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1. 9 Replace Burner Observation Cover and Front Jacket Panel 10 Adjust thermostats to normal setting Controls as required by control manufacturer 1 Safety Relief Valve Conduct try lever test as outlined in manufacturer s instruction tag on the safety relief valve 2 LowWater Cut off if used Follow instructions provided by control manufacturer General Inspection and Maintenance Annual For continued safe operation a qualified service agency must provide a more detailed inspection of burners heat exchanger and vent system and pro vide maintenance as specified in the Installation Operation and Maintenance Manual OUTER CONE IS l DARK BLUE Pa i COLOR t a A PILOT 7 INNER CONE IS pal Re BLUE A E A E IN COLOR IW IA i Y I A aed AE ad PJ N I Figure 5 Pilot and Main Burner and Flames Controls maintenance may be part of annual inspection and maintenance by a qualified service agency if annual frequency is specified by controls manufacturer HVX USER S INFORMATION MANUAL PAGE 7 HydroTherm IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONTARIO L5S 1L4 905 672 2991 FAX 905 672 2883 www hydrotherm com
2. UMHVX3 1 Hydro Therm er HVX GAS BOILERS USER S INFORMATION MANUAL H CD e LISTED Intertek 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 IFYOU 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 TO THE INSTALLER THIS MANUAL IS THE PROPERTY OF THE OWNER AND MUST BE AFFIXED NEAR THE BOILER FOR FUTURE REFERENCE TO THE OWNER THIS BOILER SHOULD BE INSPECTED ANNUALLY BY A QUALIFIED SERVICE AGENCY PAGE 2 BASIC OPERATION ZAN WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency ZAN CAUTION 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 Do not use this boiler if any part has been under water Immediately call a q
3. borne RCF when inhaled have been classified by the International Agency for Research on Cancer IARC as a possible carcinogen to humans After the RCF materials have been exposed to temperatures above 1800 F 980 C they can change into crystalline silica which has been classified by the IARC as carcinogenic to humans If particles become airborne during service or repair inhalation of these particles may be hazardous to your health Avoid Breathing Fiber Particulates and Dust Suppliers of RCF recommend the following precautions be taken when handling these materials Precautionary Measures Provide adequate ventilation Wear a NIOSH MSHA approved respirator Wear long sleeved loose fitting clothing and gloves to prevent skin contact Wear eye goggles Minimize airborne dust prior to handling and removal by water misting the material and avoiding unnecessary disturbance of materials Wash work clothes separately from others Rinse washer thoroughly after use Discard RCF materials by sealing in an airtight plastic bag First Aid Procedures Inhalation If breathing difficulty or irritation occurs move to a location with fresh clean air Seek immediate medical attention if symptoms persist Skin Contact Wash affected area gently with a mild soap and warm water Seek immediate medical attention if irritation persists Eye Contact Flush eyes with water for 15 min utes while holding eyelids apart Do not r
4. ctivated to interrupt boiler operation do not attempt to place boiler in operation Contact a qualified service agency B HVX USER S INFORMATION MANUAL 4 Pilot The pilot provides the ignition source for the main burners Your boiler has an intermittent pilot The intermittent pilot ignites only when there is a call for heat and extinguishes when the call for heat ends See Figure 5 5 Gas Valve The gas valve monitors pilot flame and regulates gas flow to the burners and pilot See Figure 1 6 Safety Relief Valve A device which protects the boiler against excessive pressure The safe ty relief valve can discharge a large amount of hot water the installer should provide piping to discharge water near floor at a floor drain See Figures 2 and 3 If the safety relief valve discharges water follow instructions TO TURN OFF GAS TO APPLIANCE see Figure 4 and contact a qualified service agency Instructions to place boiler in operation and to turn off the boiler are shown on the Operating Instruction Label posted on the inner jacket panel of the boiler The instructions are also shown in Figure 4 C Sequence of Operation 1 Thermostat calls for heat energizes circulator 2 Limit senses boiler water temperature Prevents operation until water temperature falls approxi mately 15 F 8 C below the cut out tempera ture 3 Fan energizes 4 Gas valve energizes a Igniter on b Pilot gas on igniting pil
5. lights the pilot Do not try to light the pilot by hand GAS CONTROL SWITCH OUTLET 5 If the gas valve is not visible remove control access panel If the gas control switch is not in the OFF postion slide the switch to OFF Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Slide the gas control switch to ON Replace control access panel if applicable Turn on all electrical power to the appliance Set thermostat or operating control 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 ARES TO TURN OFF GAS TO APPLIANCE MS Set the thermostat or operating control to lowest setting Turn off all electric power to the appliance if service is to be performed If the gas valve is not visible remove the control access access panel 4 Slide the gas control switch to OFF 5 Replace control access panel if applicable SV9501 SV9601 9318 REV 2 MM YY Figure 4 Intermittent Ignition Operating Instructions HVX USER S INFORMATION MANUAL USER MAINTENANCE AN WARNING Product Safety Information Refractory Ceramic Fiber Product This appliance contains materials made from refractory ceramic fibers RCF Air
