MODEL FX SERIES INSTALLATION, OPERATION AND
Contents
1. BUILDING OVERHANG 4 012 7 MAXIMUM 3 FL 0 9 M N MINIMUM N CLEARANCES PER N N VENT MANUFACTURE S 6 8 M INSTRUCTIONS MINIMUM R 7 ADJACENT BUILDING N PITCH PIPES DOWN N TOWARDS TERMINAL 1 4 IN PER FOOT CERTIFIED TEDMINAL 20 EE 8 SEE TABLE L N 1 0 FT 3 M MINIMUM DISTANCE FROM TERMINAL COMBUSTION AR TO MAXIMUM SNOW LINE Ec VAV A AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV A A AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV A FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 9 Figure 9 Vertical Negative Pressure Masonry Chimney System using Outside Combustion Air 10 FT 3 0 M MINIMUM ADJACENT BUILDING 5 FT 0 9 M MINIMUM MAXIMUM SNOW JA LINE USE APPROVED METAL CHIMNEY OR MASONRY CHIMNEY MASONRY CHIMNEY SHOWN LINER THIMBLE EXHAUST CLEANOUT CERTIFIED TERMINAL SEE TABLE 4 1 0 FT 0 3 M MINIMUM DISTANCE FROM COMBUSTION AIR INTAKE TO MAXIMUM SNOW LINE MAXIMUM SNOW LINE Figure 10 Vertical Positive Pressure Venting using Outside Combustion Air 5 FL L5 M MINIMUM TO WALL OR ADJOIN2. page 24 Boiler Operation page 24 Checking amp Adjusting page 25 Boiler Maintenance page 26 Replacement page 28 Instructions to the Installer page 31 Health page 31 BEFORE YOU START WARNING This manual must be read and fully understood before installing operation or servicing this boiler Failure to follow these instructions could result in a fire or explosion causing extensive property damage personal injury or death These instructions cover the FX gas fired direct vent low pressure sectional cast iron hot water boiler FX boilers have been design certified by CSA for use with natural and propane gas under the latest edition of ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers Each unit has been constructed and hydrostatically tested for a maximum working pressure of 30 psi in accordance with the ASME Boiler and Pressure Vessel Code Section IV for cast iron boilers Each boiler has been equipped with a 30 psi pressure relief valve This manual covers the application installation operation and maintenance of a FX low pressure hot water boiler To obtain the safe dependable efficient ope
3. A CED DISPLAY 9 E923 AQUASTAT ja AQUASTAT 9 5 9 8 7 8087879 w T GND T DETAIL A VIEWED FROM WIRE ENTRY AQUASTAT END OF CONNECTOR Y Y BLOWER INTEGRATED S BOILER CONTROL UTEC SERIES 1013 13 70 210 BTU 3 7 SECTION 60174 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 21 Figure 20B Wiring Ladder Diagram IF ANY OF THE ORIGIONAL WIRE AS SHANSEOHUEH SUPPLIED WITH THE APPLIANCE MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C WIRE OR ITS EQUIVALENT 24VAC 120VAC INTEGRATED BOILER 5 ah ee E AVEC L APPAREIL DOI MPLAC CONTROL UTILISER UN CONDUCTEUR DE TYPE 105 UTEC SERIES 1013 13 OU L QUIVEALENT R w BK w NY NY NY 5 4 3 1 THERMOSTAT 2 5 NO P3 P7 L2 NEUTRAL pe TX 35 o VAG 5 pa gt 3 7x sen 54550 L P 36 w P6 2 AQUASTAT E W oo 43 c IGNITOR 1 NNN P3 BK w 7 4 x CIRCULATOR PUMP K1 16 909 BK w AIR SWITCH BLOWER c P3 K2 5343 E P5 7 f B NC BK A BK BL P3 SPILL 1 P7 L1 LINE SWITCH BL BL 2 07 Q 120 vac 0 0 GAS VALVE LK EMPTY P1 TRANSFORMER 0 0 5 2 EARTH GROUND EMPTY 5 3 24 PUMP EARTH m GROUND EMPTY
4. Diameter 4 Diameter FX 3 45 feet 13 7 m 65 feet 19 8 m FX 4 45 feet 13 7 m 65 feet 19 8 m FX 5 45 feet 13 7 m 65 feet 19 8 m FX 6 n a 40 feet 12 2 m FX 7 n a 40 feet 12 2 m Note Subtract 5 feet 1 5 m for each 90 elbow HORIZONTAL DIRECT VENT SYSTEMS See figures 7 amp 8 The vent materials used in horizontal positive pressure vent systems must be certified to UL 1738 for installations in the United States ULS636 for installations in Canada Certified vent systems are manufactured by the following companies Heat Fab Inc 130 Industrial Blvd Turners Falls MA 01376 800 772 0739 Z Flex U S Inc 20 Commerce Park North Bedford NH 03110 6911 800 654 5600 Protech Systems Inc 26 Gansevoort Street Albany NY 12202 518 463 7284 The maximum equivalent length for the horizontal vent System is listed in Table 4 Each 90 elbow is equal to 5 linear feet 1 5 m of pipe To maximize the performance of single wall sheet metal vent systems locate 90 elbows as far from the boiler as possible and from one another For best results horizontal vent systems should be as short and straight as possible The vent system must be both gas tight and watertight All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions When horizontal vent runs exceed 5 feet 1 5m they must be supported at 3 foot 0 98 m intervals with over
5. P5 BLOWER EARTH gt 2 GROUND P7 P3 ac L 2 6 ny GROUND GROUND ROD FLAME ROD EE FS FLAME ROD 70 210 BTU E sn 3 7 SECTION FIELD INSTALLED WIRING COE ADU FACTORY WIRING Page 22 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS E FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instrucitons exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not tough any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas suppliers instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualif
6. Page 6 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 5 Vertical Negative Pressure Metal Chimney System and Inside Combustion Air TWO STORM COLLAR ROOF FLASHING OFFSET ONLY IF NECESSARY FIRESTOP FEET 0 61 ABOVE THE HIGHEST POINT WITHIN 10 FT 3 1 M CLEARANCES VENT MANUFACTURER S INSTRUCTIONS FRAMING MEMBERS JOIST BETWEEN JOISTS K INSULATION CLEARANCES PER VENT MANUFACTURER S INSTRUCTIONS OPENINGS PER ABOVE INSTRUCTIONS MINIMIZE HORIZONTAL VENT CONNECTOR LENGTH exaust Intake Air Option General Guidelines Table 2 Combustion Air System Sizing This configuration provides combustion air directly to the boiler using a dedicated pipe Combustion air can be drawn in horizontally through an outside wall or vertically through the roof see Figures 6 7 8 9 amp 10 WARNING Each boiler must have it s own intake air system Common intake air systems are not to be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death Single wall galvanized smoke pipe single wall aluminum pipe flexible aluminum pipe PVC or CPVC pipe can be used for the intake air pipe It must be sized per Table 2 Boiler Equivalent Intake Equivalent Intake
7. 03 1567 03 1568 03 1569 03 1570 03 1571 Left Jacket Side Panel 03 1551 Right Side Panel 03 1550 RIO Gas Valve White Rodgers 36E65 02 1567 Gas Valve White Rodgers 36D27 02 1568 Blower Fasco 702110816 58 1849 Transformer Honeywell AT140B 1016 40 VA 26 3206 Ignition Control 02 4129 o 4 Pressure Switch 45 WC 02 4878 lt 49 WC 02 4879 54 WG 02 4880 Terminal Strip 2 Position 58 2298 10 Terminal Strip 3 Position 58 2299 11 Gas Tube BM 8642 12 Filter 60 4298 13 Limit Control Honeywell L4008A 1015 02 3210 Ny 14 Blower Mounting Plate Assembly BM 8630 4 BM 8631 BM 8632 BM 8633 BM 8634 Main Gas Orifice Natural 0 182 25 0051 0 234 25 0053 0 265 25 0054 0 323 25 0055 0 375 25 0056 Main Gas Orifice LP 0 144 25 0050 0 182 25 0051 0 209 25 0052 0 234 25 0053 0 265 25 0054 Thermal Switch 58 2542 Page 30 FX DIRECT VENT BOILER INSTAL
8. 5 NEVER store objects on or around the boiler WARNING Never store combustible materials gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler Failure to comply with this warning can result in extensive property damage severe personal injury or death Figure 2 Moving Boiler HAND TRUCK NYLON STRAP 3 O 7 77777777777 27777777 777 7777 3 Page4 COMBUSTION AIR amp VENTILATION WARNING This boiler must be supplied with combustion air in accordance with Section 5 3 Air for Combustion amp Ventilation of the latest revision of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and all applicable local building codes Canadian installations must comply with CSA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Failure to provide adequate combustion air for this boiler water heater can result in excessive levels of carbon monoxide which can result in severe personal injury or death To operate properly and safely this boiler requires a continuous supply of air for combustion NEVER store objects on or around the boiler CAUTION Combustion air contaminated with fluorocarbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in t
