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HydroTherm HC-165 User Manual

HydroTherm HC-165
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HCD2-501
42-9156 REV. 1
AA
AA
AA
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
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HydroTherm HC-165 Specifications

General IconGeneral
BrandHydroTherm
ModelHC-165
CategoryBoiler
LanguageEnglish

Summary

Boiler Installation Procedures

Locating & Setting the Boiler

Procedures for locating, setting, and ensuring adequate combustion air for the boiler.

Water Piping Installation & Purging

Guidance on installing vent assembly, relief valve piping, and water piping systems.

Condensation Control Piping Options

Explains System Bypass, Pump Away Bypass, Pumped Blend, and Reverse Acting Aquastats for condensation management.

Combination Systems & System Purging

Covers installation for combination systems and procedures for filling and purging the heating system.

Venting the Boiler Setup

Instructions for mounting the draft hood, spill switch, and installing the vent damper.

Venting Requirements & Chimney Inspection

Details additional venting requirements, common venting, and essential chimney inspection procedures.

Gas Piping Installation & Testing

Guidance on selecting gas pipe size, connecting gas piping, and testing for leaks.

Boiler Wiring Diagrams & Sequences

Wiring diagrams and operating sequences for various ignition and control configurations.

Boiler Start-Up & Operation Guide

Safety Controls Functionality

Explains the function of spill switches and flame rollout switches in preventing unsafe operation.

Initial Boiler Start-Up Procedures

Step-by-step procedures for initial boiler start-up, including thermostat settings and air purging.

Honeywell VR8204 Operating Instructions

Specific instructions for starting up the boiler using the Honeywell VR8204 intermittent pilot system.

Boiler Maintenance Procedures

General Maintenance & Safety Precautions

Covers routine examination, fire/explosion hazard warnings, and water treatment recommendations.

Seasonal Maintenance Checks

Outlines pre-heating season tasks including inspecting draft hood, vent piping, and flue passageways.

Burner & Orifice Maintenance Guide

Details procedures for cleaning burners, changing orifices, and troubleshooting common issues.

Troubleshooting Boiler Performance Issues

Lists common problems like no heat, overheating, odors, yellow flame, and noise with potential causes.

Replacement Parts Information

How to Order Replacement Parts

Guidance on how to order replacement parts, including required model and serial numbers.

HC-D Series Parts Identification

Comprehensive list of replacement parts for HC-D series boilers with part numbers and quantities.

Orifice Size Part Number Cross-Reference

Specific part numbers for various orifice sizes used in the boilers.

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