HydroTherm VS-85B, VS-110B, VS-135B, VS-165B Installation, Operation & Maintenance Manual And Replacement Parts List

VSB2-605

42-9187

VS-B SERIES

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

AND REPLACEMENT

PARTS LIST

Gas-Fired Steam
Cast Iron Boilers

85,000 to 165,000 Btuh Input

Intermittent

Pilot/Vent Damper

And

Standing Pilot/Vent Damper

260 NORTH ELM ST. • WESTFIELD, MA 01085 • [phone] • FAX [phone]

5211 CREEKBANK ROAD • MISSISSAUGA, ONTARIO L4W 1R3 • [phone] • FAX [phone]

SECTION 1: INTRODUCTION

Code Compliance ..........................................................2

Venting Requirements ...................................................2

Chimney Requirements .................................................3

Combustion Air Requirements ......................................3

Water Treatment ............................................................3

Shipment of Boiler .........................................................3

SECTION 2: BOILER INSTALLATION

Step 1: Locating/Setting Boiler ......................................4

Step 2: Installing Steam Piping .....................................5

Step 3: Installing Hydronic Components .......................5

Step 4: Venting Boiler.....................................................6

Step 5: Installing/Testing Gas Piping..............................7

Step 6: Wiring Boiler ......................................................9

SECTION 3: START-UP & OPERATION

Sequence Of Operation................................................11

Prior To Start-Up ..........................................................11

Start-Up & Adjustments................................................11

SECTION 4: MAINTENANCE

Before Each Heating Season .......................................15

How To Change Orifices...............................................16

Heating System Problems & Causes ...........................16

REPLACEMENT PARTS ..............................................17

TABLE OF CONTENTS

2

SECTION 1: INTRODUCTION

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

CAUTION: Indicates a potentially hazardous situa­tion which, if not avoided, may result in minor injury
or property damage.

NOTE: Used to notify of special instructions on
installation, operation or maintenance which are
important to equipment but not related to personal
injury hazards.

CODE COMPLIANCE

Boiler installations must conform to the requirements of
the authority having jurisdiction or, in the absence of
such requirements, to the National Fuel Gas Code ANSI
Z223.1-latest edition. Where required by the authority
having jurisdiction, the installation must also conform to
the American Society of Mechanical Engineers Code for
"Controls and Safety Devices for Automatically Fired
Boilers", ANSI/ASME CSD-1.

All electrical wiring must be in accordance with National
Electric Code ANSI/NFPA No.70-latest edition and any
additional state or local code requirements. If an exter­nal source is utilized, the boiler, when installed, must be
electrically grounded in accordance with requirements of
the authority having jurisdiction or, in the absence of
such requirements, with the National Electrical Code,
ANSI/NFPA No.70-latest edition. UL listed power limited
circuit cable is almost universally approved for safety
controls on heating equipment, either internally or exter­nally, without protection of conduits or raceway.

DANGER: Indicates an imminently hazardous situ­ation which, if not avoided, will result in death,
serious injury or substantial property damage.

WARNING: Indicates a potentially hazardous situa­tion which, if not avoided, could result in death,
serious injury or substantial property damage.

VENTING REQUIREMENTS

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 existing boiler is removed from common venting
system, common venting system is likely to be too large
for proper venting of appliances remaining connected to
it. At time of removal of existing boiler, the following
steps shall be followed with each appliance remaining
connected to the common venting system placed in
operation, while other appliances remaining connected
to the common venting system are not in operation:

1. Seal all unused openings in common venting system.

2. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and win-

dows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.

4. Place in operation the appliance being inspected. Fol­low the lighting instructions. Adjust 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.

6. After it has been determined that each appliance
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 the installation conforms
with 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.

3

CHIMNEY REQUIREMENTS

DANGER: A chimney which does not meet modern
safety standards will result in a fire or deadly carbon
monoxide poisoning of the building residents.

Chimney condition is of paramount importance for a
safe and efficient boiler installation. All new and replace­ment 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 chimney liner. Most utilities require complete
chimney cleaning. Others may require installation of new
liner, spill switches or other chimney upgrades. Check
with local utility for required safety precautions.