9. Figure 16 should be used on multiple zone systems The bypass must be installed between the supply and return pipes on the suction side of the zone circulators The bypass valve must be installed on the pressure side of the bypass circulator Figure 16 Pumped Bypass Piping CHECK VALVE BYPASS CIRCULATOR VALVES PUMP FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Piping For Use With Cooling Units The boiler when used in connection with a refrigera tion system must be installed so the chilled medium is piped in parallel with the boiler Appropriate valves must be used to prevent the chilled water from entering the boiler See Figure 17 for the proper piping layout Figure 17 Chiller Schematic NOTE FOR HEATING VALVES H OPEN VALVES C CLOSED FOR COOLING VALVES H CLOSED VALVES C OPEN EXP TANK RELIEF VALVE ral DRAIN FILL VALVE DRAIN BOILER CHILLER When a boiler is connected to a heating coil that may be exposed to refrigerated air from an air handling device the piping system must be equipped with flow control valves or some other automatic means of preventing gravity circulation of the boiler water during the cooling cycle Circulators The TACO 007 circulator supplied with the boiler is sized for use in a closed heating system with a 30 psi maximum operating pressure If the 007 ci
10. INSTRUCTIONS Tout mauvais fonctionnement du syst me d vacu tion commun devrait tr corrig de fagor que l installation soit conforme au National Fue Gas Code ANSI Z223 1 NFPA 54 et ou aux codes d in stallation CSA B149 Si la grosseur d une section du syst me d vacuation doit tr modifi e le syst me devrait tr modifi pour respecter les valeurs minimales des tableaux pertinents de l appendice F du National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou des codes d installation CSA B149 CONDENSATE PIPING A small amount of condensate is generated on start up To prevent an excess amount of condensate collecting in the flue collector a condensate drain has been provided A condensate trap or pump MUST be connected to the condensate fitting in the bottom of the flue collector A trap can be made by tie wrapping a 4 loop in a piece of vinyl hose attached to the condensate drain fitting The trap must be filled with water to prevent flue gasses from escaping see Figure 12 Figure 12 Condensate Trap TO SUITABLE DRAIN WARNING Failure to connect a condensate trap or pump to the flue collector can result in excessive levels of carbon monoxide which can cause severe personal injury or death HEATING SYSTEM PIPING CAUTION All heating system piping must be installed in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section IV All applicable local codes and ordinances must also be foll
11. Model Length see note Length see note Number 3 Diameter 4 Diameter FX 3 45 feet 13 7 m 65 feet 19 8 m FX 4 45 feet 13 7 m 65 feet 19 8 m FX 5 45 feet 13 7 m 65 feet 19 8 m FX 6 n a 40 feet 12 2 m FX 7 n a 40 feet 12 2 m Note Subtract 5 feet 1 5 m for each 90 elbow FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS All joints in metal intake air systems must be secured using corrosion resistant fasteners and sealed using a suitable Silicone caulk If PVC or CPVC is used the joints must be cleaned with a suitable solvent and connected using a solvent based PVC cement The intake air system MUST be supported by the building structure not the boiler water heater Intake Air Option Vertical Guidelines A listed nonrestrictive intake air cap must be used The intake air cap must terminate as shown in Figure 6 The penetration point in the roof must be properly flashed and sealed Intake Air Optional Horizontal Guidelines The maximum equivalent length for the horizontal intake air pipe is listed in Table 3 The intake air system must be pitched down toward the terminal 1 4 per foot 21 mm per meter If horizontal runs exceed 5 feet 1 5 m they must be supported at 3 foot 0 98 m intervals with overhead hangers Figures 6 through 9 show the four horizontal air intake options The intake terminations certified for use the FX are listed in Table 5 Figure 6 Vertical Positive P
12. are present VACATE THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED HEATING SERVICE COMPANY OR THE GAS COMPANY OR THE FIRE DEPARTMENT WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this boiler This boiler contains crystalline silica materials that have been identified as carcinogenic or possibly carcinogenic to humans when inhaled AVERTISSEMNET Une installation un r glage une modification une r paration ou un entretien non comforme aux normes peut entrainer des dommages mat riels des blessures exposition des mati res dangereuses ou la mort L installation et l entretien doivent tre effectu s par un installateur ou un service d entretien qualifi ou le fournisseur de gaz qui doivent avoir lu les instructions fournies avant de faire l installation l entretien ou l enl vement de la chaudi re et les respecter Cette chaudi re contient des mat riaux qui ont t identifi s comme tant canc rog nes ou pouvant l tre Page 31 HydroTherm IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 CANADA 5211 CREEKBANK RD MISSISSAUGA ONT LAW 1
13. pressure of 0 5 psig and a 0 3 WC pressure drop Table 9 Equivalent Pipe Length Chart Type of pipe fitting Iron Pipe 90 Elbow Le Gas Gas Cock Size in branch flow full port Equivalent length of pipe fitting in feet 3 4 2 6 5 2 0 6 1 5 17 3 5 6 9 0 8 1 9 11 47 4 0 8 0 0 9 2 3 11 2 5 2 10 3 1 2 3 0 Whenever the gas supply piping is pressure tested the boiler gas controls must be protected If the test pres sure is equal to or less than 1 2 psig 3 5 kPa isolate the boiler by closing it s manual shut off valve see Figure 8 If the test pressure is greater than 1 2 psig 3 5 kPa disconnect the boiler and it s individual shut off valve from the gas supply piping WARNING Never use an open flame to test for gas leaks Always use an approved leak detection method Failure to comply with this WARNING could result in an explosion ELECTRICAL WIRING CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation ATTENTION Au moment de l entretien des commandes tiquetez tous les fils avant de les d brancher Des erreurs de cablage peuvent entrainer un fonctionnement inad quat et dangereux S assurer que l appareil fonctionne ad quatement une fois l entretirn termin The electrical connections to this boiler water heater must be made in accord
14. 05 mm of but not less than 3 inches 76 mm from the top of the enclosure The bottom opening must be within 12 inches 305 mm of but not less than 3 inches 76 mm from the bottom of the enclosure Where directly communicating with the outdoors or communicating with the outdoors through vertical ducts each opening shall have a minimum free area of 1 in 4000 Btu hr 550 mm2 kW of the total input rating of all of the equipment in the enclosure Where communicating with the outdoors through hori zontal ducts each opening shall have a minimum free area of 1 in 2000 Btu hr 1100 mm kW of the total input rating of all of the equipment in the enclosure When ducts are used they must have the same cross sectional area as the free area of the opening to which they connect Sizing of an outside air duct must be based on the total input rating of all gas utilization equipment in the confined space FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 5 When calculating the free area necessary to meet the Table 1 Combustion Air Duct Sizing make up air requirements of the enclosure Input Btuh Input Btuh Input Btuh consideration must be given to the blockage effects of FreshAir 1 4 Wire Metal Wooden louvers grills and screens Duct Size Screen Mesh Louvers Louvers 3 x 12 144 000 108 000 36 000 Screens must have a minimum mesh size of 1 4 8 x 8 256 000 192 000 64 000 6 4mm If the free area throug
15. 5 Elbow 3 Protech 300131 45 Elbow 4 Protech 300160 90 Elbow 3 Protech 300161 90 Elbow 4 Field SWH 4 Vent Hood 4 Controls CAT 4HG Air Tee 4 Heat Fab 7390GC Mitered 3 Heat Fab 7490GC Mitered 4 Heat Fab 7390TEE Tee 3 Heat Fab 7490 4 Heat Fab 7392GC Screen Heat Fab 7492GC Screen Heat Fab 7314TERM 90 Elbow 3 Heat Fab 7414TERM 90 Elbow 4 VERTICAL DIRECT VENT SYSTEMS See Figures 6 amp 10 The vent materials used in vertical positive pressure vent systems must be certified to UL 1738 for installations in the United States ULS636 for installations in Canada Certified vent systems are manufactured by the following companies Heat Fab Inc 130 Industrial Blvd Turners Falls MA 01376 800 772 0739 Z Flex U S Inc 20 Commerce Park North Bedford NH 031 1 800 654 5600 Protech Systems Inc 26 Gansevoort Street Albany NY 12202 518 463 7284 The maximum length for the vertical vent system is listed in Table 4 Each 90 elbow is equal to 5 linear feet 1 5 m of pipe To maximize the performance of single wall sheet metal vent systems locate 90 elbows as far from the boiler as possible and from one another If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F Structural penetrations must be made using approved fire stops The vent system must be both gas tight and watertight All seams and joints in metal pipe
