Grid 03-2206.1 1

30 Dome - 7" 01-2104 1 1

Dome - 7" 01-2106 1

Dome - 8" 01-2105 1
31 Bracket, Dome 55-3800 2 2 2 2
32 Draft Hood for Spill Switch - 7" (R Only) 03-8144 1

Draft Hood for Spill Switch- 7"(R Only) 03-8143 1 1

Draft Hood - 8" (R-300) 03-7609 1
33 Nipple - 3/4" X 9 " 53-1133 1 1

Nipple - 3/4" X 11" 53-1135 1 1

Coupling - 3/4" 56-5001 1

34

1

1

35 Press. Relief Valve - 30 PSI 22-1203 1 1 1 1

Press. Relief Valve - 50 PSI 22-1200 1 1 1 1

Press. Relief V

alve - 75 PSI 22-1803 1 111

Press. Relief Valve - 100 PSI 22-1201 1 1 1 1
36 Transformer - 115/24V, 20VA 26-3005 1 1 1 1
37 Junction Box - 24V 58-1800 1 1 1 1
38 Side Panel - Jacket 03-1060.1 2 2 2 2
39 Front Panel - Jacket 03-1033 1 1 1 1
40 Rear Panel - Jacket 03-1034 1 1 1 1
41 Top Panel - L.H. - Jacket 03-1060.4 1 1 1 1
42 Top Panel - R.H. - Jacket 03-1060.6 1 1 1 1

Jacket

-

Ass'y (Less Front Panel) 03-1032 1 1 1 1

- Cope Seal - 5 Ft. Increments 10-6625 - - - -

B

1

24

4

1

42

38

44

39

48

*

20 & 50

*

*

THESE ITEMS ARE USED WITH

INTERMITTENT PILOT SYSTEMS

36 & 46

*

37

25

26

27

3

5

34

33

6

5

7

12

11

9

24 & 47

*

23

18

19 & 20

17

22

16

13

8

14

15

10

4

3

3

2

1

29

30

31

3

2

43

38

4

0

FFIIGGUURREE 11:: RR GGEENNEERRAALLAASSSSEEMMBBLLY

Y

25

F

RREEF
NNOO..NNAAMMEE OOFF PPAARRT

3 Spill Switch (Manual Reset) (R Only) 58-2526 1 1 1

4
44 Rollout Switch (Thermal Fuse)(R Only) 58-2525 1 1

Rollout Switch (Thermal Fuse)(R Only) 58-2538 1

T

PPAARRTT NNOO.

.

NNUUMMBBEERR RREEQQUUIIRREEDD PPEERR BBOOIILLEERR

RR--118800C

C

RR--221100C

C

RR--225500C

C

RR--330000B

B

D

)

RR--221100C

T

PPAARRTT NNOO.

C

.

R

RR--225500C

NNOO.. RREEQQ''D

C

RR--330000B

MMUULLTTII--TTEEMMPPJJAACCKKEETT PPAARRTTSS LLIISST

""AA"" BBAATTTTEERRYY((22 MMOODDUULLEESS))""BB"" BBAATTTTEERRYY((33 MMOODDUULLEESS)

NNAAMMEE OOFF PPAARRT

Jacket - Complete BM-9112 1 BM-9113 1
Side Panel 03-1060.1 2 03-1060.1 2
Front Panel
Rear Panel 03-1060.3 1 03-1061.3 1
Top Panel L.H. 03-1060.4 1 03-1060.4 1

op Panel - Center 03-1060.5 1 03.1060.5 2

T
Top Panel - R.H. 03-1060.6 1 03-1060.6 1
Stiffening Channel 03-1060.7 2 03-1060.7 3

T

PPAARRTT NNOO.. NNOO.. RREEQQ''D

03-1060.2 1 03-1061.2 1

AADDDDIITTIIOONNAALLCCOOMMPPOONNEENNTTSS FFOORR VVEENNTT DDAAMMPPEER

((FFoorr uussee wwiitthh IInntteerrmmiitttteenntt PPiilloott OOnnllyy)

F

RREEF
NNOO..NNAAMMEE OOFF PPAARRT

- Vent Damper 7" 02-5854 1 1 1

- Vent Damper 8" 02-5855 1

- Cable Bracket 03-7144 1 1 1 1

T

PPAARRTT NNOO.

.

NNUUMMBBEERR RREEQQUUIIRREEDD PPEERR BBOOIILLEERR

C

RR--118800C

)

D

B

PPAARRTTSS FFOORR HHOONNEEYYWWEELLLLIINNTTEERRMMIITTTTEENNTT PPIILLOOTT SSYYSSTTEEMM ((SSEEEE FFIIGGUURREE 11)

RREEFFNNUUMMBBEERR RREEQQUUIIRREEDD PPEERR BBOOIILLEERR
NNOO..NNAAMMEE OOFF PPAARRT

46 Transformer - 40VA 26-3001 1 1 1 1

Gas Valve-24V Nat. VR8304P 4332 02-1554 1 1 1 1

47

Gas Valve-24V Prop. VR8304P 4330 02-1555 1 1 1 1

48 Pilot Control - S8600F (Nat.) BM-8142 1 1 1 1

Pilot Control - S86600M (Prop.) BM-8143 1 1 1 1

50 Igniter Sensor - Q3451B-1103 62-3668 1 1 1 1

T

PPAARRTT NNOO.

26

)

.

RR--118800C

C

RR--221100C

C

RR--225500C

C

RR--330000B

B

NNOOTTEES

S

27

260 NORTH ELM STREET
WESTFIELD, MA

01085

[phone] FAX: [phone]

5211 CREEKBANK ROAD
MISSISSAUGA, ONT

ARIO L4W 1R3

[phone] FAX: [phone]