COMBUSTION AIR REQUIREMENTS

Provisions for combustion air must be in accordance
with the National Fuel Gas Code ANSI Z223.1 - latest

edition, as well as all applicable local codes. If the boiler
is installed in an unconfined space, adequate air will be
available via normal infiltration. However, if building con­struction is unusually tight or the boiler is installed in a
confined space (a space whose volume is less than 50
cubic feet per 1000 Btu/hr of gas input for all fuel burn­ing equipment), adequate air for combustion must be
provided by two openings: one located about 6” below
the ceiling, the other about 6” above the floor. When
communicating directly with the outside or through a
vertical duct, each opening must have a minimum free
area of one square inch per 4000 Btu/hr of gas input.
Horizontal ducts to the outside must have a minimum
free area of one square inch per 2000 Btu/hr of gas
input. When ventilation is provided by openings in doors,
etc. to adjoining spaces having adequate infiltration,
each opening must have a minimum free area of one

square inch per 1000 Btu/hr of gas input.

NOTE: Boiler employs atmospheric combustion.
Combustion air must not be contaminated with halo­genated hydrocarbon vapors, aerosol propellants or
freon. Otherwise, boiler heat exchanger will be sub­ject to corrosion, reducing boiler life.

WATER TREATMENT

Water treatment is recommended in areas where water
quality is a problem. A local water treatment company
should be consulted to determine the requirements for
your particular system and locality.

NOTE: Boiler is not for use in systems where water
is replenished. Minerals in the water can build up on
the heat transfer surfaces and cause overheating
and subsequent failure of the heat exchanger.

NOTE: Boiler utilizes EPDM synthetic rubber seals.
Water treatment chemicals and system cleaning
chemicals must be compatible with this and all
other construction materials.

SHIPMENT OF BOILER

Each boiler is shipped in a single carton.

Optional Vent Damper

When ordered, the vent damper is shipped in an individ­ual carton packaged with the boiler. Mounting of the
damper and flue outlet extension are required.

WARNING: Adequate fresh air must be provided for
combustion. Improper boiler operation and inade­quate venting of deadly flue gases may otherwise
result.

4

SECTION 2: BOILER INSTALLATION

Boiler may be installed in an alcove (see dimensions in
Figure 2.1). Locate boiler so connecting flue pipe
between draft hood and chimney is as short as possible.

Observe the following minimum clearances to com­bustibles: 18" on sides...alcove at front...28" at top 18" at
rear...6" from flue pipe in any direction. Maintain a mini­mum 1” clearance between hot water piping and com­bustible materials. Local code requirements may specify
greater clearances and must be adhered to.

Remove boiler from carton and set it in position. Install
on non-combustible floor only, unless local codes permit
use and fabrication of a fireproof base (see Figure 2.2).

Remove all packing material from boiler. Check that
burners, draft diverter and controls are in proper position.

Boiler shall be installed such that the gas
ignition system components are protected
from water (dripping, spraying, rain, etc.)
during appliance operation and service
(low water cut-off replacement, condensate
trap, control replacement.).

NOTE: Do not loosen tie rods on boiler absorption
unit. They are intended to accommodate thermal
expansion. Loss of boiler's structural integrity and
water leaks/damage may result.

FIGURE 2.1: MODEL VS-B BOILER DIMENSIONS

WARNING: Never install boiler on carpeting as heat
damage and/or fire may result.

STEP 1: LOCATING/SETTING BOILER

15 3/8"

18 7/8"

18 7/8"
22 3/8"

PRESS.
RELIEF VALVE

GAS
VALV E

6 3/4"

DIMENSIONS

A

PRESS.
GAUGE

LOW
WATER
CUT-OFF

41"

2 1/2"

21"

14 3/4"

2" RETURN
FRONT

BOILER
MODEL

VS-85

VS-110

VS-135

VS-165

B

SPILL SWITCH

9 7/8"

16 1/2"

18 1/8"

21 7/8"

-LEFT SIDE VIEW- -FRONT VIEW- -RIGHT SIDE VIEW-

NOTE: OPTIONAL FLOAT LOW WATER CUT-OFF SHOWN.