16. EMS See Figures 4 5 amp 9 The FX is listed as a Category appliance when vented vertically into a metal chimney System or masonry chimney sized as listed in Table 7 WARNING If an appliance using any type of a mechanical draft system operating under positive pressure is connected to a chimney flue never connect any other appliances to this flue Doing so can result in excessive levels of carbon monoxide which can cause severe personal injury or death Chimney Inspection amp Sizing A thorough inspection of the masonry chimney must be performed to ensure that the chimney is clean properly constructed and properly sized Exterior masonry chimneys should not be used unless properly lined to prevent condensation and draft problems Table 4 lists the equivalent breeching and flue sizes required for the boiler water heater When more than one appliance is connected to the same chimney flue the flue must be large enough to safely vent the combined output of all of the appliances Table 6 Vent Intake amp Equivalent Chimney Size Boiler Vent amp Chimney Diameter Intake Diameter Model inches mm inches mm FX 70 3 7 6 3 7 6 FX 105 4 10 2 3 7 6 FX 140 4 10 2 3 7 6 FX 175 5 12 7 4 10 2 FX 210 5 12 7 4 10 2 Note These sizes are based on a 20 foot 6 1m chimney height FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 13 The vent connector shoul
17. ES CAS SUPPLY PIPING GROUND JOINT UNION TO BOILER SEDIMENT TRAP OR DRIP LEG n da TO EXTEND TO FLOOR CAUTION Always use a wrench on the gas valve body when making gas connections to it Never over tighten the piping entering the gas valve body or the gas valve will be damaged Table 8 should be used to ensure that the gas supply piping is sized properly If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand Do not neglect the pressure drop due to pipe fittings Table 9 should be used in conjunction with Table 8 to ensure that the gas supply piping is sized properly 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 All gas connections MUST be leak tested before putting the boiler into operation FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Table 8 Gas Pipe Capacity Nominal Pipe length in feet Iron Pipe 10 20 30 40 50 60 80 100 0 Size in Gas pipe Capacity ft hr 3 4 278 190 152 130 115 105 90 79 64 1 520 350 285 245 215 195 170 150 120 1147 1050 730 590 500 440 400 350 305 0 1127 1600 1100 890 760 670 610 530 460 0 Note Maximum pipe capacity in ft hr is based on a 0 60 specific gravity gas at a
18. FXIOM 1 HydroTherm MODEL FX SERIES INSTALLATION OPERATION AND MAINTENANCE MANUAL Direct Vent Natural or Propane Gas Fired Cast Iron Water Boilers 70 000 to 210 000 Btuh Input WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier INSTALLER THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE HEATER CONSUMER RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE PURPOSES HydroTherm IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 5211 CREEKBANK RD MISSISSAUGA ONT LAW 1R3 905 625 2991 FAX 905 625 6610 www hydrotherm com Page2 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS AVERTISSMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum le risque d ince
19. Gas Valve 0 6 Amp 24 VAC 0 45 power factor Page 19 Page 20 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 20A Wiring Connection Diagram GROUND ROD FLAME ROD NOTE IGNITOR 1 FIELD INSTALLED WIRING 2 IF A GROUND WIRE IS USED FOR PUMP CONNECT TO GND TERMINAL ON POWER INPUT TERMINAL STRIP 3 THE FLAME ROD WIRE IS SUPPLIED WITH 3 16 SNAP W ON CONNECTOR TO PREVENT IMPROPER WIRING DO NOT Y MODIFY CIRCULATOR w G NU PUMP a ON SPILL SWITCH T 60 pba saan eat I RESET BL BUTTON in I I I I ME 5 SEE NOTE 1 R W TE mx AIR SWITCH i 1 CIRCULATOR PUMP POWER INPUT THERMOSTAT 120VAC TERMINAL STRIP 120 VAC TERMINAL STRIP TIT MN cll Te U i i NC NO COM L1 L2 GND 0 U U SEE NOTE 2 BK BL FS SEE NOTE 3 P3 rcs a n 5 3 2 1 ZU ZZ 4 AIR GAS SPILL 42 n 7 SWITCH SWITCH Lc
20. ING CERTIFIED BUILDING VENT TEE SEE TABLE 4 NAE MAXIMUM i 0 5 T SNOW LINE CLEARANCES PER VENT MANUFACTURE S k CO EXHAUST n CERTIFIED TERMINAL SEE TABLE 4 1 0 FT 5 M MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE MAXIMUM SNOW LINE Page 10 GENERAL VENTING GUIDELINES WARNING The vent installation must be in accordance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision or applicable provisions of the local building codes Canadian installations must comply with CSA B149 1 or 2 Installation Code Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death WARNING Thimbles and fire stops must be used where required A minimum clearance of 6 must be maintained between single wall metal vents and combustible construction or a fire resulting in severe personal injury or death may occur WARNING Each boiler water heater must have it s own vent system Common positive pressure vent systems are not to be used Improper installation can result in excessive levels of carbon monoxide which can cause severe personal injury or death All vent systems must be fully supported by the building structure and not by the boiler water heater VENT SYSTEM OPTIONS The FX may be vented the following ways 1 Direct Vent Po
21. LATION AND OPERATION INSTRUCTIONS Model Size with Item Quantities Below Ref Name of Part Part 70 105 140 175 210 17 Burner Box Assembly BM 8625 1 BM 8626 1 BM 8627 1 BM 8628 1 BM 8629 1 18 Frame Cross Members 04 1579 2 04 1580 2 04 1581 2 04 1582 2 04 1583 2 19 Right Base Frame Assembly BM 8640 1 1 1 1 1 20 Left Base Frame Assembly BM 8641 1 1 1 1 il 21 Flue Collector Drain Fitting 60 4299 1 1 1 1 1 22 Flue Collector BM 8635 1 BM 8636 1 BM 8637 1 BM 8638 1 BM 8639 1 23 Block Assembly BM 8615 1 BM 8616 1 BM 8617 1 BM 8618 1 BM 8619 1 24 Burner Box Frame Assembly BM 8620 1 BM 8621 1 BM 8622 1 BM 8623 1 BM 8624 1 25 Igniter Norton 601XBM 04 1339 1 1 1 1 1 26 Flame Rod PSE ME7 G 04 1340 1 1 1 1 1 27 Ground Rod PSE ME8 GS1 04 1341 1 1 1 1 1 28 Ingiter Flame amp Ground Rod Spring Clip 57 5222 3 3 3 3 3 N S Ingiter Flame amp Ground Rod Gasket 59 1050 1 1 1 1 1 N S Relief Valve 22 1203 1 1 1 1 1 N S Temperature amp Pressure Gauge 20 1019 1 1 1 1 1 See Transformer Primary Harness P1 BM 8643 1 1 1 1 1 Fig Transformer Secondary Harness P2 BM 8644 1 1 1 1 1 20A Control Harness P3 BM 8645 1 1 1 BM 8646 1 1 Circulator Harness P4 BM 8647 1 1 1 1 1 HSI Harness P6 BM 8648 1 1 1 1 1 L1 L2 Harness P7 BM 8649 1 1 1 1 1 N S Jacket Polish 4 oz Bottle 70 3398 1 1 1 1 1 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS INSTRUCTIONS TO THE INSTALLER The INSTALLER must give this copy of the INSTAL LATI
22. OFF Do not force Replace control access panel FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Page 23 E POUR VOTRE S CURIT LISEZ AVANT DE METTRE EN MARCHE AVERTISSEMENT Quinconque ne respecte pas la lettre les instructions dans la pr sente notice risque de d clencher un incendie ou une explosion entra nant des dommages des blessures ou la mort Si vous ne pouvez rejoindre le fournisseur appelez le service de incendies A Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allume automatique la br leur Ne tentez pas d allumer C Ne poussez ou tournez la maneette d admission la br leur manuellement AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pour d celer une odeur de gaz Reniflez pr s du plancher car certains gaz sont plus lourds que l air et peuvent s accumuler au niveau du sol QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer d appareil Ne touchez aucun interrupteur ne pas vous servir du gaz qu la main ne jamais utiliser d outil Si la manette reste coinc e ne pas tenter de la r parer appelez un technicien qualifi Le fait de forcer la manette ou de la r parer peut d clencher une explosion ou un incendie N utilisez pas cet appareil s il a t plong dans l eau m me partiellement Faites inspecter l appareil par un tecnicien qualifi et remplacez toute part
23. ON AND OPERATING INSTRUCTIONS to the boiler owner and make sure that the owner or operator has a basic understanding of the following 1 The operating instructions the type of ignition system installed and how it operates What the labels on the boiler say How to start up and shut off the boiler How to turn the gas and electrical power on or off What to do if the boiler ignition system locks out Where to check the system temperature and pressure and what they should be 7 The importance of reading understanding and following these instructions 8 The importance of visually inspecting the vent system on a monthly basis The INSTALLER MUST make sure that the owner knows to shut the boiler off and call for service if the following conditions occur Yellow lazy flames or flames outside the jacket Gas smell or other strange odors Discoloration of the boiler or surrounding materials Water leaking from the heating system piping or relief valve Flue products leaking from the vent system into the living space Dampness or condensation in the building is a good indicator of this condition 6 The boiler s flame rollout safety system is actuated 7 Control malfunction or sporadic operation 5 e Any appliance that burns natural gas propane gas fuel oil wood or coal is capable of producing carbon monoxide CO Carbon Monoxide CO is a gas which is odorless colorless and tasteless but is
