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HydroTherm HC-65 User Manual

HydroTherm HC-65
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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-65 Specifications

General IconGeneral
BrandHydroTherm
ModelHC-65
CategoryBoiler
LanguageEnglish

Summary

Boiler Installation Steps

Locating and Setting the Boiler

Details selecting a location, clearances, and combustion air requirements for boiler installation.

Installing and Purging Water Piping

Covers the process of connecting and purging the hydronic piping system, including bypass options.

Venting the Boiler

Explains the installation of the draft hood, spill switch, and vent damper for safe exhaust.

Installing and Testing Gas Piping

Guides on selecting gas pipe sizes, connecting gas lines, and performing pressure tests.

Wiring the Boiler

Details the electrical wiring requirements and connections for the boiler's operation.

Boiler Control Wiring and Operation

IID & Vent Damper Wiring Diagrams

Provides wiring diagrams and operating sequences for boilers with IID and vent damper controls.

IID, Vent Damper & Aquastat Relay Wiring

Shows wiring diagrams for boilers with IID, vent damper, and L8148E aquastat relay.

IID, Vent Damper & Dual Aquastat Wiring

Illustrates wiring for boilers with IID, vent damper, and dual aquastat L4081A.

Zoning System Wiring Diagrams

Presents wiring diagrams for heating systems with zone valves and circulators.

Boiler Start-up, Maintenance & Troubleshooting

Safety Controls

Explains the function of safety devices like spill and flame rollout switches for preventing hazardous operation.

Start-Up and Adjustments

Provides step-by-step instructions for initial boiler start-up, thermostat settings, and burner observation.

Routine Maintenance Procedures

Outlines essential maintenance tasks for before each heating season and annually.

Water Treatment and Freeze Protection

Advises on water quality management and protecting the system from freezing.

Changing Gas Burner Orifices

Provides instructions on how to safely replace gas orifices for proper fuel input.

Troubleshooting Common Issues

Lists common operational problems and their potential causes and solutions.

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