20"

PRESSURE CONTROL

PROBE LOCATION
FOR ELECTRIC

2" STEAM
SUPPLY

WATER
LEVEL
INDICATOR

1/2"
PLUGGED
TAPPING

3 3/8"

2 3/8"

LWCO

23 1/4"

3"

MINIMUM CLEARANCES

WATER

LINE

A

TO COMBUSTIBLES

Top: 28"

Rear: 18"

Left & Right: 18"

Front: ALCOVE

3/4" PLUGGED
TAPPING

23 1/4"

18 1/4"

26 7/8"

2" RETURN
REAR

18 1/8"

14 3/4"

B

5"

6"

6"
7"

ROLLOUT SWITCH

23 7/8"

2 1/2"

5

STEP 2: INSTALLING STEAM PIPING

Typical piping connections are shown in Figure 2.3. All
external piping must be supported by hangers, not by
the boiler or its accessories.

Supply outlet must run full size from the boiler to a head­er at least 24" above top of boiler. Condensate return
piping should be connected to boiler through a "Hartford
Loop." Install gate valves in supply and return.
Proper steam piping practices must be followed at all
times. Maintain proper clearances between piping and
combustible material.

The supply and return lines should be equipped with
drain cocks to drain sediment and sludge from lowest
points of boiler.

STEP 3: INSTALLING

HYDRONIC COMPONENTS

A low-water cutoff must be installed to protect the unit
from dry fire.

Screw extension nipple into 3/4" tapping on top of the
absorption unit and install relief valve into top of nipple
with the spindle in the vertical position (i.e., with the

valve discharge in the horizontal).

Most localities require the discharge piping to terminate
within 6" of the floor. Check local code requirements if in
doubt. Discharge piping must be of same size or larger
than the relief valve outlet and should be run as short
and straight as possible. Elbows in the discharge piping
should be placed as close to the valve as possible. If
valve discharge is to be drained away, the discharge pip­ing must not be hard-piped to the drain piping (i.e., an
open funnel or similar arrangement must be used).

CAUTION: Piping must be installed from the relief
valve discharge so there will be no danger of scald­ing personnel.

FIGURE 2.2: RECOMMENDED FIREPROOF BASE

6" OVERHANG OF BLOCKS

FIGURE 2.3: TYPICAL STEAM BOILER PIPING

WARNING: No Valve of any type may be installed
between the boiler and the relief valve to prevent
accidental explosion from over-pressure.

AND SHEETMETAL ALL
AROUND

6"

22 GAUGE
SHEETMETAL

4" HOLLOW CLAY

TILE (TWO COURSES)

OPENINGS THRU BLOCKS

IN TOP COURSE TO

BE AT 90° ANGLE

TO OPENINGS THRU

BOTTOM COURSE

FLOOR

MUST BE CLOSE
NIPPLE

HARTFORD
LOOP

GATE
VALVE

RETURN

DRAIN
COCKS

STEAM

SUPPLY

GATE VALVE

SUPPLY
TAPPING
3" NPT

RETURN
TAPPING
2" NPT

COLD WATER FILL

12" MIN.

WATER LINE

C/L OF HARTFORD

LOOP TO BE 2"

BELOW WATER

23 1/4"

LINE

6

A factory-mounted spill switch is provided on all VS-B
boilers (see Figures 2.4 & 2.4A).

The flue or vent connectors must be installed flush with the
inside chimney liner surface and sealed in place with fur­nace cement. Horizontal positions of the single wall and
type B venting systems shall be supported by use of strap
hangers or their equivalent. Vent supports should be
placed a maximum of 15 feet apart and as required to pre­vent sagging. The vent connectors shall be pitched 1/4" per
foot upwards towards the chimney or vent termination.

INSTALLING VENT DAMPER

The vent damper must be mounted directly on top of the
draft diverter.The vent outlet extension must be installed
between the damper and the outlet to allow the damper
plate to open and close.

Locate the motor on the right side and position the cable so
that it does not touch the metal surface of the draft diverter
(see Figure 2.4). If necessary, turn angle connector on
vent damper upward until cable clears; tighten locknut to
secure.The direction of the flow arrow imprinted on the vent
damper must point upward. The damper position indicator,
which is located on the side of the vent damper opposite
the motor, must be visible.

CAUTION: A minimum of 6" between vent damper and
combustible materials must be maintained. The vent
damper must be accessible for servicing and checking
position indicator.

Remove hairpin shipping clip which holds damper blade in
closed position and observe that damper blade rotates
slowly to open position. Do not force it closed as it may
damage the gear train and void the warranty. The blade
should move freely and without obstruction.

Secure the vent damper housing to the draft diverter outlet
with sheet metal screws or pop rivets. Refer to Figure 2.5
for fastener locations. Install flue pipe over top of vent
damper and secure to damper housing with sheet metal
screws or pop rivets.