24. OX COVER B Read understand and follow the operating instructions on pg 22 of this manual C Raise the thermostat at least 5 degrees above the room temperature A delay of about 30 seconds will take place as the silicon carbide ignitor heats up Once the ignitor is hot the main gas valve will open and the burner should light If the burner fails to light the system will make two more ignition attempts If the burner lights but goes out within 4 seconds the system will make three ignition attempts If the burner has not lit after the last ignition try the gas valve will close and the system will go into lock out DO NOT attempt to reset the system until the ignition system has been inspected and the problem resolved Once the problem has been resolved and 5 minutes have passed since the last ignition attempt reset the system by turning the thermostat to it s lowest setting and then back to where it was or by momentarily interrupting the electrical power to the boiler D With the burner in operation the manometer should show 1 9 W C manifold pressure If not see the BOILER CHECKING amp ADJUSTMENT section below Close the manual shutoff valve in the gas supply line As soon as the burner flame goes out open the manual shutoff valve A normal ignition sequence should take place E With the burner in operation interrupt the power to the control circuit by lowering and raising the thermo stat A normal ignition sequence should f
25. R3 905 625 2991 FAX 905 625 6610 www hydrotherm com
26. Safety Read Before Operating section of this manual pg 18 Failure to comply with this WARNING could result in a fire or explosion Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance En cas de surchauffe ou si l alimentation de gaz ne peut tre coup e ne pas couper ni d brancher l alimentation lectrique de la ponpe Fermer plut t le robinet d admission de gaz l ext rieur de l appareil Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water N utiliisez pas cet appareil s il a t plong dans l eau m me partiellement Faites inspecter l appareil par un tecnicien qualifi et remplacez toute partie du syst me de contr le et toute commande qui ont t plong s dans l eau Direct Ignition System A Connect a manometer to the pressure ports shown in Figure 21 Make sure that the gas supply piping has been purged of air and that all gas joints up to the gas valve have been thoroughly checked for leaks Wait at least five minutes for any gas to dissipate before turning on the electrical power FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 21 Manifold Pressure FILTER B
27. The control will continuously monitor the thermostat limit switch pressure switch and flame sense If the thermostat opens the control will de energize the gas valve and begin post purge If the limit switch opens the control will de energizes the gas valve run through post purge and wait for the limit switch to re close before attempting re ignition If flame is lost the control will de energize the gas valve run through post purge and go to pressure switch proving mode for re ignition If the pressure switch opens for more than 0 1 seconds the inducer is turned off for 30 seconds then the control goes to the pressure switch proving mode for a re ignition attempt When the thermostat is satisfied the post purge period starts A post purge will be performed at any time the gas valve has been on and is turned off except for loss of pressure switch when a post purge would be ineffective The post purge must be completed before a new ignition sequence can start In the event that the flame signal is lost after the flame has been proven the system will turn off the gas valve within 2 0 seconds perform the post purge and repeat the ignition sequence As a preventative measure to avoid nuisance shutdown due to a flickering flame the flame must be lost for a minimum of 0 5 seconds Control Outputs Induced draft blower 1 75 Amps 120 VAC Circulator Pump 2 7 Amps 120 VAC Hot Surface Igniter 5 0 Amp resistive 120 VAC
28. adjustment screw clockwise to increase the manifold pressure counterclockwise to decrease it Never force the regulator adjustment Screw or the gas valve will be damaged 4 The CO reading should fall between 7 and 9 with a CO reading of less than 50 ppm air free 5 Adjust the air damper using the screw on the front of the filter box if the CO and CO readings are not within the range given in step 4 6 Recheck the manifold pressure and adjust it if necessary 7 Replace the regulator adjustment screw cap and pressure port caps once the boiler is properly set up PROPANE GAS A manifold pressure of 1 9 W C must be maintained for proper operation of the boiler If the manifold pressure is off by more than 5 or if the CO and CO readings are not within the range specified in step 4 above adjust it according to steps 1 through 7 above Page 25 Page 26 Main Burner Flame A properly adjusted main burner flame will produce a tight blue flame pattern about 1 2 inch tall from the burner s surface Figure 22 A yellow floating or tall stringy flame is not normal and must be corrected WARNING Yellow floating flames indicate a lack of combustion air DO NOT operate the boiler until the problem is solved or severe personal injury or death may occur Figure 22 Burner Flame TIGHT BLUE FLAME YELLOW FLOATING FLAME Thermostat Adjustment Set the heat ant
29. ance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform with CSA C22 1 Canadian Electrical Code Part if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler A properly rated shut off switch should be located at the boiler The boiler must be grounded in accordance with the authority having jurisdiction or if none the latest revision of the National Electrical Code ANSI NFPA 70 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of 14 awg Low voltage wiring must not be less than 18 awg with a neoprene thermoplastic or other equivalent insulation having a minimum insulation thickness of 0 012 inches Refer to Figures 20A and 20B for proper wiring connections Thermostat Installation ALWAYS follow the instructions included with the ther mostat to be used to control the boiler Proper location of the thermostat will ensure efficient trouble free operation of the boiler Mount the thermostat to an inside wall at a height approximately five feet above the floor Avoid placing the thermostat in areas that will not pro vide an accurate measurement of the room temperature Locating the thermostat behind a door in an alcove close to a source of thermal radiation or in a drafty area will cause poor or sporadic
30. and vegetation from degradation caused by the flue gases VERTICAL VENT POSITIVE PRESSURE SYSTEMS See Figure 11 The vent materials used in vertical positive pressure vent systems must be certified to UL 1738 for installations in the United States ULS636 for installations in Canada Certified vent systems are manufactured by the following companies Heat Fab Inc 130 Industrial Blvd Turners Falls MA 01376 800 772 0739 Z Flex U S Inc 20 Commerce Park North Bedford NH 03110 6911 800 654 5600 Protech Systems Inc 26 Gansevoort Street Albany NY 12202 518 463 7284 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS The maximum length for the vertical vent system is listed in Table 4 Each 90 elbow is equal to 5 linear feet 1 5 m of pipe To maximize the performance of single wall sheet metal vent systems locate 90 elbows as far from the boiler as possible and from one another If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F Structural penetrations must be made using approved fire stops The vent system must be both gas tight and watertight All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions Vertical vent systems must terminate as shown in Figures 6 amp 11 An approved terminal cap must be used VERTICAL VENT NEGATIVE PRESSURE SYST
