HydroTherm HC-100 User Manual

HCD2-501
42-9156 REV. 1
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HYDROTHERM
IN UNITED STATES: 260 NORTH ELM ST., WESTFIELD, MA 01085 (413) 564-5515/FAX (413) 568-9613
IN CANADA: 5211 CREEKBANK ROAD, MISSISSAUGA, ONT. L4W 1R3 (905) 625-2991/FAX (905) 625-6610
MODEL HC-D SERIES
INSTALLATION,
OPERATION &
MAINTENANCE
MANUAL & REPLACE-
MENT PARTS MANUAL
Gas-Fired Cast Iron Water Boilers
65,000 to 165,000 Btuh Input
Intermittent Pilot & Vent Damper
SECTION 1: BOILER INSTALLATION
Introduction ...............................................................2
Step 1: Locating & Setting the Boiler ........................3
Step 2: Installing/Purging Water Piping.....................4
Step 3: Venting the Boiler..........................................6
Step 4: Installing/Testing Gas Piping ........................8
Step 5: Wiring the Boiler ...........................................9
SECTION 2: START-UP & OPERATION
Safety Controls........................................................15
Start-Up & Adjustments...........................................15
SECTION 3: MAINTENANCE
Water Treatment......................................................18
Freeze Protection ....................................................18
Before Each Heating Season.................................. 18
How To Change Orifices..........................................19
Troubleshooting.......................................................19
Appendix A (French Vent Damper Translation)....... 20
Replacement Parts List ......................................... 21
MEA# 90-77-E

HydroTherm HC-100 Specifications

General

Brand	HydroTherm
Model	HC-100
Category	Boiler
Language	English

Summary

Boiler Installation

Locating and Setting the Boiler

Guidance on selecting a location, clearances, and proper positioning of the boiler for safe installation.

Installing and Purging Water Piping

Instructions for connecting water piping, including relief valve discharge and system circulation.

Venting the Boiler

Procedures for mounting the draft hood, spill switch, and installing the vent damper and flue pipe.

Installing and Testing Gas Piping

Selecting appropriate gas pipe size and testing for leaks to ensure safe gas supply to the boiler.

Wiring the Boiler

Electrical wiring requirements and diagrams for connecting controls, circulators, and power supply.

Start-Up and Operation

Safety Controls Overview

Explanation of spill switch and flame rollout switch functions and reset procedures.

Boiler Start-Up and Adjustments

Step-by-step guide for initial boiler start-up, checking safety devices, and burner operation.

Boiler Maintenance

Water Treatment and Freeze Protection

Recommendations for water treatment and system antifreeze for optimal boiler performance and longevity.

Pre-Heating Season Checks

Procedures for inspecting draft hood, vent piping, and flue passageways before the heating season.

How to Change Orifices

Instructions on how to safely change gas orifices and check equivalent sizes for high altitudes.

Troubleshooting Common Issues

Guidance on diagnosing and resolving common problems like no heat, overheating, or poor combustion.