Attach vent damper cable to cable clamp on boiler front
panel and join the Molex connector (see Figures 2.4 &

2.4A).

TRANSFORMER

PILOT
CONTROL

VENT DAMPER

PRESSURE
CONTROL

THERMOSTAT
CONNECTION

DK. BLUE

SPILL
SWITCH

CABLE
BRACKET

THERMOSTAT
CONNECTION

MOLEX
CONNECTORS

STEP 4: VENTING BOILER

DANGER: Draft diverter, vent outlet and vent
damper as supplied must not be altered in any way,
as proper boiler operation would be jeopardized.
Flame rollout, fire or carbon monoxide poisoning
will result.

DANGER: Only the boiler may be served by the
vent damper. Do not attempt to use it to vent an
additional appliance. This will cause fire or carbon
monoxide poisoning.

FIGURE 2.4: VENT DAMPER INSTALLATION

FOR INTERMITTENT PILOT

TRANSFORMER

GAS
VALVE

VENT DAMPER

PRESSURE
CONTROL

THERMOSTAT
CONNECTION

DK. BLUE

SPILL
SWITCH

CABLE
BRACKET

THERMOSTAT
CONNECTION

MOLEX
CONNECTORS

FIGURE 2.4: VENT DAMPER INSTALLATION

FOR STANDING PILOT

7

STEP 5: INSTALLING/TESTING

GAS PIPING

Connect the gas piping from the meter to the boiler
using a pipe size which will result in a pressure drop of
less than 0.3" W.C. for natural gas or 0.5" W.C. for
propane. See Figure 2.7 for the appropriate gas pipe
sizing and example.

Good piping practices should be followed at all times.
See Figure 2.6 for a typical gas piping arrangement. All
piping must be supported by hangers, not by the boiler
or its accessories.

Install a full-sized sediment trap at the low point in gas
line upstream of gas valve. Install a non-restrictive lubri­cated plug valve in the gas line close to the boiler. Install
a ground joint union at the gas valve inlet to allow for
servicing. Check local codes and utilities for any special
requirements and procedures.

Pipe joint compound (pipe dope) must be compatible
with the fuel (natural gas or propane) being used.

FIGURE 2.6: TYPICAL GAS PIPING

FIGURE 2.5A: VENTING

ADDITIONAL CHIMNEY REQUIREMENTS

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 (see Figure 2.5A).

Particular attention should be paid on all oil-to-gas con­versions. Soot may have accumulated in chimney and/or
degraded chimney liner. Most utilities require complete
chimney cleaning. Others may require installation of new
liner, spill switches or other chimney upgrades. Check
with local utility for required safety precautions.

DANGER: A chimney which does not meet modern
safety standards will result in a fire or deadly car­bon monoxide poisoning of the building residents.

FIGURE 2.5: ATTACHING VENT DAMPER TO DRAFT

DIVERTER & FLUE PIPE

MAKE SURE MOTOR IS

CLOSED OPEN

FLOW DIRECTION

FLOW DIRECTION

ARROW POINTS UP

(REAR VIEW)

LOCATED ON RIGHT SIDE

MOUNT VENT DAMPER
OVER DRAFT DIVERTER

INSTALL SWITCH IN
OPENING
ON DRAFT DIVERTER

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"

FIGURE 2.7: GAS PIPE SIZING TABLES & EXAMPLE

Example: Boiler Model VS-135B is to be installed. The distance from the existing gas meter to the installation site

is 30 ft. What pipe size must be used? The local utility indicates the heating value of natural gas being supplied is
1000 Btu per cu.ft. Determine cubic feet of gas per hour for above boiler model:

135,000 Btu per hour

= 135 cu.ft. per hour

1000 Btu per cu.ft.

1. Find 30 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 is acceptable. In our case it is 152 cu.ft.

3. Move to left-hand column "Nominal Iron Pipe Size, Inches," to read required pipe size. In our case it is 1/2".

8

TESTING GAS PIPING

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.

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 these limits, a pres­sure regulator must be installed. If the gas pressure is

DANGER: Before placing gas piping into service,
carefully test it to assure every joint is gas tight.
Bubble test all joints with a soap solution. NEVER
TEST WITH AN OPEN FLAME AS FIRE OR EXPLO­SION WILL RESULT.