31. ar as is practical close all building doors and windows 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 exhaust so they will operate at maximum speed Do not operate a summer exhaust fan for a boiler installation Close fireplace dampers FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre l espace o les appareils toujours raccord s du syst me d vacuation sont install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s au syst me d vacuation commun et tous les ventilateurs d extraction comme les hottes de cuisin re et les ventilateurs des salles de bain S assurer que ces ventilateurs fonctionnent la vitesse maximale Ne pas faire fonctionner les ventilateurs d t Fermer les registres des chemin es Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Mettre l appareil inspect en marche Suivre les instructions d allumage R gler le thermostat de facon que l appareil fonctionne de fa on continue Test for spil
32. ations must be made using approved thimbles The vent system must be both gas tight and watertight All seams and joints in metal pipes must be joined and sealed in accordance with the vent system manufacturer s instructions Page 11 Page 12 Horizontal vent systems shall terminate at least 4 feet 1 3 m below 4 feet 1 3 m horizontally from or 1 foot 0 23 m above any door window or gravity air inlet into any building It must not terminate less than 4 feet 1 3 m horizontally from and in no case above or below unless a 4 feet 1 3 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment and not less than 7 feet 2 3 m from any adjacent public walkway The bottom of the vent terminal s shall be located at least 5 feet 1 5 m above the air intake terminal s Avoid terminal locations likely to be affected by winds snowdrifts people and pets Table 5 Certified Vent Terminals Company Part No Description Dia in Protech 300311 Tee 3 Protech 300312 Tee 4 Protech 300130 45 Elbow 3 Protech 300131 45 Elbow 4 Protech 300160 90 Elbow 3 Protech 300161 90 Elbow 4 Field SWH 3 Vent Hood 3 Field SWH 4 Vent Hood 4 Heat Fab 7390TEE Tee 3 Heat Fab 7490 4 Heat Fab 7314TERM 90 Elbow 3 Heat Fab 7414TERM 90 Elbow 4 The certified vent terminals listed in Table 5 must be used Protect building materials
33. cause severe personal injury or death If an existing boiler water heater is removed from a common venting system the common venting system may then be too large for the proper venting of the remaining appliances connected to it At the time of removal of an existing boiler water heater the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation Au moment du retrait d une chaudi re existante les mesures suivantes doivent tre prises pour chaque appareil toujours raccord au syst me d vacuation commun et qui fonctionne alors que d autres appareils toujours raccord s au syst me d vacuation ne fonction nent pas syst me d vacuation a Seal any unused openings in the common venting system Sceller toutes les ouvertures non utilis es du sys t me d vacuation b 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 Inspecter de facon visuelle le syst me d vacu ation pour d terminer la grosser et l inclinaison horizontale qui conviennent et s assurer que le syst me est exempt d obstruction d tranglement de fruite de corrosion et autres d faillances qui pourraient pr senter des risques c Insof
34. d be sloped up toward the Always provide a minimum clearance of 6 inches chimney 1 4 per foot Ensure that the vent connector between single wall metal vent pipe and any combustible is properly supported and each connection securely materials Type B1 vent may be used clearance between fastened with at least 3 corrosion resistant sheet metal it and any combustible material must be as listed screws The termination of the vent pipe must be flush with the inside of the chimney flue WARNING Failure to maintain minimum clearances between vent connectors and CAUTION The vent connector length must never combustible materials can result in a fire causing exceed 3 4 of the height of the chimney or venting extensive property damage severe personal problems will occur injury or death Figure 11 Vertical Positive Pressure Venting 5 FT 1 5 M MIN TO WALL OR ADJOINING BUILDING CERTIFIED VENT TEE SEE TABLE 5 MAXIMUM SNOW LINE EAS ROOF 1 FT FLASHING 0 5 MINIMUM mr 22272777777 CLEARANCES PER VENT MANUFACTURE S INSTRUCTIONS k oe EXHAUST MINIMIZE HORIZONTAL M VENT CONNECTOR LENGTH Page 14 COMMON VENT SYSTEMS WARNING DO NOT connect this boiler or any other appliance using a positive pressure common vent system or a mechanical draft system Failure to comply with this WARNING could result in the accumulation of carbon monoxide gas which can
35. d with a low water cut off device follow the manufacturer s instructions for cleaning and to confirm proper operation Relief Valve The relief valve should vent water when the test lever is lifted It should not weep or discharge water at normal system pressure NEVER try to clean or repair the relief valve If the valve fails replace it Aquastat High Limit The aquastat high limit controls the maximum water temperature in the boiler It is adjustable from 140 60 C to 220 F 104 C If the water temperature reaches the set temperature before the demand for heat has been met the aquastat high limit should shut the burners off The outlet water temperature should never exceed 220 F 104 C If the aquastat high limit fails to function properly replace it Page 27 Page 28 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS 7 7 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS SERVICE AND REPLACEMENT PARTS LIST Page 29 Ref Name of Part Model Size with Item Quantities Below Part 70 105 140 175 210 Jacket Panel Set BM 8610 BM 8611 BM 8612 BM 8613 BM 8614 Front Panel 03 1552 03 1553 03 1554 03 1555 03 1556 Rear Panel 03 1557 03 1558 03 1559 03 1560 03 1561 1c Top Panel 03 1562 03 1563 03 1564 03 1565 03 1566 Inner Front Panel
36. ding Any home utilizing other gas burning appliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time If the boiler is to be located in an alcove closet or other confined space the distances from the boiler and it s vent system to all combustible construction must be equal to or greater than the minimum clearances in Figure 1 When installed in a closet or confined space two permanent openings of equal area adjoining another room or rooms having sufficient volume to meet the requirements of an unconfined space must be provided Figures 4 amp 5 Each opening must have a minimum free area of one square inch 1000 Btu hr 2200 mm kW based on the total input rating of all gas utilization equipment in the confined area Each opening must be no less than 100 square inches 64516 mm in size The upper opening must be within 12 inches 305 mm of but not less than 3 inches 76 mm from the top of the enclosure The bottom opening must be within 12 inches 805 mm of but not less than 3 inches 76 mm from the bottom of the enclosure All Combustion Air From Outside The Building When installed in a confined space without the intake air option two permanent openings communicating directly with or by ducts to the outdoors or spaces that freely communicate with the outdoors must be present The upper opening must be within 12 inches 3
37. flow rate 36 s f Input Rate 1000 Btu ft 3600 s hr 36 5 3 Input Rate 100 000 Btu hr If the computed rate deviates by more than 5 from the rated input value of the unit adjust the gas valve pressure accordingly DO NOT adjust the manifold pressure by more than 5 If a proper rate cannot be maintained without adjusting the manifold pressure beyond the 5 limit the burner orifice must be replaced If the input rate is too low go to the next larger size orifice if the input rate is too high go to the next smaller size orifice PROPANE GAS The input rate for LP units is factory set based on the orifice size The manifold pressure must be set at 1 9 W C and the orifice supplied with the boiler used unless the unit is to be derated for altitude CAUTION Never increase the input to the boiler above that for which it is rated Doing so can cause premature failure of the boiler GAS PRESSURE ADJUSTMENT NATURAL GAS Optimum results are obtained when the boiler is operated at its full input rating with 1 9 W C of manifold pressure The manifold pressure should not be more that 596 off this value The gas valve pressure regulator has been preset at the factory If adjustment is necessary the following steps must be followed 1 Connect each side of a manometer to the two pressure ports shown in Figure 21 to obtain the manifold pressure 2 Connect a flue gas analyzer to the vent pipe 3 Rotate the regulator