6. m operates under positive pressure when venting horizontally or vertically with 3 diameter AL294C vent Leakage in vent system will spill products of combustion into building Severe vent system leakage can cause carbon monoxide poisoning PAGE 6 C Inspect Pilot and Main Burner Flames Monthly 1 Remove Front Jacket Panel by lifting and pulling out 2 Adjust thermostat to lowest setting 3 Loosen screws at Burner Observation Cover located on base just above main burners and remove cover by lifting ZN CAUTION Burner Observation Cover may be hoti 4 Adjust thermostat to highest setting Verify operation follows Section C Sequence of Operation of this manual D 5 Viewflames through observation port 6 Check pilot flame See Figure 5 The pilot flame should be medium blue covering approximately Ye to 1 2 10 to 12 mm of the sensing probe If the flame is yellow and lazy follow instructions TO TURN OFF GAS TO APPLIANCE see Figure 4 and contact qualified service agency E HVX USER S INFORMATION MANUAL 7 Check main burner flames See Figure 5 The flames should have clearly defined inner cones approximately 1 40 mm high and should have a very sharp blue color characteristic If the flame is yellow and lazy follow instructions TO TURN OFF GAS TO APPLIANCE see Figure 4 and contact qualified service agency 8 Adjust all thermostats to lowest setting to shut down boiler
7. ns exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot 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 touch any electric 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 Use only your hand to slide the gas control switch Never use tools If the witch will not slide 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 qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water EEE OPERATING INSTRUCTIONS III STOP Read the safety information above on this label Set the thermostat or operating control to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically
8. ot 5 Pilot flame detected a Igniter off b Main gas on igniting main burners Note If pilot flame is not detected within 30 seconds the igniter is turned off for 30 seconds and then turned back on If the pilot is not detected within 30 seconds the igniter and pilot gas are turned off for 5 minutes The sequence then resumes at Step 4a 6 Call for heat ends Pilot and main gas off extinguishing pilot and main burners If this sequence is not followed exactly follow instructions TO TURN OFF GAS TO APPLIANCE see Figure 4 and contact a qualified service agency HVX USER S INFORMATION MANUAL TO THERMOSTAT TO CIRCULATOR LIMIT FLAME ROLLOUT SWITCH PRESSURE W Figure 1 Control Locations SMICH SAFETY RELIEF VALVE 3 4 X 6 NIPPLE TO DRAIN Figure 2 Safety Relief Valve Hook Up Installation with Air Elimination in System Piping PAGE 3 TO LINE VOLTAGE POWER SUPPLY FAN FAN RELAY CENTER GAS VALVE INNER JACKET PANEL TO AIR ELIMINATION DEVICE SUPPLY 3 4 TEE SAFETY 3 4 X 6 RELIEF NIPPLE VALVE 3 4 X 2 NIPPLE pt BU NT pad p Figure 3 Safety Relief Valve Hook Up vvith Air Elimination TO DRAIN 3 4 STREET ELBOW PAGE 4 HVX USER S INFORMATION MANUAL MON For Your SAFETY READ BEFORE LIGHTING AI WARNING If you do not follow these instructio
9. ualified service agency to inspect the boiler and to replace any part of the control system and any gas control which has been under water A General This water boiler is an induced draft appliance and is equipped with controls for proper operation All controls must be in proper working order Contact a qualified service agency to provide annual maintenance as specified in Installation Operation and Maintenance Manual 1 Limit See Figure 1 A device which automati cally interrupts boiler operation when the water temperature exceeds the set point Maximum allowable temperature is 220 F 104 C Original equipment with this boiler is a Honeywell L4080B1253 Boiler operation is interrupted when system temperature reaches cut out temperature Boiler operation resumes automatically when system temperature falls approximately 15 F 8 C below the cut out temperature 2 Flame Rollout Switch See Figure 1 A device which automatically interrupts boiler operation when flames or excessive heat are present in the combustion area The control is a single use device If the control is activated to interrupt boiler operation do not attempt to place boiler in operation Contact a qualified service agency 3 Pressure Switch See Figure 1 A device which automatically interrupts boiler operation when there is excessive blockage in the vent system or fan motor does not operate This control is an automatic reset device If control is a
10. ub eyes Seek immediate medical attention if irrita tion persists Ingestion Drink 1 to 2 glasses of water Do not induce vomiting Seek immediate medical attention PAGE 5 AN WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency Inspections should be per formed at intervals specified in the Installation Operation and Maintenance Manual and this User s Information Manual Maintain manuals in a legible condition Keep boiler area clear and free of combustible materials gasoline and other flammable vapors and liquids Do not place any obstructions in boiler room that will hinder flow of combustion and ventilation air A General Housekeeping Continuous 1 Keep boiler area clear and free of combustible materials and obstructions to the free flow of combustion and ventilation air to the boiler 2 Donotstore or use gasoline or other flammable vapors or liquids in the vicinity of the boiler or any other appliance 3 Donotstore or use sources of hydrocarbons in the vicinity of the boiler Sources of hydrocar bons include bleaches cleaners chemicals sprays paint removers fabric softeners and refrigerants 4 Check Safety Relief Valve for water leakage If leakage exists contact a qualified service agency Inspect Vent System Monthly Vent pipe must be sealed with no separations obstructions or sags ZN CAUTION Vent syste

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