38. h a louver or grill is not 8 x 12 384 000 288 000 96 000 known ducts should be sized per Table 1 8 1 2 x 16 512 000 384 000 128 000 Figure 3 Horizontal Positive Pressure Venting Using Inside Combustion Air BUILDING OVERHANG 4 FT 1 2 M MAX H H H 3 FT H 0 9 M CERTIFIED MIN H TERMINAL M SEE TABLE 5 10 FT 0 5 M MINIMUM DISTANCE FROM TERMINAL TO MAXIMUM SNOW LINE Vi Vi CLEARANCES PER VENT MANUFACTURE S INSTRUCTIONS PITCH PIPE DOWN TOWARDS TERMINAL 1 4 IN PER FT 20 MM M 22277 zzz4 VAV AV AV AV AV AV AV AV AV AV AV AV AV AV 4 Z ZZ Z ZZ ZZ Z AV AV AV AV AV AV Figure 4 Vertical Negative Pressure Masonry Chimney System Using Inside Combustion Air CHIMNEY LINER THIMBLE H EXHAUST CLEANOUT OPENINGS PER ABOVE INSTRUCTIONS MINIMIZE HORIZONTAL VENT CONNECTOR LENGTH r
39. he combustion chamber These acids will cause premature failure of the boiler voiding the warranty CAUTION If the boiler is operated while the building is under construction it MUST be protected from wood concrete sheet rock and other types of dust Failure to properly protect the unit from construction dust will damage the unit voiding the warranty Buildings may require the installation of a fresh air duct or other means of providing make up air if the intake air option isn t used Any building utilizing other gas burning appliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time Sizing of an outside air duct must be done to meet the requirements of all such devices WARNING Never operate this boiler in an environment subjected to a negative pressure unless the air intake is connected to the outdoors Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS All Combustion Air From Inside The Building Older houses often have enough leakage to provide an adequate amount of combustion air provided that the demand for combustion air is not too great Figure 3 Homes that are relatively new or tight will most likely require that the combustion be ducted to the boiler from outside the buil
40. head hangers The vent system must be pitched down toward the vent terminal 1 4 per foot 21mm per meter If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F Structural penetrations must be made using approved thimbles FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Horizontal vent systems shall terminate at least 4 feet 1 3 m below 4 feet 1 3 m horizontally from or 1 foot 0 23 m above any door window or gravity air inlet into any building It must not terminate less than 4 feet 1 3 m horizontally from and in no case above or below unless a 4 feet 1 3 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment and not less than 7 feet 2 3 m from any adjacent public walkway The bottom of the vent terminal s shall be located at least 5 feet 1 5 m above the air intake terminal s Avoid terminal locations likely to be affected by winds snowdrifts people and pets The certified vent terminals listed in Table 4 must be used Protect building materials and vegetation from degradation caused by the flue gases Table 4 Certified Vent amp Intake Terminals Company Part No Description Dia in Protech 30031 1 Tee 3 Protech 300312 Tee 4 Protech 300186 Bird Screen 3 Protech 300187 Bird Screen 4 Protech 300130 4
41. heating OPERATIONAL SEQUENCE The control energizes the circulator motor when the thermostat contacts are closed The control then checks that the limit switch is closed if not the control will wait for the limit switch to close With the limit switch closed the pressure switch contacts are checked If the pressure switch contacts are open the blower motor is energized If the pressure switch contacts aren t open the control will wait 45 seconds then lock out The PURGE light will flash to indicate a pressure switch fault Also if the pressure switch does not close within 5 minutes of the blower being turned on the control will lock out with the PURGE light flashing to indicate a pressure switch fault The pre purge period begins when the pressure switch contacts close At the end of the pre purge period the control energizes the HSI igniter for an HSI warm up period This condition will be indicated by illumination of the IGNITER light A one second trial for ignition will take place In the event ignition is not achieved by the end of the first trial for ignition period the control will run through a post purge and then de energize the inducer When the pressure switch contacts open the control will begin a new ignition sequence Failure to establish flame after the third attempt will result in ignition lock out and the VALVE light on the control will flash Once the flame has been proven the system is in Steady State heating mode
42. icipator to 1 1 amps when controlling the boiler directly For zoned systems set the heat anticipator to match the amp draw of the zone valves or pump relays BOILER MAINTENANCE The boiler should be cleaned and inspected once a year before each heating season Refer to Figures 21 for component identification CAUTION Servicing inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes Improper servicing or adjustment could damage the boiler FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Control Panel Use a soft brush and or a vacuum cleaner to ensure that the electrical components are free from dust or deposits that would impair the boiler s performance Air Filter 1 Remove the front jacket panel 2 Remove the filter box cover and filter 3 Wash the filter in warm water Shake out all excess moisture before reinstalling Burner Box Removal amp Replacement CAUTION The burner box should not be removed unless there is a problem with it or the boiler is being converted for a different type of gas Careless handling can damage the burner WARNING The ceramic combusiton chamber in the burner box and its gasket contain crystalline silica Wear a tightly fitted dust mask when servicing the burner and gently handle the burner and its gasket to prevent inhalation of airborne fibers Crystalline silica fibers have been identified as carcinoge
43. ie du syst me de contr le et toute des t l phones se trouvant dans le b timent commande qui ont t plong s dans l eau Appelez imm diatement votre fournisseur de gaz depuis un voisin Suives les instructions du fournisseur 1 ARR TEZ Lisez les instructions de s curit sur a 7 Attendre cinq 5 minutes pour laisser chapper la portion sup rieure de cette tiquette i tout le gaz Reniflez tout autour de l appareil y 2 Mette le thermostat la temp rature la plus compris pr s du plancher pour d celer une odeur basse de gaz Si vous sentez une odeur de gaz T e ARR TEZ Passez l tape B des instructions de Coupez l alimentation lectrique de l appareil FRE y s curit sur la portion sup rieure de cette Cet appareil est quip d un dispositif d allumage tiquette S il n y a pas d odeur de gaz passez automatique la br leur l tape suivante BOUTON DE COMMANDE 8 Tourner le bouton de commande de gaz vers la POSITION D ARR T enm gauche en position de marche ON OFF ARRIV E 9 si 9 Replacer le panneau de parte du r chauffer SORGE 2 10 R tablir toute l alimentation lectrique de la chaudiere BEAU TEUER DE BRESSION 11 Mette le thermostat thermostat sur le r gleage 5 Enlever le panneau de parte du r chauffer posue 12 Si l appareil ne fonctionn pas voir les instructions Tourner
44. ied service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water 1 2 3 4 STOP Read the safety information above Turn off all electric power to the appliance Set the thermostat to lowest setting This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand GAS CONTROL KNOB SHOWN IN OFF POSITION J It o 7 7 L GAS INLET PRESSURE REGULATOR 5 10 11 12 Remove control access panel Turn the gas control knob clockwise Z lt to the full OFF position on the White Rodgers 36E push the knob before turning it Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn the gas control knob counterclockwise ON Replace control access panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions TO TURN OFF GAS TO APPLIANCE and call your service technician or gas supplier 1 Turn off all electric power to the appliance 2 Setthe thermostat to lowest setting 3 Remove control access panel 4 5 Push in gas control knob slightly and turn clock wise to
45. ill occur For the three systems listed below adjust the bypass valve to divert some of the heated water back into the boiler s return piping When adjusted correctly the temperature of the boiler water will exceed 140 F within five minutes of a warm start A plug valve should be used as the bypass valve for best system performance NOTE Some of the circulator s capacity will be used in the blending process for the first two systems Large heating systems may require a larger circulator System Bypass The system bypass shown in Figure 14 should be used on single zone systems or multiple zone systems using zone valves when the circulator is installed in the return piping The bypass must be installed between the supply and return pipes on the suction side of the circulator Figure 14 System Bypass Piping CHECK VALVE BYPASS CIRCULATOR PUMP RETURN PIPING FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Pump Away Bypass The system bypass shown in Figure 15 should be used on single zone systems or multiple zone systems using zone valves when the circulator is installed in the supply piping The bypass must be installed between the supply and return pipes on the pressure side of the circulator Figure 15 Pump Away Bypass Piping CHECK VALVE BYPASS CIRCULATOR PUMP SUPPLY PIPING VALVES Pumped Blend Bypass The system bypass shown in
46. lage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe Faire fonctionner le br leur principal pendant 5 min ensuite d terminer si le coupe tirage d borde l ouverture de d charge Utiliser la flamme d une allunette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Une fois qu il a t d termin selon la m tode indiqu e ci dessus que chaque appareil raccord au syst me d vacuation est mis l air libre de fa or ad quate Remettre les portes et les fen tres les ventilateurs les registres de chemin es et les appareils au gaz leur position originale Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 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 F in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 Installation Codes FX DIRECT VENT BOILER INSTALLATION AND OPERATION
47. le bouton de commande de gaz vers la droite w en position d arr t OFF Ne pas forcer de COUPURE DE L ARRIVE DE GAZ A LA CHAUDI RE et appeler un technicien reparateur 1 Mette le thermostat la temp rature la plus basse 2 Si un entretien doit tre effectu coupez l alimentation lectrique de l appareil 3 Lever le panneau de parte du r chauffer COUPURE DE L ARRIVE DE GAZ A LA CHAUDIERE ou le fournisseur de gaz 4 Tourner le bouton de commande de gaz vers la droite 7 en position d arr t OFF Ne pas forcer 5 Replacer le panneau de parte du r chauffer Page 24 BOILER SET UP NOTE Before starting the boiler turn off the electrical supply going to it Make sure that gas is available at the gas valve inlet Open the valves in the return and supply piping Failure to take these precautions will prevent the boiler from operation properly Fill the boiler and all of the radiation with water Make sure that the system is completely purged of air Review these instructions and make sure that the boiler installation complies with ALL of the instructions up to this point BOILER OPERATION WARNING Before operating read and understand the instructions contained in this manual Do not attempt to operate this boiler if it has not been installed in accordance with the guidelines set forth in this manual Read and fully understand the operating instructions in the For Your
48. n set up for the type of gas available at the installation site Other important considerations are the availability of an adequate electrical supply fresh air for combustion and proximity a suitable outside wall BOILER LOCATION WARNING The clearances to combustible construction show in Figure 1 must be main tained Failure to comply with this warning can result in extensive property damage severe personal injury or death CAUTION Do not lift the boiler by the jacket Use a hand truck under the base frame as shown in Figure 2 1 Locate the boiler in an area that provides good access to the unit Keep in mind that servicing may require the removal of jacket panels Accessibility clearances must take precedence over fire protection clearances 2 An optimum site will be level central to the hot water piping system close to an outside wall and have adequate fresh air for combustion 3 Ensure that the floor is structurally sound and will support the weight of the boiler Figure 1 Clearances to Combustible Construction LI 6 15 2 6 6 LL 18 2 18 2 ANE H NOTE This boiler is designed for direct placement on a combustible floor Never install this boiler on carpeting 4 DO NOT install this boiler in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or servicing
49. ndie ou d explosion ou pour viter tout dommoge mat riel toute blessure ou la mort Ne pas tenter d allumer d appareil le b timent intructions du fournisseur Ne pas entreposer ni utiliser d essence ou ni d autres vapeurs ou liquides inflammables proximit de cet appareil ou de tout autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans e Appelez imm diatement votre fournisseur de gas depuis un voisin Suivez les Si vous ne purvez rejoindre le fournisseur appelez le service des incendies L installation et l entretien doivent tre assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz CONTENTS Before You Start page 2 Boiler Ratings amp Capacities page 3 Boiler Location 22 2 page 3 Clearances to Combustible Construction page 3 Combustion Air amp Ventilation page 4 Chimney amp Vent Pipe Connections page 10 Heating System Piping page 15 Gas Supply Piping page 18 Electrical Wiring page 18 Lighting Instructions page 22 Boiler Set Up
50. nic or possibly carcinogenic when inhaled 1 Close the manual shutoff valve in the gas supply line and turn off electrical power to the boiler 2 Lift off the front amp top jacket panels 4 Disconnect the wires going to the igniter flame rod ground rod and thermal switch 5 Release the eight hold down latches page 28 6 Slightly lift and slide the burner towards that back of the boiler 7 Gently lift the burner out of the boiler 8 Install the factory assembled replacement burner box and the new gasket 9 Engage the eight hold down latches and reconnect all of the wires 10 Confirm proper operation of the boiler 11 Replace the jacket panels FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Heat Exchanger Cleaning In the unlikely event that the heat exchanger becomes blocked consult the factory for the proper cleaning procedure Condensate System Ensure that the condensate removal system is sound and working properly Vent System The entire vent system must be thoroughly inspected for any signs of blockage corrosion or leaks Immediately replace any unsound vent system piping Remove any foreign matter in or near the vent terminal or around the boiler that might obstruct the flue of combustion and ventilation air Blower Motor Every 3 to 6 months lubricate the inducer motor using 2 drops of 20W non detergent motor oil in each oil port Low Water Cutoff If the boiler has been equippe
51. ollow F To test the ignition safety shutoff device close the manual shutoff valve in the gas supply line Within 6 seconds of main burner flame extinction the main gas valve solenoid should close with an audible noise The igniter should glow and make three attempts at ignition After unsuccessfully attempting to light the burner the ignition module should lock out Open the manual shutoff valve in the gas supply line Reset the ignition control system by interrupting then restoring electrical power to the boiler A normal ignition sequence should take place FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS BOILER CHECKING amp ADJUSTMENT INPUT RATE Gas appliances are rated based on sea level operation with no adjustment required at elevations up to 2000 feet At elevations above 2000 feet input ratings should be reduced by 4 for each 1000 feet above sea level Check the input rate as follows NATURAL GAS 1 Turn off all other gas appliances that use the same gas meter as the boiler 2 Callthe gas company for the gas heating value 3 Start the boiler and let it run for 15 minutes 4 Using the gas meter and a stopwatch clock the time that it takes to burn 10 cubic feet of gas and divide the time by 10 5 Insert the heating value and the time in seconds into the formula below Input Rate Heating Value Btu ft9 3600 s hr Flow Rate s ft EXAMPLE If the heating value 1000 Btu ft and the
52. owed If the boiler is installed above any radiation elements it must be fitted with a low water cutoff device installed above the normal boiler water level The FX hot water boiler comes from the factory ready to be piped to the heating system Each boiler is equipped with a safety relief valve which must be piped in accordance with the ANSI ASME Boiler and Pressure Vessel Code Section IV see Figure 13 Table 7 Boiler Water Volume Boiler Water Volume Model Gallons Liters FX 3 1 8 6 8 FX 4 2 4 9 1 FX 5 3 0 11 4 FX 6 3 6 13 6 FX 7 4 2 15 9 Figure 13 Relief Valve Piping PRESSURE RELIEF VALVE 1 1 4 CROSS TEMPERATURE AND PRESSURE GUAGE Ensure that the boiler is level from front to back and from side to side Use metal shims to level the boiler NEVER use combustible materials for shims Page 15 Page 16 Bypass Piping CAUTION Never connect this boiler directly to a large volume system in floor radiant system snow melt system or any other system that would cause the steady state water temperature in the boiler to drop below 140 F To prevent damage due to excessive condensation one of the following piping options must be used or the boiler warranty will be voided CAUTION The blend pump arrangement shown in Figure 16 must be used when flow from any zone in a multiple zone system is less than 4 GPM or boiler short cycling on the high limit w
53. ration and long life for which this boiler was designed these instructions must be read understood and followed Direct all questions to your Hydrotherm distributor or to the Customer Service Department 260 North Elm Street Westfield MA 01085 Always include the model and serial numbers from the rating plate of the boiler in question The owner should maintain a record of all service work performed with the date and a description of the work done Include the name of the service organization for future reference Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 The installation 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 revision In Canada the installation must be in accordance with the requirements of CSA B149 1 or B149 2 Installation Code for Gas Burning Appliances and Equipment FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS BOILER RATINGS amp CAPACITIES Before undertaking the installation of the FX check the boiler rating plate to ensure that the boiler is the proper size for the job The Net Ratings specify the equivalent amount of direct cast iron radiation that the boiler can handle under normal conditions Also ensure that the boiler has bee
54. rculator does not have the required capacity for the system in which it is to be installed an extra zone circulator or a higher capacity circulator will be needed Figure 18 depicts the performance curve for the TACO 007 circulator Figure 18 TACO 007 Performance Curve 10 HEAD FEET OF WATER TACO 007 CIRCULATOR PERFORMANCE CURVE 0 5 10 15 20 25 FLOW GPM Page 17 Page 18 GAS SUPPLY PIPING The FX hot water boiler comes from the factory ready to be piped to the gas supply The gas supply can be piped from the left or right side of the boiler If for any reason the boiler is not for the type of gas available at the installation site call the nearest Hydrotherm distributor to resolve the problem Figure 19 depicts the proper way to connect the boiler to the gas supply piping The manual shut off valve MUST be installed in the supply piping It should be approximately 5 feet above the floor Provide a sediment trap drip leg at the bottom of the vertical section of the gas supply pipe A ground joint union should be installed between the boiler gas controls and the supply piping Each of these items is needed to ensure long life and ease of servicing Always use a pipe sealant that is suitable for use with LP gas Figure 19 Gas Supply Piping GAS INLET INSTALL MANUAL SHUT OFF VALVE 5 FT 1 5 M ABOVE FLOOR WHERE REQUIRED BY LOCAL COD
55. ressure Venting with Outdoor Combustion Air CAPS 5 FT 1 5 M MINIMUM TO WALL OR ADJOINING BUILDING 1 FT 0 3 M MINIMUM 2 FT 0 6 M MINIMUM MAXIMUM SNOW LINE 1 FT ROOF 0 3 M decis COMBUSTION AIR 22 3 0 9 MINIMUM CLEARANCES PER VENT MANUFACTURE S INSTRUCTIONS EXHAUST MINIMIZE HORIZONTAL VENT CONNECTOR LENCTH F i C i i i CC Ci CCC CIC CCC Page 7 Page 8 FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS Figure 7 Horizontal Positive Pressure Venting with Outdoor Combustion Air BUILDING OVERHANG 4 1 2 M MAXIMUM VAV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV AV CLEARANCES PER VENT MANUFACTURE S INSTRUCTIONS EXHAUST i N 2 FT 0 6 M MINIMUM CENTER LINE COMBUSTION AIR n 3 FT 0 9 M MINIMUM 6 FT 1 8 M EN MINIMUM d 7 TO ADJACENT d BUILDING n H CERTIFIED 0 TERMINALS SEE TABLE 4 6 1 0 FL 0 5 M MINIMUM DISTANCE FROM INTAKE TO MAXIMUM SNOW LINE PITCH PIPES DOWN TOWARDS TERMINAL CAPS 1 4 IN PER FOOT 20 MM M Figure 8 Horizontal Positive Pressure Concentric Venting with Outdoor Combustion
56. s must be joined and sealed in accordance with the vent system manufacturer s instructions Vertical vent systems must be terminated with an approved terminal cap as shown in Figures 6 amp 10 HORIZONTAL VENT POSITIVE PRESSURE SYSTEMS See Figure 3 The vent materials used in horizontal positive pressure vent systems must be certified to UL 1738 for installations in the United States ULS636 for installations in Canada Certified vent systems are manufactured by the following companies Heat Fab Inc 130 Industrial Blvd Turners Falls MA 01376 800 772 0739 Z Flex U S Inc 20 Commerce Park North Bedford NH 03110 6911 800 654 5600 Protech Systems Inc 26 Gansevoort Street Albany NY 12202 518 463 7284 The maximum equivalent length for the horizontal vent System is listed in Table 4 Each 90 elbow is equal to 5 linear feet 1 5 m of pipe To maximize the performance of single wall sheet metal vent systems locate 90 elbows as far from the boiler as possible and from one another Horizontal vent systems should be as short and straight as possible When horizontal vent runs exceed 5 feet 1 5 m they must be supported at 3 foot 0 98 m intervals with overhead hangers The vent system must be pitched down toward the vent terminal 1 4 per foot 21 mm per meter If any part of a single wall metal vent system passes through an unheated space it must be insulated with insulation rated for 400 F Structural penetr
57. sitive Pressure uses a vent system certified to UL 1738 for installations in the United States ULS636 for installations in Canada Combustion air is piped from the outdoors to the blower inlet 2 Horizontal Vent Positive Pressure uses a vent system certified to UL 1738 for installations in the United States ULS636 for installations in Canada Combustion air is obtained from the space in which the unit is installed 3 Vertical Vent Positive Pressure uses a vent system certified to UL 1738 for installations in the United States ULS636 for installations in Canada Combustion air is piped from the outdoors to the blower inlet or is obtained from the space in which the unit is installed 4 Vertical Chimney Vent Negative Pressure uses an approved metal chimney system or masonry chimney Combustion air is obtained from the space in which the unit is installed or is piped from the outdoors to the blower inlet FX DIRECT VENT BOILER INSTALLATION AND OPERATION INSTRUCTIONS GENERAL DIRECT VENT INFO In this configuration the boiler blower is used to push the flue products to the outdoors while drawing combustion air from the outdoors The instructions under the COMBUSTION AIR amp VENTILATION SECTION must be followed The vent system must be sized per Table 3 Table 3 Positive Pressure Vent System Sizing Boiler Equivalent Intake Equivalent Intake Model Length see note Length see note Number 3
58. very toxic If your Hydrotherm boiler is not working properly or is not vented properly dangerous levels of CO may accumulate CO is lighter than air and thus may travel throughout the building BRIEF EXPOSURE TO HIGH CONCENTRATIONS OF CO OR PROLONGED EXPOSURE TO LESSER AMOUNTS OF CO MAY RESULT IN CARBON MON OXIDE POISONING EXPOSURE CAN BE FATAL AND EXPOSURE TO HIGH CONCENTRATIONS MAY RESULT IN THE SUDDEN ONSET OF SYMPTOMS INCLUDING UNCONSCIOUSNESS Symptoms of CO poisoning include the following Dizziness vision problems shortness of breath headaches loss of muscle control unclear thinking nausea weakness and unconsciousness The symptoms of CO poisoning are often confused with those of influenza and the highest incidence of poisoning occurs at the onset of cold weather or during flu season A victim may not experience any symptoms only one symptom or a few symptoms Suspect the presence of carbon monoxide if symptoms tend to disappear when you leave your home The following signs may indicate the presence of carbon monoxide Hot gases from appliance venting system pipes or chimney escaping into the living space Flames coming out around the appliance Yellow colored flames in the appliance Stale or smelly air The presence of soot or carbon in or around the appliance Very high unexplained humidity inside the building If any of the symptoms of CO poisoning occur or if any of the signs of carbon monoxide
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